ABB OmniCore IRB 6740 Product Manual Download

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Note

Action

xx2200001736

Disconnect the power cable connector by
first removing the attachment screw and
then parting the connector.

xx2200001737

Disconnect the signal cable connector by
pulling it out.

Continues on next page

Product manual - IRB 6740

369

3HAC085701-001 Revision: A

5 Repair

5.8.1 Replacing the axis-1 motor

Continued

Summary of Contents for OmniCore IRB 6740

Page 1: ...ROBOTICS Product manual IRB 6740 ...

Page 2: ...Trace back information Workspace 23B version a13 not checked in Published 2023 06 21 at 17 07 40 Skribenta version 5 5 019 ...

Page 4: ...ranty 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 obtaine...

Page 5: ... 3 2 2 Risk of tipping stability 55 3 3 On site installation 55 3 3 1 Brief installation procedure 56 3 3 2 Installing a base plate 64 3 3 3 Lifting the robot 64 3 3 3 1 Lifting robot with lifting accessory recommended lifting method 66 3 3 3 2 Lifting the robot with fork lift 67 3 3 3 3 Lifting the robot with roundslings 72 3 3 4 Orienting and securing the robot 75 3 3 5 Manually releasing the br...

Page 6: ...ancing device 172 4 6 Cleaning activities 172 4 6 1 Cleaning the IRB 6740 177 5 Repair 177 5 1 Introduction 178 5 2 General procedures 178 5 2 1 Performing a leak down test 179 5 2 2 Mounting instructions for bearings 181 5 2 3 Mounting instructions for sealings 185 5 2 4 Cut the paint or surface on the robot before replacing parts 186 5 3 Axes 1 and 2 186 5 3 1 Replacing the axis 1 cassette seali...

Page 7: ...3 Installation locations for the calibration tools 625 6 4 4 Axis Calibration Running the calibration procedure 629 6 4 5 Reference calibration 631 6 5 Verifying the calibration 632 6 6 Checking the synchronization position 633 7 Troubleshooting 633 7 1 Introduction to troubleshooting 635 7 2 Oil and grease stains on motors and gearboxes 636 7 3 Mechanical noise or dissonance 637 7 4 Manipulator c...

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Page 9: ...it to the foundation to making it ready for operation maintenance work repair work decommissioning work Note It is the responsibility of the integrator to conduct a risk assessment of the final application It is the responsibility of the integrator to provide safety and user guides for the robot system Who should read this manual This manual is intended for installation personnel maintenance perso...

Page 10: ...roduct manual OmniCore V250XT Type A 3HAC086333 001 Circuit diagram IRB 6710 IRB 6720 IRB 6730 IRB 6740 3HAC065041 001 Technical reference manual System parameters 3HAC050944 001 Operating manual Service Information System Tip All documents can be found via myABB Business Portal www abb com myABB Revisions Description Revision First edition A 10 Product manual IRB 6740 3HAC085701 001 Revision A Co...

Page 11: ...ation Troubleshooting Decommissioning 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...

Page 12: ...handling of the products The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved Product documentation Continued ...

Page 13: ...so include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 15 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 differe...

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

Page 15: ...obot 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 as intended 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 o...

Page 16: ...fluence 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 instructions 16 Product manual IRB 6740 3HAC085701 001 Revis...

Page 17: ...ided 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 situation which if ...

Page 18: ...used to indicate where to find additional information or how to do an operation in an easier way TIP 18 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 19: ...scription 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 xx0900...

Page 20: ...000815 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 20 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 2 2 Safety sy...

Page 21: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 6740 21 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 22: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 22 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 23: ...xx1000001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 6740 23 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...that this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 24 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Contin...

Page 25: ...cy stop The protective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRB 6740 25 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 26: ...le 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 Hazards due to the working position and posture for a person working...

Page 27: ...obot 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 A robot may perform unexpected limited movement WARNING Manipulator movements can c...

Page 28: ...ment of robot arm WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 28 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 5 Safety during operation...

Page 29: ...ns are working as intended Hot surfaces Surfaces can be hot after running the robot and touching these may result in burns Allow the surfaces to cool down before maintenance or repair Allergic reaction Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn When working with lubricants there is a risk of an allergic reac tion Allergic reaction...

Page 30: ...uctions Al ways use the type of oil specified for the product Mixing types of oil may cause severe damage to the gearbox Do not mix types of oil Make sure that protective gear like goggles protective visor gloves and arm protection are always worn during this activity Oil residues might be present in a drained gearbox and spilled when separating a motor and gearbox during repair Put oil absorbent ...

Page 31: ... recharge puncture incinerate crush immerse force discharge or expose to temperatures above the declared operating temperature range of the product Risk of fire or explosion Operating temperatures are listed in Operating conditions robot on page 39 See safety instructions for the batteries in Material product safety data sheet Battery pack 3HAC043118 001 Unexpected movement of robot arm WARNING Ha...

Page 32: ...quire using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the manipulator does not result in additional hazards for example even more severe injuries on a trapped person DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot ...

Page 33: ... 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 Note It is recommended to run the service routine BrakeCheck as part of the regular maintenance see the operating manual for the robot controller For robots with the option SafeMove the Cyclic ...

Page 34: ...ld engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered 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 inform...

Page 35: ...ment of robot arm WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 6740 35 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 1 Safety 1 8 Safety during decommiss...

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Page 37: ... additional options tools and other equipment fitted on the robot Mounting positions The table shows valid mounting positions and the installation mounting angle for the manipulator Installation angle Mounting position 0 Floor mounted Note The actual mounting angle must always be configured in the system parameters otherwise the performance and lifetime is affected Continues on next page Product m...

Page 38: ... operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Maximum load emergency stop Endurance load in operation Force 21 2 kN 8 8 kN Force xy 17 7 17 2 kN 17 7 5 kN Force z 45 1 kNm 25 5 kNm Torque xy 13 3 kNm 6 5 kNm Torque z Continues on next page 38 Product manual IRB...

Page 39: ... the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movement even if the frequency is well below the stated frequency The robot should be mounted as rigid as possibly to the floor Disturbances from other machinery will affect the robot and the tool accuracy The robot has resonance frequencies in the region 10 20 H...

Page 40: ...nipulator protection type Foundry Plus 2 i According to IEC 60529 Environmental information The product complies with IEC 63000 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances 40 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 1 Technical dat...

Page 41: ...ws the unrestricted working range of the robot 2799 3234 342 1989 1238 972 A xx2300000706 Path intersect with axis 5 center A Continues on next page Product manual IRB 6740 41 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range ...

Page 42: ...icted working range of the robot A 2997 540 3432 2187 1395 1022 xx2300000707 Path intersect with axis 5 center A Continues on next page 42 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range Continued ...

Page 43: ...icted working range of the robot A 3175 718 3610 2365 1544 1110 xx2300000708 Path intersect with axis 5 center A Continues on next page Product manual IRB 6740 43 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range Continued ...

Page 44: ...tricted working range of the robot 2799 3234 342 1989 972 1538 A xx2300000709 Path intersect with axis 5 center A Continues on next page 44 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range Continued ...

Page 45: ...tricted working range of the robot A 2997 540 3432 2187 1022 1714 xx2300000710 Path intersect with axis 5 center A Continues on next page Product manual IRB 6740 45 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range Continued ...

Page 46: ...740 310 2 8 IRB 6740 270 2 8 LID R972 R2799 2x 170 xx2300000703 Continues on next page 46 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range Continued ...

Page 47: ...RB 6740 230 3 0 LID R1022 R2997 2x 170 xx2300000704 Continues on next page Product manual IRB 6740 47 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range Continued ...

Page 48: ...LID IRB 6740 230 3 0 LID IRB 6740 220 3 2 LID 160 70 300 Axis 4 IRB 6740 310 2 8 IRB 6740 260 3 0 IRB 6740 240 3 2 130 Axis 5 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID IRB 6740 220 3 2 LID 120 iii IRB 6740 310 2 8 IRB 6740 260 3 0 IRB 6740 240 3 2 360 Axis 6 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID IRB 6740 220 3 2 LID 220 iii i Option Extended Working Range Axis 1 3324 1 Continues on next page 4...

Page 49: ...itation The working range of axis 1 can be reduced by altering the parameter values Installation of additional mechanical stops is recommended See Working range alterations on page 87 Product manual IRB 6740 49 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 2 Manipulator description 2 2 Working range Continued ...

Page 50: ...estroy sensitive electronics Safe handling Use one of the following alternatives Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly Use an ESD protective floor mat The mat must be grounded through a current limiting resistor Use a dissipative table mat The mat should provide a controlled discharge of static voltages and must be ...

Page 51: ...dards and regulations The technical data is detailed in section Technical data on page 37 Safety information Before any installation work is commenced all safety information must be 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 page1...

Page 52: ... lifting accessory used if required is suitable to handle the weight of the robot as specified in Weight robot on page 37 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 39 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 39 7 Before taking ...

Page 53: ... before securing it to the foundation Transportation position This figure shows the robot in its transportation position 34 39 2 0 913 62 615 62 7 0 xx2200001841 Note The robot might be positioned in a different position at delivery due to actual configurations and options for example DressPack Angle of axis Axis number 0 Axis 1 34 to 39 Axis 2 70 Axis 3 0 Axis 4 Continues on next page Product man...

Page 54: ...NG The robot is likely to be mechanically unstable if not secured to the foundation 54 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 2 2 Risk of tipping stability Continued ...

Page 55: ...he plat form foundation 3 See Orienting and securing the ro bot on page 72 See Product manual OmniCore V250XT Type A Connect the manipulator to the controller 4 See Product manual OmniCore V250XT Type A Configure the safety settings 5 See Product manual OmniCore V250XT Type A How to start and run the robot is described in the product manual for the controller 6 Install required equipment if any 7 ...

Page 56: ...ening the robot base directly onto The base plate has a greater number of fastening points to the foundation and makes a larger footprint which reduces the load on each fastening point to reduce surface pressure on the foundation contact points which minimizes the risk of wearing down an uneven surface and thereby causing changes in the robot fastening tightening torque to be able to prepare the i...

Page 57: ... 2x 12H7 0 0 018 2 x 1 x 4 5 2 x 1 8 1 H 7 2 0 1 2 3 2 1 M 5 0 1 A B D A B 0 2 Common Zone E F G H xx1500000246 Description Pos Hole for guide pin cylindrical see Guide pins on page 60 A B Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page Product manual IRB 6740 57 3HAC085701 001 Revision A Copyright 2023 ABB All rights rese...

Page 58: ... 0 0 0 7 0 0 1 8 D C L 2x R22 5 B 3 x R 1 3x 90 3 x 4 C C xx1500000247 Continues on next page 58 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 59: ... 9 2x 132 8 87 27 87 27 5x M16 16x 22 1020 950 0 0 0 0 2x 271 2x 774 41 123 358 175 538 721 773 855 896 923 1 933 1 2x 860 2x 726 2x 543 2x 363 2x 206 110 448 786 878 87 1 87 27 1 27 50 18 69 2x 904 50 3 1 xx1500000249 Continues on next page Product manual IRB 6740 59 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Con...

Page 60: ...ide pins on page 60 A Assembly of guide pins 800 B B B B A B A Description Pos Cylindrical guide pin x2 A M5 x 40 Tightening torque 6 Nm x2 B Continues on next page 60 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 61: ...s for leveling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page Product manual IRB 6740 61 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 62: ...Base plate guide sleeve holes The illustration below shows the guide sleeve holes in the base plate A xx0300000045 Guide sleeve holes 2 pcs A Continues on next page 62 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 63: ...in figure Base plate orienting grooves and leveling bolts on page 61 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the fo...

Page 64: ...etailed instruction see the user instructions enclosed with the accessory Note The user manual may be out of date The latest revision is available for download via myABB Business Portal www abb com myABB xx2200002013 Required equipment Note Article number Equipment Includes user instructions 3HAC15971 2 3HAC15607 1 Lifting accessory robot Continues on next page 64 Product manual IRB 6740 3HAC08570...

Page 65: ...s de scribed in the enclosed instruction Go to the user instructions enclosed with the lifting accessory DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 3 CAUTION The IRB 6740 robot weighs IRB 6740 310 2 8 1 370 kg IRB 6740 260 3 0 1 380 kg IRB 6740 240 3 2 1 350 kg IRB 6740 270 2 8 LID 1 440 kg IRB 6740 230 3 0 LID 1 450 kg IR...

Page 66: ...ft pockets and all required hardware for installation on robot base User instructions are enclosed with the tool 3HAC047054 003 Fork lift accessory set Required documents Document number Document 3HAC048484 002 Directions for use Fork lift accessory set 3HAC047054 001 Lifting the robot Note Action Lift the robot according to the user instructions enclosed with the fork lift accessory 1 66 Product ...

Page 67: ...obot can also be lifted with roundslings as detailed in this section Illustration lifting position This figure shows the robot in its lifting and transportation position 34 39 2 0 913 62 615 62 7 0 xx2200001841 DANGER Attempting to lift a robot in any other position than the recommended lifting position may result in the robot tipping over causing severe damage or injury Continues on next page Pro...

Page 68: ...ting eye M20 D i Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport ii Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport Continues on next page 68 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 3 3 Lift...

Page 69: ...ndslings Note Action 34 39 2 0 913 62 615 62 7 0 xx2200001841 Make sure the robot is positioned in the recom mended position for transportation and lifting WARNING The robot is mechanically unstable if not se cured to the foundation 1 CAUTION The weight of the IRB 6740 robot is IRB 6740 310 2 8 1 370 kg IRB 6740 260 3 0 1 380 kg IRB 6740 240 3 2 1 350 kg IRB 6740 270 2 8 LID 1 440 kg IRB 6740 230 ...

Page 70: ...yes to the base of the robot 3 4x xx2100000718 Continues on next page 70 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 3 3 Lifting the robot with roundslings Continued ...

Page 71: ...pending on robot vari ant ii Roundsling C 4 pcs Lifting eye M20 D i Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport ii Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport WARNING Personnel must not under any circumstances be present under the suspended load 5 Raise the overhead c...

Page 72: ... tightening yield point utilization factor v according to VDI2230 0 3 mm i Level surface requirements i See Requirements foundation on page 39 Securing a floor mounted robot Use this procedure to orient and secure the robot floor mounted Note Action Make sure the installation site for the robot con forms to the specifications in section Technical data on page 37 1 The hole configuration of the bas...

Page 73: ...he holes in the base 6 For more information see Guide pins on page 60 Make sure the robot base is cor rectly fitted onto the pins Guide the robot gently using the attachment screws while lowering it into its mounting position 7 Screws M24 x 100 8 pcs quality 8 8 Fit the securing screws and washers in the attach ment holes of the base 8 Washers 4 mm flat washer Tightening torque Tighten the bolts i...

Page 74: ... 2 7 0 2 25 H8 R400 0 3 A B 2 x 2 0 25 H8 M M 0 3 A B A CLAxis 1 4x 90 4x 15 2x 7 5 K K Ref C 8x 49 5 4x 16 8 x 5 3 4x 45 H8 8x 30 0 5 K K 0 3 A B 0 12 0 3 A B xx2200001840 74 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 4 Orienting and securing the robot Continued ...

Page 75: ... is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes Note If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 76 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpec ted w...

Page 76: ...nable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously and instantly 1 xx0600002937 Supply 0V on pin 12 24V on pin 11 Note Do not interchange the 24V and 0V pins If they are mixed up damage can be caused to internal electrical components 2 Use the brake releasing button as described in Rel...

Page 77: ...tops or major damage to the robot Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot See the product specification for the robot listed in References on page 10 Product manu...

Page 78: ...s 4 R4 Measurements The measurements are given in mm R4 R3 R1b R1a G F E D C B A Variant 230 457 582 700 35 375 350 1 225 220 1 212 5 2 401 IRB 6740 310 2 8 230 457 582 700 35 375 350 1 225 220 1 412 5 2 401 IRB 6740 260 3 0 216 446 582 700 35 345 350 1 225 200 1 592 5 2 391 5 IRB 6740 240 3 2 230 457 582 700 35 375 350 1 225 380 1 212 5 2 401 IRB 6740 270 2 8 LID Continues on next page 78 Product...

Page 79: ...f gravity of arm load and robot payload Frame The table and figure shows allowed extra load on the frame Description JH 100 kgm2 Permitted extra load on frame JH JH0 M4 x R2 Recommended position see the fol lowing figure where JH0 is the moment of inertia of the equipment R is the radius m from the center of axis 1 M4 is the total mass kg of the equipment including bracket and harness 250 kg R xx2...

Page 80: ...oad up to maximum 200 kg in combination with the reduced payload use RobotStudio add in RobotLoad or contact ABB 200 400 200 C LAxis 3 C LAxis 4 xx2200002036 Continues on next page 80 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 81: ...6 M12 20 A A 80 190 4 x M12 24 min 2 x M12 18 min 2 x M8x1 25 24 2 x M10 15 min 2x 28 120 190 200 C L Axis 3 C L Axis 4 xx2200002039 Continues on next page Product manual IRB 6740 81 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 82: ...C L Axis 4 Axis 6 xx2200002040 Continues on next page 82 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 83: ... 16 min 2x 30 xx2200002055 Continues on next page Product manual IRB 6740 83 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 84: ...2200002056 Continues on next page 84 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 85: ...M10 20 min 30 4x 15 0 4 x M10 15 xx2200002057 Continues on next page Product manual IRB 6740 85 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 86: ...A B 8 min 100 H7 200 h8 1 X 45 1 X 45 A xx2200002061 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID IRB 6740 220 3 2 LID Fastener quality When fitting tools on the tool flange only use screws with quality 12 9 For other equipment use suitable screws and tightening torque for your application 86 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and c...

Page 87: ...e working range values set in the software parameters Note The mechanical stops are only installed as safety precaution to physically stop the robot from exceeding the working range set A collision with a mechanical stop always requires actions for repair and troubleshooting Movable mechanical stopii Fixed mechanical stopi Axis yes The working range can be reduced by altering the parameter values ...

Page 88: ...duction of working range Graduation of limited working range from 5 and 125 in both directions 15 Illustration reduced working range 5 5 5 0 5 0 125 125 A A xx2100000973 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional stops as well as deformed attachment screws must also be replaced after a hard collision Continues ...

Page 89: ...re 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 6740 via myABB Business Portal www abb com myABB Note Article number Spare part Screws and washers are en closed 3HAC048533 003 Movable mechanical stop set axis 1 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page ...

Page 90: ...re Location of the mechanical stops on page 89 Note Install the washer with the chamfer turned downwards A A xx2100000974 3 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 4 DANGER ...

Page 91: ...ded work range to limit the working range and before removing the mechanical stops For information about the option SafeMove see Application manual Functional safety and SafeMove If the mechanical stop is removed then the manipulator should have a marking for this for example a label If the robot is delivered with the option Extended work range then such a label is included on delivery Extending t...

Page 92: ...otion The Arm parameters Upper Joint Bound and Lower Joint Bound can be changed to the values corresponding to the actual installation 3 Related information The system parameters are described in detail in the reference manual see References on page 10 For more information about SafeMove see Application manual Functional safety and SafeMove 92 Product manual IRB 6740 3HAC085701 001 Revision A Copy...

Page 93: ...th equipment fitted on the robot by the customer low voltage signals and high voltage power supply protective ground Customer cables The customer cables also handle databus communication See the product manual for the controller see document number in References on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Conn...

Page 94: ...540 1 Signal cable shielded 22 m 3HAC2566 1 Signal cable shielded 30 m Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Continues on next page 94 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 3 Installation and commissioning 3 5 1 Robot cabli...

Page 95: ... Harness CP CS 7 m 3HAC085739 002 Harness CP CS 15 m 3HAC085739 003 Harness CP CS 22 m 3HAC085739 004 Harness CP CS 30 m Customer cables Ethernet floor cable Article number Ethernet floor cable length 3HAC079476 001 Ethernet cable 7 m 3HAC079476 002 Ethernet cable 15 m 3HAC079476 003 Ethernet cable 22 m 3HAC079476 004 Ethernet cable 30 m Product manual IRB 6740 95 3HAC085701 001 Revision A Copyrig...

Page 96: ...ict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Verify that all safety equipment is installed as designed for the application 5 Verify that no personnel are inside the safeguarded space 6 If maintenance or repair has been done verify the function of the part that was main tained 7 Verify the application in the operat...

Page 97: ... in different sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 15 before performing any service ...

Page 98: ...pecified in months regardless of whether the system is running or not Operating time specified in operating hours More frequent running means more frequent maintenance activities Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant 98 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 AB...

Page 99: ...lly during the first running hours Wipe down affected areas with a dry cloth x Cleaning the seals Cleaning the IRB 6740 on page 172 x Cleaning the robot Inspecting the balancing device on page 104 x Inspecting the balancing device Inspecting the dampers on page 110 x Inspecting the dampers Inspecting the information labels on page 112 x Inspecting the information labels Inspecting the axis 1 mecha...

Page 100: ...s 5 gearbox Changing the oil in axis 6 gearbox on page 162 x Changing the oil in axis 6 gearbox Replacing the SMB battery on page 167 x iii Replacing the SMB battery pack Lubricating the spherical roller bearing balancing device on page 170 x iv Lubricating the balancing device bearings i Operating hours counted by the DTC Duty Time Counter ii Replace when damage or cracks is detected or life limi...

Page 101: ...plications and limited use of bending backwards mode of axis 3 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 and major use of bending backwards of axis 3 iv The given life for the balancing device is based o...

Page 102: ...cated on each motor flange The figure shows axis 1 motor as an example xx1500001057 Plug in the evacuation hole New motors have a transparent plug sight glass installed in the evacuation hole Remove the plug or drill a drainage hole with diameter 3 mm if an open evacuation hole is required instead xx2200002188 Continues on next page 102 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2...

Page 103: ...s or if any oil has been spilled out from the evacuation hole replacement of the motor is recommended Note If oil is present in the evacuation it is an indication that the primary seal of the motor is leaking A secondary seal after the evacuation is keeping the oil out from the motor but it is still recommen ded to replace the motor at a suitable timing if oil is present in the evacuation 3 Replac...

Page 104: ...ng device is located at the top rear of the frame as shown in the figure The figure also shows the inspection points further described in the instructions xx2200001850 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 104 Product manual IRB 6740 3HAC085701 001 Revisio...

Page 105: ...ck for dissonance from the balancing device a tap ping sound caused by the springs inside the cylinder 2 How to replace the device is detailed in section Repla cing the balancing device on page211 This section also specifies the spare part number If dissonance is detected wipe clean the piston rod Check for dissonance from the piston rod squeaking may indicate worn plain bearings internal contamin...

Page 106: ... power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 3 Check the area around the o ring and radial sealings at the front ear for leakage 4 Maintenance set link ear 3HAC087168 001 Replace o ring and radial sealings if leaks are detected 5 Replacement of the complete bearing is described in section Replacing spherical roller bearing balancing...

Page 107: ...rded space 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 6740 107 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 2 Inspecting the balancing device Continued ...

Page 108: ...the cable harness Use this procedure to inspect cable harness of axes 1 6 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Continues on next page 108 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 3 Inspecting the cable harness ...

Page 109: ... Check the connectors and cables at the base visually for any damage 5 xx2200001791 Check the cabling going through the protec tion tube to detect possible cable chafing by using your hands inside the tube to feel the cables Ensure that the cables are un damaged Remove any objects that may cause pos sible cable chafing Replace damaged cabling if any CAUTION Sharp debris might occur Always wear pro...

Page 110: ...d in the table can be out of date See the latest spare parts of the IRB 6740 via myABB Business Portal www abb com myABB Note Article number Spare part Axis 2 3HAC046884 001 Damper Axis 3 3HAC11750 1 Damper Axis 5 3HAC054956 001 Damper Required equipment Visual inspection no tools are required Continues on next page 110 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All right...

Page 111: ...k attachment screws for deformation 3 Attachment screws If any damage is detected the damper must be replaced with a new one 4 Axis 2 and axis 3 M6x60 8 8 A2F 9ADA624 65 Axis 5 M6x25 A4 80 9ADA620 58 Locking liquid Loctite 2400 or equi valent Loctite 243 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page...

Page 112: ...bb com myABB The figures show the location of the information labels to be inspected The symbols are described in section Safety symbols on manipulator labels on page 19 A A 102 102 15 28 SECTION A A D E O P A J L Q R G G R R B F xx2200001848 Continues on next page 112 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 5 Inspecting the inform...

Page 113: ...ication label Kyodo Yushi TMO 150 3HAC032726 001 B Lubrication label 3HAC032905 001 C Warning label Tipping robot 3HAC9191 1 D ABB logotype label 3HAC0453 5 3HAC077301 002 E Continues on next page Product manual IRB 6740 113 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 5 Inspecting the information labels Continued ...

Page 114: ...Warning label Stored energy 3HAC9526 1 Q Lubrication label Optimol longtime PD 0 3HAC021525 001 R ABB logotype label 3HAC0453 2 3HAC5127 1 S Instruction label Lifting of robot 3HAC046732 001 T Required tools and equipment Visual inspection no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before ...

Page 115: ...l electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Mechanical stop pin 3HAC047059 001 Inspect the axis 1 mechanical stop pin 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 2 Continues on next page Product manual IRB 6...

Page 116: ...cified tightening torque 3 Locking liquid Loctite 2400 or equivalent Loctite 243 The attachment screw is accessed from the side xx2200001398 Make sure the mechanical stop pin can move in both directions 4 116 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 6 Inspecting the axis 1 mechanical stop Continued ...

Page 117: ...sumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6740 117 3HAC085701 001 Revision A Copy...

Page 118: ...29 2 Make sure that the oil temperature is 25 C 10 C 3 xx2200002147 Open the oil plug 4 xx2200002147 Check the oil level Required oil level is 0 10 mm below the oil plug hole 5 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 6 Further information about how to drain or fill with oil is found in section Changing the oil in ...

Page 119: ... DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 8 Product manual IRB 6740 119 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 7 Inspecting the oil level in axis 1 gearbox Continued ...

Page 120: ...sumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page 120 Product manual IRB 6740 3HAC085701 001 Revision A Copy...

Page 121: ...mperature is 25 C 10 C 3 xx2100002059 Open the oil plug 4 Check the oil level 5 Required oil level is 0 10 mm below oil plug hole floor mounted robot 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 the oil in axis 2 gearbox on page 14...

Page 122: ... DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 8 122 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 8 Inspecting the oil level in axis 2 gearbox Continued ...

Page 123: ...sumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6740 123 3HAC085701 001 Revision A Copy...

Page 124: ...c power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 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 29 4 xx2300000203 Open the oil plug 5 Continues on next page 124 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 A...

Page 125: ...d 8 Further information about how to drain or fill with oil is found in section Changing the oil in axis 3 gearbox on page 147 O ring G 1 2 3HAC061327 059 Refit the oil plug with a new o ring 9 Tightening torque 24 Nm xx2300000203 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 10 Product manual IR...

Page 126: ...sumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page 126 Product manual IRB 6740 3HAC085701 001 Revision A Copy...

Page 127: ...ure supply to the robot before entering the safe guarded space 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 29 4 xx2200001796 Open the oil plug 5 Continues on next page Product manual IRB 6740 127 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 10 Inspec...

Page 128: ...n section Changing the oil in axis 4 gearbox on page 152 O ring G 1 2 3HAC061327 059 Refit the oil plug with a new o ring 8 Tightening torque 24 Nm xx2200001796 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 9 128 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights rese...

Page 129: ...sumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6740 129 3HAC085701 001 Revision A Copy...

Page 130: ...ure supply to the robot before entering the safe guarded space 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 29 4 xx2200001798 Open the oil plug 5 Continues on next page 130 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 11 Inspec...

Page 131: ...n section Changing the oil in axis 5 gearbox on page 157 O ring G 1 2 3HAC061327 059 Refit the oil plug with a new o ring 8 Tightening torque 24 Nm xx2200001798 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 9 Product manual IRB 6740 131 3HAC085701 001 Revision A Copyright 2023 ABB All rights rese...

Page 132: ... in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 060 O ring G 1 4 Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Inspecting the oil level in axis 6 gearbox Use this procedure to inspect the oil level in the gearbox Note Action Run the robot to calibration position 1 Cont...

Page 133: ...10 2 8 IRB 6740 260 3 0 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID 75 80 mm below oil plug hole IRB 6740 240 3 2 IRB 6740 220 3 2 LID 51 58 mm below 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 the oil in axis 6 gearbox ...

Page 134: ...DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 9 134 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 3 12 Inspecting the oil level in axis 6 gearbox Continued ...

Page 135: ...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 Location of gearboxes The figure shows the location of the gearboxes xx2200001901 Axis 1 gearbox A Axis 2 gearbox B Axis 3 gearbox C Axis 4 gearbox D Axis 5 gearbox E Axis 6 gearbox ...

Page 136: ...uggested dispenser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring 136 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 4 1 Type of lubrication in gearboxes Continued ...

Page 137: ...unt of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubric ation in gearboxes on page 135 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting ...

Page 138: ... risks see Gearbox lubricants oil or grease on page 29 2 Make sure that the oil temperature is 25 C 10 C 3 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 4 xx2200002147 Remove the plug from the venting hole WARNING Let the venting hole stay open during draining and filling using the dispenser to avoid ...

Page 139: ...8 Floor mounted robot Filling oil into the axis 1 gearbox Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 2 Continues on next page Produc...

Page 140: ... Note The amount of oil to be filled depends on the amount previously being drained 5 Required oil level 0 10 mm below the oil plug hole Inspect the oil level through the inspection hole CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 6 xx2200002147 Remove the oil dispenser and refit the protective cap to t...

Page 141: ...e 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 See Test run after installation maintenance or repair on page 96 10 Product manual IRB 6740 141 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 4 2 Changing the oil in axis 1 gearbox Continued ...

Page 142: ...e amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubric ation in gearboxes on page 135 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refit...

Page 143: ... several safety risks see Gearbox lubricants oil or grease on page 29 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 xx2300000002 Remove the plug from the venting hole WARNING Let the venting hole stay open during draining and filling using the dispenser to avoid damaging vital parts in the gearbox...

Page 144: ...orma tion 7 Filling oil into the axis 2 gearbox Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 2 Continues on next page 144 Product manu...

Page 145: ...f oil to be filled depends on the amount previously being drained 5 Required oil level is 0 10 mm below oil plug hole Inspect the oil level at the ventilation hole level plug CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 6 More information is found in Inspecting the oil level in axis 2 gearbox on page 121...

Page 146: ...00002059 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 9 146 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 4 3 Changing the oil in axis 2 gearbox Continued ...

Page 147: ...n be found in section Type of lubric ation in gearboxes on page 135 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Note Doc...

Page 148: ... 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 29 3 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 4 Continues on next page 148 Product manual IRB 6740 3HAC085701 001 Revision...

Page 149: ...he oil hole and connect the oil dis penser 6 Suck out the oil with the oil dispenser Note There will be some oil left in the gear after draining 7 WARNING Used oil is hazardous material and must be disposed of in a safe way See Decom missioning on page 639 for more informa tion 8 Continues on next page Product manual IRB 6740 149 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 M...

Page 150: ...ply 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 29 3 xx2300000203 Remove the plug from the ventilation hole WARNING Let the venting hole stay open during draining and filling using the dispenser to avoid damaging vital parts in the gearbox 4 Continues on next page 150 Product manual IR...

Page 151: ...lation hole level plug CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 7 Remove the oil dispenser 8 Refit the protective cap on the nipple O ring G 1 2 3HAC061327 059 Refit the oil plug with a new o ring 9 Tightening torque 24 Nm xx2300000203 DANGER Make sure all safety requirements are met when performing ...

Page 152: ...of lubric ation in gearboxes on page 135 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Note Document number Document name ...

Page 153: ...Gearbox lubricants oil or grease on page 29 3 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 4 Place the oil collecting vessel underneath the oil drain plug 5 xx2100002095 Remove the oil plug from the drain hole and let the oil run into the vessel 6 Continues on next page Product manual IRB 6740 153 3H...

Page 154: ...l plug for the drainage hole with a new o ring 9 Tightening torque 24 Nm xx2100002095 Filling oil into the axis 4 gearbox Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Continues on next page 154 Product manual IRB 6740 3HAC085701 001 Revision...

Page 155: ...ined 4 Required oil level is 0 10 mm below oil plug hole Inspect the oil level CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 5 See Inspecting the oil level in axis 4 gear box on page 127 O ring G 1 2 3HAC061327 059 Refit the oil plug with a new o ring 6 Tightening torque 24 Nm xx2200001796 Continues on ne...

Page 156: ...t when performing the first test run See Test run after installation maintenance or repair on page 96 7 156 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 4 5 Changing the oil in axis 4 gearbox Continued ...

Page 157: ...e of lubric ation in gearboxes on page 135 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Required documents Note Document number Document nam...

Page 158: ...ricants oil or grease on page 29 3 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 4 xx2200001798 Remove the oil plug from the fill hole Note The oil plug hole is opened to speed up the drainage 5 Place the oil collecting vessel underneath the oil drain plug 6 Continues on next page 158 Product manual I...

Page 159: ... drainage hole with a new o ring 9 Tightening torque 24 Nm xx2200001797 Filling oil into the axis 5 gearbox Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Continues on next page Product manual IRB 6740 159 3HAC085701 001 Revision A Copyright 2...

Page 160: ...10 mm below oil plug hole Inspect the oil level at the oil fill level hole level plug CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 5 More information is found in Inspecting the oil level in axis 5 gearbox on page 130 O ring G 1 2 3HAC061327 059 Refit the oil plug with a new o ring 6 Tightening torque 24 ...

Page 161: ...t when performing the first test run See Test run after installation maintenance or repair on page 96 7 Product manual IRB 6740 161 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 4 6 Changing the oil in axis 5 gearbox Continued ...

Page 162: ...e of lubric ation in gearboxes on page 135 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 135 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HAC061327 060 O ring G 1 4 Required documents Note Document number Document nam...

Page 163: ...Gearbox lubricants oil or grease on page 29 3 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 4 Place the oil collecting vessel underneath the oil drain plug 5 xx2100002101 Remove the oil plug from the drain hole and let the oil run into the vessel 6 Continues on next page Product manual IRB 6740 163 3H...

Page 164: ...lug for the drainage hole with a new o ring 9 Tightening torque 20 Nm xx2100002101 Filling oil into the axis 6 gearbox Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Continues on next page 164 Product manual IRB 6740 3HAC085701 001 Revision A ...

Page 165: ...nt previously being drained 4 See Inspecting the oil level in axis 6 gear box on page 132 Check the oil level CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 5 O ring G 1 4 3HAC061327 060 Refit the oil plug with a new o ring 6 Tightening torque 20 Nm xx2100002077 Continues on next page Product manual IRB 67...

Page 166: ...t when performing the first test run See Test run after installation maintenance or repair on page 96 7 166 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 4 7 Changing the oil in axis 6 gearbox Continued ...

Page 167: ...Only replace with the specified spare part or an ABB approved equivalent 3HAC044075 001 Battery pack Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 652 Standard toolkit Removing the battery Use this procedure to remove the SMB battery Note Action This is done in order to facilitate updating of the revolution counter Jog the robot t...

Page 168: ... can cause shortage on the boards which can result in hazardous failures 4 Pull out the battery and disconnect the battery cable 5 Remove the SMB battery Note Battery includes protection circuits Only replace with a specified spare part or with an ABB ap proved equivalent 6 Refitting the battery Use this procedure to refit the SMB battery Note Action DANGER Turn off all electric power supply hydra...

Page 169: ...ector is assembled in the correct direction according to its keying 3 Tightening torque 6 Nm xx2100002131 Secure the SMB battery cover with its attachment screws 4 See Updating revolution counters on page 616 Update the revolution counters 5 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 6 Product...

Page 170: ...bol GR 100 0 PD 31 ml 3HAA1001 294 Grease 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 170 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All ri...

Page 171: ... until new grease appears in the lower hole 2 xx2200001477 Use a grease nipple Refit the two screws and wipe clean from residual grease 3 Product manual IRB 6740 171 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 5 1 Lubricating the spherical roller bearing balancing device Continued ...

Page 172: ...6 months 3 If the oil level is decreased replace the gearbox 4 Oil spills discolors painted surfaces Oil spills on painted surfaces of the robot can result in discoloration Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil WARNING Turn off all electrical power supplies to the robot before starting the cleaning Special cleaning considerations ...

Page 173: ...aning agent to be tested on a small surface prior usage on complete manipulator Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard or Foundry Plus can be cleaned by rinsing with water water cleaner The following list defines the prerequisites Spray nozzle should be used with minimum 45 spread Minimum distance from nozzle to encapsulation 0 4...

Page 174: ...01055 Rotational sealings xx2300001056 Gaskets xx2300001057 Connectors Continues on next page 174 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 6 1 Cleaning the IRB 6740 Continued ...

Page 175: ...rial such as sand dust and chips if it prevents cable movement Clean the cables if they have a crusty surface for example from dry release agents Cassette sealings Minor seepage of grease from the seals can occur Wipe down affected areas with a dry cloth Product manual IRB 6740 175 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 4 Maintenance 4 6 1 Cleaning the IRB 6740 Continued ...

Page 176: ...This page is intentionally left blank ...

Page 177: ...by ABB Report replaced units Note When replacing a part on the IRB 6740 report to your local ABB the serial number the article number and the revision of both the replaced unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 15 before commencing ...

Page 178: ...ure with the knob until the correct value is shown on the manometer CAUTION The pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur T...

Page 179: ...be exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradual...

Page 180: ... started 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 180 Product manual IR...

Page 181: ...an workbenches Use a protective sleeve for the main lip during mounting when sliding over threads keyways or other sharp edges Radial sealings A radial sealing consists of a flexible rubber lip bonded to a rigid metal case Only one side of the sealing is static with a metal insert xx2300000433 Note Action Check the sealing to ensure that The sealing is of the correct type There is no damage on the...

Page 182: ...f the space between the dust lip and the main lip with grease If the sealing is without dust lip just lubricate the main lip with a thin layer of grease A xx2000000072 A Gap Mount the sealing correctly with a mounting tool Never hammer directly on the sealing as this may result in leakage 4 Continues on next page 182 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights r...

Page 183: ...r that can cause lubricant to seep out and in some cases produce minor residues of rubber particles This is normal behavior of the sealing and does not indicate a seal problem Wipe the surrounding surfaces after initial run time Flange sealings and static sealings The following procedure describes how to fit flange sealings and static sealings Action Check the flange surfaces They must be even and...

Page 184: ...ccuracy or deformation 2 Check the o ring grooves and mating surfaces 3 They should be free of pores contamination and obvious scratches damage 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 6 184 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 2 3 Mo...

Page 185: ...paint Standard Foundry Plus ABB Orange 3HAC037052 001 Touch up paint Standard Foundry Plus Removing Description Action xx2300000950 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 6740 185 3HAC085701 001 Revision A C...

Page 186: ...in axis 1 gearbox 3 Remove the cable harness from the base 4 Remove the protection ring from the frame 5 Replace the cassette sealing 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 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC070194 011 Cassette sealing Continues ...

Page 187: ...ith the tool 3HAC074411 001 Hydraulic press equipment balan cing device Used for removing and fitting shaft and bearings User instructions are enclosed with the tool 3HAC028920 001 Dismantle and mounting tool To be used with the press and puller tools See technical specifications in the user instructions for the press equipment 3HAC13086 1 Hydraulic pump 80 MPa To be used with the press and puller...

Page 188: ...pace 3 Remove any installed equipment on or close to the balancing device 4 See Changing the oil in axis 1 gearbox on page 137 Drain 500 ml of oil from the axis 1 gearbox to lower the oil level beneath the cassette sealing 5 Unloading the balancing device springs and locking position with the Hydraulic press equipment balancing device Use this procedure to unload and lock the balancing device in u...

Page 189: ...osed with the tool xx0900000813 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 Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 1 ...

Page 190: ...essory to the shackle and raise to unload the weight 3 xx2200001459 Removing the shaft in the front link ear Note Action xx2200001460 Remove the protection plug at the link ear 1 Continues on next page 190 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cassette sealing Continued ...

Page 191: ...ruc tions enclosed with the equipment 3 User instructions are enclosed with the tool xx0900000813 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 on next page Product manual IRB 6740 191 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5...

Page 192: ... a risk of damaging the bearing inside The damaged VK cover must be replaced with a new Remove the protection plug from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 VK cover 100x10 3HAA2166 13 Position for screwdriver xx1300000662 Vent hole for air pressure xx2300000003 Wipe off any residual grease inside the re cess 2 Continues...

Page 193: ...ke the balan cing device go free If this is not possible the shaft end must be pulled out a bit with the dismantle and mounting tool see Removing the shaft end cradle on page 249 5 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 6 Continues on next page Product manual IRB 6740 193 3HAC085701 001 Revision A Copyright 2023...

Page 194: ...all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2100000981 Remove the base cover 2 xx2100001109 Loosen the connectors R1 MP R1 SMB 3 Continues on next page 194 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cassette sealing Continued ...

Page 195: ...cable harness safely on the frame or on the axis 2 motor 2 Removing the protection ring in the frame Note Action Foundry Plus 1 Cut the flange sealant at the protection ring xx2200001610 Remove the protection ring 2 Continues on next page Product manual IRB 6740 195 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cassette sealing Continued ...

Page 196: ...cond part of the mounting tool 2 xx2100002216 Drill three holes in the old cassette sealing through the holes in the tool Use a drill 3 5 mm 3 xx2100002217 Screw the three enclosed wood screws through the drilled holes and into the cassette sealing 4 Continues on next page 196 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis...

Page 197: ...cleaner 6 Refitting the cassette sealing Use these procedures to refit the cassette sealing Refitting the cassette sealing Note Action xx2100002377 Remove any old assembly lubricant residues or other contamination from the contact surfaces for the sealing in the frame 1 Continues on next page Product manual IRB 6740 197 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 ...

Page 198: ...d part of the mounting tool on top of the sealing 4 xx2100001192 First push down the tool by hand to guide down the sealing aligned 5 Then use a rubber mallet to knock down the tool and sealing evenly until the sealing has reached the bottom all the way around Remove the mounting tool 6 Continues on next page 198 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reser...

Page 199: ... casol 3110 Waxcoat Recommended drying time is 24h Protection type Foundry Plus Apply rust preventive to the outer surface of the gearbox tube and outer surface of the frame hole all the way down to the cassette sealing as shown in the figure 8 xx2100001170 xx2100001172 Continues on next page Product manual IRB 6740 199 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 ...

Page 200: ...s undamaged and placed in its groove on the protection ring 10 xx2100001136 Replace if damaged Refitting the cable harness in the base Note Action xx2200001924 Run the robot cable harness through the frame recess and down through the protec tion tube 1 Continues on next page 200 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the ax...

Page 201: ...les are facing the base cover when connected 3 Screw dimension for R1 MP M6x25 A2 70 Connect connectors R1 MP and R1 SMB 4 Tightening torque for R1 MP 10 Nm Tightening torque for R1 SMB 10 Nm xx2100001109 Screw dimension M6x16 Connect the earth cable 5 Washer dimension 6 4x17x3 Tightening torque 10 Nm xx2200001790 Continues on next page Product manual IRB 6740 201 3HAC085701 001 Revision A Copyrig...

Page 202: ...B C xx1400000367 A Mercasol red dotted lines B Balancing device C Shaft end in the cradle Foundry Plus Apply Mercasol on matching surfaces on the shaft end in the cradle and the balan cing device See the figure 2 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 3 Continues on next page 202 Product manual IRB 6740 3HAC0857...

Page 203: ...be fitted 5 xx2200001470 Hold a big screwdriver between the cradle and the balancing device while securing each screw in following step This is done to keep the distance between the balancing device and the bearing while tightening the screw 6 Continues on next page Product manual IRB 6740 203 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cass...

Page 204: ...Note Action Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 1 Lifting accessory chain 3HAC15556 1 Remove all residue of Loctite in the screw hole of the shaft 2 Wipe all contact surfaces inside the recess clean from contamination 3 A B C A xx1400000368 A Front link ear B Shaft C Mercasol red dotted lines Foundry Plus Apply Mercasol on the surface...

Page 205: ...ss in the shaft using the dismantle and mounting tool according to user instructions en closed with the equipment 7 User instructions are enclosed with the tool xx0900000813 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 on next page Product manual IRB 6740 205...

Page 206: ...octite 2400 or equivalent Loctite 243 xx2200001916 Tightening torque 200 Nm Secure the shaft with screw and washer 9 xx2200001461 xx2200001460 Fit the protection plug 10 Continues on next page 206 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cassette sealing Continued ...

Page 207: ...d wipe clean from residual grease 12 Remove the lifting accessory from the balancing device 13 Securing the shaft ends Note Action Tightening torque 280 Nm Secure both shaft end screws with tighten ing torque 1 xx2200001471 Continues on next page Product manual IRB 6740 207 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cassette sealing Continu...

Page 208: ... to let go of overpressure if the VK covers are hard to fit xx2300000003 2 xx2200001464 Concluded refitting of the front shaft Note Action xx2200001332 Remove the locking screw M16x120 1 Continues on next page 208 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cassette sealing Continued ...

Page 209: ... incorrectly will cause serious injury Read and follow enclosed user instructions for the tool Hex socket head cap screw M10x25 8 8 A3F Apply flange sealant and refit the cover plate on the back of the balancing device 4 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 5400 or equivalent Loctite 577 xx2200001330 Continues on next page Product manual IRB 6740 209 3HAC085701 001 R...

Page 210: ...ction See Changing the oil in axis 1 gearbox on page 137 Refill oil in the gearbox 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 2 210 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the axis 1 cassette sealing Continued ...

Page 211: ...e 2 Remove the shaft in the front link ear 3 Replace the balancing device 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 6740 via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC051384 002 Graphite White 3HAC051384 003 ABB Orange Balancing device Continues on next page Product manual ...

Page 212: ...ructions are enclosed with the tool 3HAC074411 001 Hydraulic press equipment balan cing device Used for removing and fitting shaft and bearings User instructions are enclosed with the tool 3HAC028920 001 Dismantle and mounting tool To be used with the press and puller tools See technical specifications in the user instructions for the press equipment 3HAC13086 1 Hydraulic pump 80 MPa To be used wi...

Page 213: ...nd into the lower arm to secure the weight of the lower and upper arms CAUTION Do not tighten the lock screw since too hard tightening could damage the gear 2 xx2200001332 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Continues on next page Product manual IRB 6740 213 3HAC085701 001 Revision A Copyright...

Page 214: ...he back of the balancing device DANGER DO NOT remove any other screws than the rear cover attachment screws 2 Hydraulic press equipment balancing device 3HAC074411 001 Unload the balancing device with the press equipment to make the piston rod and front ear adjustable when pulling the shaft out 3 User instructions are enclosed with the tool xx0900000813 Go to the user instructions enclosed with th...

Page 215: ...ly 1 Lifting shackle SA 10 8 NA1 Fit a lifting shackle to the balancing device 2 xx2200001355 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle and raise to unload the weight 3 xx2200001459 Continues on next page Product manual IRB 6740 215 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the balancing device Continued ...

Page 216: ... link ear 1 Hex socket head cap screw M16x70 8 8 A3F Unscrew the attachment screw and washer 2 Washer Steel 17x25x3 xx2200001461 Continues on next page 216 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the balancing device Continued ...

Page 217: ...ns are enclosed with the tool xx0900000813 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 on next page Product manual IRB 6740 217 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the balancing device Continued ...

Page 218: ... is a risk of damaging the bearing inside The damaged VK cover must be replaced with a new Remove the protection plug from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 VK cover 100x10 3HAA2166 13 Position for screwdriver xx1300000662 Vent hole for air pressure xx2300000003 Wipe off any residual grease inside the re cess 2 Contin...

Page 219: ... make the balan cing device go free If this is not possible the shaft end must be pulled out a bit with the dismantle and mounting tool see Removing the shaft end cradle on page 249 5 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 6 Continues on next page Product manual IRB 6740 219 3HAC085701 001 Revision A Copyright 2...

Page 220: ...ing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 1 Lifting shackle SA 10 8 NA1 Fit a lifting shackle to the balancing device 2 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle 3 xx2200001915 Continues on next page 220 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Repla...

Page 221: ...o make the piston rod and front ear adjustable when pulling the shaft out 2 User instructions are enclosed with the tool xx0900000813 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 Refitting the balancing device Perform this procedure on both sides Note Action DANGER Mak...

Page 222: ... cing device See the figure 2 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 3 xx2200001469 Lift the balancing device into position in the cradle 4 Continues on next page 222 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the balancing device Continued ...

Page 223: ...ews insert them on both sides and tighten by hand 7 Washer 3HAC047681 001 The screws are not possible to torque tighten at this point since the front ear is not fastened to the lower arm Locking liquid Loctite 2400 or equivalent Loctite 243 xx2200001475 Refitting the front shaft of the balancing device Note Action Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if n...

Page 224: ...00001918 Align the balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 5 xx2200001917 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 next page 224 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Repla...

Page 225: ...ctly will cause serious injury Read and follow enclosed user instructions for the tool Hex socket head cap screw M16x70 8 8 A3F Apply locking liquid on the first threads of the screw 8 Washer Steel 17x25x3 Locking liquid Loctite 2400 or equivalent Loctite 243 xx2200001916 Tightening torque 200 Nm Secure the shaft with screw and washer 9 xx2200001461 Continues on next page Product manual IRB 6740 2...

Page 226: ...Refit the two screws and wipe clean from residual grease 12 Remove the lifting accessory from the balancing device 13 Securing the shaft ends Note Action Tightening torque 280 Nm Secure both shaft end screws with tighten ing torque 1 xx2200001471 Continues on next page 226 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the balancin...

Page 227: ...adle to let go of overpressure if the VK covers are hard to fit xx2300000003 2 xx2200001464 Concluded refitting of the front shaft Note Action xx2200001332 Remove the locking screw M16x120 1 Continues on next page Product manual IRB 6740 227 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the balancing device Continued ...

Page 228: ...ool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool Hex socket head cap screw M10x25 8 8 A3F Apply flange sealant and refit the cover plate on the back of the balancing device 4 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 5400 or equivalent Loctite 577 xx2200001330 Continues on next page 228 Product manual IRB 6740 3HAC085701 00...

Page 229: ...e met when performing the first test run See Test run after installation maintenance or repair on page 96 5 Product manual IRB 6740 229 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the balancing device Continued ...

Page 230: ...erformed 1 Unload the balancing device 2 Remove the shaft in the front link ear 3 Replace the spherical roller bearing 4 Restore the balancing device 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 6740 via myABB Business Portal www abb com myABB Continues on next page 230 Product manual IRB 6740 3HAC085701 001 ...

Page 231: ...ss equipment 3HAC11731 1 Hydraulic cylinder To be used with the press and puller tools See technical specifications in the user instructions for the press equipment 3HAC13086 1 Hydraulic pump 80 MPa SA 10 8 NA1 Lifting shackle Lifting instruction 3HAC15880 2 enclosed 3HAC15556 1 Lifting accessory chain Content is defined in section Standard toolkit on page 652 Standard toolkit Required service par...

Page 232: ...ame and into the lower arm to secure the weight of the lower and upper arms CAUTION Do not tighten the lock screw since too hard tightening could damage the gear 2 xx2200001332 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Continues on next page 232 Product manual IRB 6740 3HAC085701 001 Revision A Copy...

Page 233: ...balancing device DANGER DO NOT remove any other screws than the rear cover attachment screws 2 Hydraulic press equipment balancing device 3HAC074411 001 Unload the balancing device with the press equipment to make the piston rod and front ear adjustable when pulling the shaft out 3 User instructions are enclosed with the tool xx0900000813 Go to the user instructions enclosed with the press tool DA...

Page 234: ...ackle SA 10 8 NA1 Fit a lifting shackle to the balancing device 2 xx2200001355 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle and raise to unload the weight 3 xx2200001459 Continues on next page 234 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing spherical roller bearing balancing device link ear Contin...

Page 235: ... socket head cap screw M16x70 8 8 A3F Unscrew the attachment screw and washer 2 Washer Steel 17x25x3 xx2200001461 Continues on next page Product manual IRB 6740 235 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing spherical roller bearing balancing device link ear Continued ...

Page 236: ...ollow enclosed user instructions for the tool Removing the spherical roller bearing link ear Note Action xx2200001493 Lower the balancing device to a position where it is possible to apply the dismantle and mounting tool to the link ear 1 xx2200001494 Unscrew the attachment screws securing the end cover remove end cover and radial sealing with a screwdriver 2 Continues on next page 236 Product man...

Page 237: ...o 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 Refitting the spherical roller bearing Refitting the spherical roller bearing link ear Note Action Wipe clean all contact surfaces from resid ual grease 1 Continues on next page Product manual IRB 6740 237 3HAC085701 001 Revi...

Page 238: ...is turned accord ing to the figure 3 xx2200001497 xx2200001498 Use a plastic mallet or similar on the Press tool J and refit the radial sealing 4 Apply some grease on the surface for the bearing 5 Continues on next page 238 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing spherical roller bearing balancing device link ear Continued ...

Page 239: ...ad and follow enclosed user instructions for the tool xx2200001495 Refit the o ring 7 xx2200001494 Secure the end cover including the radial sealing ring with the screws 8 Refitting the front shaft of the balancing device Note Action Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 1 Lifting accessory chain 3HAC15556 1 Continues on next page Produ...

Page 240: ... front ear 4 xx2200001918 Align the balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 5 xx2200001917 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 next page 240 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 R...

Page 241: ... serious injury Read and follow enclosed user instructions for the tool Hex socket head cap screw M16x70 8 8 A3F Apply locking liquid on the first threads of the screw 8 Washer Steel 17x25x3 Locking liquid Loctite 2400 or equivalent Loctite 243 xx2200001916 Tightening torque 200 Nm Secure the shaft with screw and washer 9 xx2200001461 Continues on next page Product manual IRB 6740 241 3HAC085701 0...

Page 242: ...two screws and wipe clean from residual grease 12 Remove the lifting accessory from the balancing device 13 Removing the lifting accessory and locking screw Note Action Remove the lifting accessory from the bal ancing device 1 Continues on next page 242 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing spherical roller bearing balanci...

Page 243: ...72 Foundry Plus Apply Mercasol in the hole for the locking screw 3 Continues on next page Product manual IRB 6740 243 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing spherical roller bearing balancing device link ear Continued ...

Page 244: ...nstructions for the tool Hex socket head cap screw M10x25 8 8 A3F Apply flange sealant and refit the cover plate on the back of the balancing device 1 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 5400 or equivalent Loctite 577 xx2200001330 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run See Test run after i...

Page 245: ...cedure containing the major actions to be performed 1 Unload the balancing device 2 Replace the rear bearing 3 Restore the balancing device 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 6740 via myABB Business Portal www abb com myABB Continues on next page Product manual IRB 6740 245 3HAC085701 001 Revision A...

Page 246: ...ecifications in the user instructions for the press equipment 3HAC13086 1 Hydraulic pump 80 MPa To be used with the press and puller tools See technical specifications in the user instructions for the press equipment 3HAC11731 1 Hydraulic cylinder SA 10 8 NA1 Lifting shackle Lifting instruction 3HAC15880 2 enclosed 3HAC15556 1 Lifting accessory chain Content is defined in section Standard toolkit ...

Page 247: ...e lower arm to secure the weight of the lower and upper arms CAUTION Do not tighten the lock screw since too hard tightening could damage the gear 2 xx2200001332 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Continues on next page Product manual IRB 6740 247 3HAC085701 001 Revision A Copyright 2023 ABB ...

Page 248: ...the balancing device DANGER DO NOT remove any other screws than the rear cover attachment screws 2 Hydraulic press equipment balancing device 3HAC074411 001 Unload the balancing device with the press equipment to make the piston rod and front ear adjustable when pulling the shaft out 3 User instructions are enclosed with the tool xx0900000813 Go to the user instructions enclosed with the press too...

Page 249: ...2200001355 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle and raise to unload the weight 3 xx2200001459 Removing the shaft end cradle The procedure of removing the shaft end in the cradle is the same on both sides Note Remove one shaft end at a time Continues on next page Product manual IRB 6740 249 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Re...

Page 250: ...er must be replaced with a new Remove the protection screw from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 VK cover 100x10 3HAA2166 13 Position for screwdriver xx1300000662 Vent hole for air pressure xx1700002189 Wipe off all residual grease inside the re cess 2 Continues on next page 250 Product manual IRB 6740 3HAC085701 001...

Page 251: ...001470 Before pulling out the shaft end put a big screw driver between the cradle and balan cing device and use it as a distance tool 5 Continues on next page Product manual IRB 6740 251 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 3 Replacing the rear bearings on the balancing device Continued ...

Page 252: ...ese procedures to refit the bearing in the cradle Refitting the shaft end and rear bearings Note Action Wipe clean all contact surfaces from resid ual grease and other contamination inside the recess 1 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 Apply some grease in the...

Page 253: ...ions for the tool xx2300000006 Fit the retaining ring bore 5 Hex socket head cap screw M16x70 12 9 Gleitmo 603 Geomet 500 Apply locking liquid on the attachment screw 6 Washer 3HAC047681 001 Locking liquid Loctite 2400 or equivalent Loctite 243 Tightening torque 280 Nm While using the screw driver between the cradle and balancing device as a distance tool tighten the attachment screw com pletely 7...

Page 254: ...4 Remove both the screw and the protection plug then refill grease from the inner hole See figure 9 xx2300000004 xx2300000005 Refit the screw including washer and the protection plug 10 Wipe clean from residual grease 11 Continues on next page 254 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 3 Replacing the rear bearings on the balancing dev...

Page 255: ... 1 xx2200001332 Remove the lock screw M16x120 2 xx1400000372 Foundry Plus Apply Mercasol in the hole for the locking screw 3 Continues on next page Product manual IRB 6740 255 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 4 3 Replacing the rear bearings on the balancing device Continued ...

Page 256: ...er instructions for the tool Hex socket head cap screw M10x25 8 8 A3F Apply flange sealant and refit the cover plate on the back of the balancing device 1 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 5400 or equivalent Loctite 577 xx2200001330 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run See Test run aft...

Page 257: ... 4 Replace the arm house cover including the cassette sealing 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 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Gasket and cassette sealing included IRB 6740 310 2 8 IRB 6740 260 3 0 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID 3...

Page 258: ... tools and equipment Note Article number Equipment For removing and fitting the arm house cover including the axis 4 cassette sealing 3HAC079878 001 Replacement tool for arm house cover Used to support the arm house cover Screw M6 x minimum 70 mm Content is defined in section Standard toolkit on page 652 Standard toolkit Removing the arm house cover including the cassette sealing Use these procedu...

Page 259: ...t tool is used the other axes may need to be jogged to another position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 3 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressu...

Page 260: ... 1 xx2100002625 Cut the cable tie 2 xx2100002495 Remove the motor cover by removing the screws 3 xx2200001734 Disconnect the signal cable connector 4 Continues on next page 260 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 261: ... cables 7 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 Product manual IRB 6740 261 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 262: ... the connector bracket 3 xx2200001731 Remove the connector screw 4 Disconnect the motor cables 5 Continues on next page 262 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 263: ...The screw is located at the bottom of the carrier 2 xx1300000666 Lift out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 3 Continues on next page Product manual IRB 6740 263 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 264: ... 6 connectors 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 2 xx2300000031 Remove the side cover on the arm tube 3 Continues on next page 264 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repai...

Page 265: ...e screw is reached from outside the up per arm 4 xx2300000032 xx2200002142 Remove the arm house metal clamp 5 Continues on next page Product manual IRB 6740 265 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 266: ...on 1 working at the side hole 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 7 xx2300000037 Person 2 working a...

Page 267: ...screw to the part of the tool designed as a cross all the way until it bottoms 2 xx2100001253 xx2100001243 Fit the cross to the tube shaft with four M8 screws 3 xx2100001254 Fit the three armed tool part with three screws and wing nuts 4 Continues on next page Product manual IRB 6740 267 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover i...

Page 268: ...n the new cover WARNING Oil residues will drip out during removal Make sure that protective gear like goggles and gloves are always worn WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page29 8 WARNING Used oil is hazardous material and must be dis posed of in a safe way See Decommissioning on page 639 for more information Continues on next page 2...

Page 269: ...te Action Replacement tool for arm house cover 3HAC079878 001 Fit three holders to the arm house cover to hold the cassette sealing in place during refitting of cover 1 Use the holders marked with 2 xx2100001266 xx2100001267 Fit the three armed tool part with three screws 2 xx2100001265 Prepare the refitting tool by removing the middle screw from the part of the tool designed as a cross 3 Continue...

Page 270: ...lace by rotating the screw Check that the guide pins are inserted in the arm house 6 Torx pan head screw M6x16 A4 80 Secure the cover with the attachment screws Use locking liquid 7 Locking liquid Loctite 2400 or equivalent Loctite 243 Ensure gap closure between cover and arm house Tightening torque 10 Nm xx2100001255 Remove the tool 8 Continues on next page 270 Product manual IRB 6740 3HAC085701 ...

Page 271: ... 80 Fit the cable guide with attachment screws Use locking liquid 2 Locking liquid Loctite 2400 or equivalent Loctite 243 xx2100001242 Refitting the cable harness to the upper arm Note Action Torx pan head screw M6x16 A4 80 Refit the metal clamp beneath the arm house 1 Tightening torque 10 Nm xx2200002142 Continues on next page Product manual IRB 6740 271 3HAC085701 001 Revision A Copyright 2023 A...

Page 272: ...o and through the upper arm tube Tip This step is best performed by two persons 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 3 xx2300000039 Person 2 working at the side hole xx2300000040 Continues on...

Page 273: ...her Move the cable harness past the axis 5 motor and into the wrist 4 xx2300000035 Person 2 working at the wrist xx2300000041 Torx pan head screw M6x16 A4 80 Refit the metal clamp axis 4 inside the arm tube Note The screw is reached from outside the up per arm 5 Tightening torque 10 Nm xx2300000033 xx2300000032 Continues on next page Product manual IRB 6740 273 3HAC085701 001 Revision A Copyright ...

Page 274: ...ews Foundry Plus Tighten the two screws closest to the outlet first shown in figure to avoid deformation xx2100002636 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001735 Continues on next page 274 Product manual IRB 6740 3HAC085701 001 Revision A Copyrig...

Page 275: ... screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms xx2200001734 Connect the signal cable connector Connect in accordance with the markings on the connectors 4 Connection box cover with gasket 3HAC072863 003 Inspect the gasket Replace if damaged 5 xx2200002141 Continues on next page Product manual I...

Page 276: ... 3HAC057966 003 Secure the cabling with a cable strap 8 xx2100002625 Inserting the axis 6 motor cables Note Action 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 brake release tool to the axis 5 motor connector release the brakes and move axis 5 manually to 90 1 Continues on next page 276 Product manual IRB...

Page 277: ...position 3 xx1300000485 Secure the carrier with the M4x10 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 4 Continues on next page Product manual IRB 6740 277 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Repla...

Page 278: ...rew is to secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 2 xx2200001731 xx2200001921 Snap the signal connectors to each other in t...

Page 279: ... the figure CAUTION Route the signal cabling correctly to avoid cable damage 5 Connection box cover MT100X with gasket Inspect the gasket 6 3HAC079381 003 Graphite White Replace if damaged 3HAC079381 004 ABB Orange xx2200001922 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 6740 279 3HAC085701 001 Revision ...

Page 280: ...ing the wrist cover Note Action xx2100002626 Make sure that the cable harness is routed and secured as shown in the figure 1 Continues on next page 280 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 281: ...e wrist cover and secure with screws 3 Tightening torque 10 Nm Foundry Plus xx2000000373 Fit all the screws first then torque tighten Concluding procedure Note Action See Filling oil into the axis 4 gearbox on page 154 Refill oil to the axis 4 gearbox 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page ...

Page 282: ...te 3HAC083688 003 ABB Orange Wrist L2 Complete unit with motors and gears IRB 6740 240 3 2 3HAC082942 002 Graphite White 3HAC082942 003 ABB Orange Wrist Required tools and equipment Note Article number Equipment Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 User instructions are enclosed with the tool 3HAC081310 001 Brake release tool Bit holder dimension 5 16 14x18 mm Used for scre...

Page 283: ...bration 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 to be calibrated with refer ...

Page 284: ... 3 jog axis 2 and 3 to a position where the upper arm is horizontal Axis 4 90 Axis 5 90 Axis 6 no significance 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 4 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover Note Action DANGER Make sure that all supplies for electrical...

Page 285: ...ctrical power hydraulic pressure and air pressure are turned off 1 xx2200001434 Unscrew the attachment screws and re move the motor cover 2 xx2200001730 Remove the connector bracket 3 Continues on next page Product manual IRB 6740 285 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 286: ...00484 Unscrew the attachment screws that hold the cable bracket 1 xx1300000485 Unscrew the M4 screw that holds the carri er Note The screw is located at the bottom of the carrier 2 Continues on next page 286 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 287: ... from its position 4 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 xx2100002625 Cut the cable tie 2 Continues on next page Product manual IRB 6740 287 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 288: ... Disconnect the signal cable connector 4 xx2200001733 Disconnect the power cable connector by removing the attachment screw 5 Continues on next page 288 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 289: ...1 m Attach a roundsling to the wrist as shown in the figure CAUTION The roundsling placement shown in the figure keeps the wrist balanced when lifted which reduces risk of damage or injury Do not attach the roundsling around the axis 5 gearbox 2 xx2100001290 Stretch the roundsling so it carries the weight of the wrist 3 Continues on next page Product manual IRB 6740 289 3HAC085701 001 Revision A C...

Page 290: ...the cabling from the wrist unit CAUTION Make sure that the cabling does not get damaged 3 Bit holder dimension 5 16 14x18 mm xx2200001808 Lift away the wrist 4 Refitting the wrist These procedures describes how to refit the wrist Preparations before refitting the wrist Note Action Wipe clean all contact surfaces 1 Continues on next page 290 Product manual IRB 6740 3HAC085701 001 Revision A Copyrig...

Page 291: ...ase tool and pressing the brake release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool Roundsling 1 m Length 1 m Attach a roundsling and guide pins to the wrist as shown in the figure CAUTION The roundsling placement shown in the f...

Page 292: ...s and fit the re maining two screws Bit holder and hexagon bit SW10 Bit holder dimension 5 16 14x18 mm xx2300000020 Tightening torque standard torque 120 Nm Tightening torque for lubricated screws Molykote Gleitmo or equivalent with allen head screws on page 650 Tighten the attachment screws 4 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Continues ...

Page 293: ... the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms xx2200001734 Connect the signal cable connector Connect in accordance with the markings on the connectors 4 Continues on n...

Page 294: ...m aged 6 Torx pan head screw M5x12 Stainless steel A2 70 Refit the motor cover and the cable protec tion with its attachment screws 7 Locking liquid Loctite 2400 or equivalent Loctite 243 Use locking liquid Tightening torque 6 Nm xx2100002495 Continues on next page 294 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Contin...

Page 295: ...the axis 5 motor connector release the brakes and move axis 5 manually to 90 1 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor Tip Moisten the rubber carrier slightly with water or grease around the contact surface to make it easier to fit into place 2 xx1300001113 Push the carrier carefully into position 3 Continues on next page Product manual IRB 6740 295 ...

Page 296: ...ct the motor cables 1 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Position the power connector to the bracket with a screw Note The purpose of the screw is to secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to ...

Page 297: ...hanical damage Handle it with care to avoid dam age to the cabling or the connector avoid any kind of tilt or skew 4 xx2200001730 xx2300000920 Verify correct cable layout as shown in the figure CAUTION Route the signal cabling correctly to avoid cable damage 5 Continues on next page Product manual IRB 6740 297 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacin...

Page 298: ...ION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Torx pan head screw M5x12 Stainless steel A2 70 6 pcs Refit the motor cover 8 Tightening torque 6 Nm xx2200001434 Continues on next page 298 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 299: ...aged 3HAC078639 004 Graphite White 3HAC078639 005 ABB Orange IRB 6740 240 3 2 IRB 6740 220 3 2 LID 3HAC078635 004 Graphite White 3HAC078635 005 ABB Orange xx2100001407 Torx pan head screw M6x16 A4 80 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm Foundry Plus xx2000000373 Fit all the screws first then torque tighten Continues on next page Product manual IRB 6740 299 3HAC085...

Page 300: ...rate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 3 300 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 301: ...isted in the table can be out of date See the latest spare parts of the IRB 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 IRB 6740 310 2 8 IRB 6740 260 3 0 3HAC084274 002 Turning disc L2 IRB 6740 240 3 2 3HAC082952 002 Turning disc L2 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID 3HAC080682 004 Process turning disc Continues on next page Product manual IRB 67...

Page 302: ...ence values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine o...

Page 303: ...any equipment fitted to the turning disc 3 Removing the turning disc Note Action xx2200001807 Remove the screws and washers that se cure the turning disc 1 xx2100002168 Remove the turning disc 2 Continues on next page Product manual IRB 6740 303 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the turning disc Continued ...

Page 304: ...ecom mended drying time is 24h Protection type Foundry Plus Apply rust preventive to the surface shown in the figure 2 xx2100002232 xx2100002169 Fit the turning disc to the wrist Orient the disc according to the synchronization marks 3 Continues on next page 304 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the turning disc Contin...

Page 305: ... 230 3 0 LID Steel 8 4x13x1 5 IRB 6740 220 3 2 LID Tightening torque standard torque 35 Nm Tightening torque for lubric ated screws Molykote Gleitmo or equivalent with allen head screws on page 650 xx2200001807 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 1 Produ...

Page 306: ...spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC078462 001 Cable harness Continues on next page 306 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness ...

Page 307: ...axis 6 motor cover and to remove the axis 6 motor cables The axis 5 position is also important to avoid the spiral of the cable harness in the carrier being unwound or placed in wrong position Depending on what tool is used the other axes may need to be jogged to another position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering ...

Page 308: ...dures describe how to remove the cable harness in the upper arm and wrist Retrieving access to the wrist cabling Use this procedure to remove the wrist cover Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 308 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Rep...

Page 309: ...cal power hydraulic pressure and air pressure are turned off 1 xx2200001434 Unscrew the attachment screws and re move the motor cover 2 xx2200001730 Remove the connector bracket 3 Continues on next page Product manual IRB 6740 309 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 310: ...4 Unscrew the attachment screws that hold the cable bracket 1 xx1300000485 Unscrew the M4 screw that holds the carri er Note The screw is located at the bottom of the carrier 2 Continues on next page 310 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 311: ...m its position 4 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 xx2100002625 Cut the cable tie 2 Continues on next page Product manual IRB 6740 311 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 312: ...sconnect the signal cable connector 4 xx2200001733 Disconnect the power cable connector by removing the attachment screw 5 Continues on next page 312 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 313: ...ectrical power hydraulic pressure and air pressure are turned off 1 Remove the motor cover by removing the screws 2 xx2200001736 Disconnect the power cable connector by first removing the attachment screw and then parting the connector 3 Continues on next page Product manual IRB 6740 313 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Cont...

Page 314: ... out 4 xx2200001738 Remove the cable bracket by removing the screws 5 Remove the motor cables from the motor 6 Continues on next page 314 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 315: ...s 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 2 xx2300000031 Remove the side cover on the arm tube 3 Continues on next page Product manual IRB 6740 315 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Remo...

Page 316: ... the arm tube Note The screw is reached from outside the up per arm 4 xx2300000032 xx2200002142 Remove the arm house metal clamp 5 Continues on next page 316 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 317: ...ist xx2300000036 Person 1 working at the side hole 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 7 xx23000000...

Page 318: ...ion DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2100000981 Remove the base cover 2 xx2100001109 Loosen the connectors R1 MP R1 SMB 3 xx2200001790 Disconnect the earth cable 4 Continues on next page 318 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness ...

Page 319: ...over by removing the screws 2 xx2200001736 Disconnect the power cable connector by first removing the attachment screw and then parting the connector 3 xx2200001737 Disconnect the signal cable connector by pulling it out 4 Continues on next page Product manual IRB 6740 319 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 320: ...c pressure and air pressure are turned off 1 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 50 2 xx2200001721 Remove the electronic box screws 3 Continues on next page 320 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the ...

Page 321: ...e to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50 1 Disconnect all connectors from the SMB board 2 Disconnect the connectors R2 BU1 and R2 BU2 from the brake release board 3 Removing the cable harness from the frame Note Action xx2200001388 Loosen the cable bracket from the frame by removing the screws 1 Continues on next page Product ...

Page 322: ...2 xx2200001739 Loosen the cable inlet by cutting any seal ing compound and carefully knocking the inlet loose 3 Continues on next page 322 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 323: ...nd out through the frame recess Guide the SMB cables out from the SMB recess at the same time 1 xx2200001741 Place the cable harness over the balancing device 2 Continues on next page Product manual IRB 6740 323 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 324: ...lower arm by removing the attach ment screws Note The screws are reached from the outside of the lower arm 1 xx2100002183 xx2300000052 Use caution and pull the cable harness out 2 324 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 325: ... numbers that are listed in the table can be out of date See the latest spare parts of the IRB 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC078462 001 Cable harness Continues on next page Product manual IRB 6740 325 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness ...

Page 326: ...AC072863 005 ABB Orange Connection box cover FS130 with gasket Replace if damaged On axis 5 motor 3HAC072863 003 Connection box cover with gasket Replace if damaged On axis 6 motor 3HAC079381 003 Graphite White 3HAC079381 004 ABB Orange Connection box cover MT100X with gasket Replace if damaged IRB 6740 310 2 8 IRB 6740 260 3 0 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID 3HAC078639 004 Graphite Whit...

Page 327: ... the new cable harness spare part Note Action Floor standing robot 1 Lay the new cable harness on the floor and place the lower part around the manipulator to under stand the layout Refitting the cable harness in the 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 ...

Page 328: ...arm 2 Torx pan head screw M6x16 A4 80 Refit the metal clamp to the arm house 3 Tightening torque 10 Nm xx2200001433 Continues on next page 328 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 329: ... of the lower arm 4 Tightening torque 6 Nm xx2100002182 Note Check that the cabling will stay a little bit twisted between the cable clamps Do not change the position of the brackets xx1300000595 xx2100002183 Continues on next page Product manual IRB 6740 329 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 330: ...ugh the base 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 cover when connected 3 Continues on next page 330 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All right...

Page 331: ...sion M6x16 Connect the earth cable 5 Washer dimension 6 4x17x3 Tightening torque 10 Nm xx2200001790 Torx pan head screw M6x16 Stainless steel A2 70 5 pcs Refit the base cover 6 Tightening torque 10 Nm xx2100000981 Continues on next page Product manual IRB 6740 331 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 332: ...n in section The unit is sensitive to ESD on page 50 1 Cover electronics Check the electronic box gasket 2 3HAC081189 003 Graphite White Replace if damaged 3HAC081189 004 ABB Orange xx2200001726 Connect all connectors to the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB If cabling is used for 7th axis option refit the connector R1 SMB7 3 Connect the connectors R2 BU1 and R2 BU2 to the brake release boa...

Page 333: ... torque 10 Nm xx2200001721 Refitting the cable harness to the frame Note Action Torx pan head screw M6x16 A4 80 Refit the cable brackets to the frame 1 Tightening torque 10 Nm xx2200001388 Cable strap outdoor 3HAC057966 003 1 pcs Collect the cables for axis 1 and axis 2 motors and secure them at the frame with straps 2 xx2200001752 Continues on next page Product manual IRB 6740 333 3HAC085701 001 ...

Page 334: ...Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001738 Connect the motor cables Note Connect in accordance with the markings on the connectors 3 Continues on next page 334 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 335: ...It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page Product manual IRB 6740 335 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Conti...

Page 336: ...nge 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 337: ... Action Torx pan head screw M6x16 A4 80 Refit the metal clamp beneath the arm house 1 Tightening torque 10 Nm xx2200002142 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 ins...

Page 338: ...son 2 working at the side hole xx2300000040 Person 1 working at the side hole Use caution and push the cable harness into the wrist Tip This step is best performed by two persons working together Person 1 Put one hand inside the side cover hole and take a hold of the cable harness Person 2 Take a hold of the cable harness from inside the wrist Together Move the cable harness past the axis 5 motor ...

Page 339: ...x2300000033 xx2300000032 xx2300000031 Refit the side cover Note Foundry Plus Make sure the gasket is fitted cor rectly on the side cover Use attachment screws made of stainless steel to fit the side cover 6 Continues on next page Product manual IRB 6740 339 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 340: ...necting the axis 3 and axis 4 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001738 Connect the motor cables Note Connect in accordance with the markings on the connectors 3 Continues on next page 340 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All righ...

Page 341: ...It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page Product manual IRB 6740 341 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Conti...

Page 342: ...nge 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 343: ...d routed correctly to each motor according to the figure and according to the markings on the connectors 1 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001735 Continues on next page Product manual IRB 6740 343 3HAC085701 001 Revision A Copyright 2023 ABB...

Page 344: ... and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms xx2200001734 Connect the signal cable connector Connect in accordance with the markings on the connectors 4 Connection box cover with gasket 3HAC072863 003 Inspect the gasket Replace if damaged 5 xx2200002141 Continues on next p...

Page 345: ... Cable strap outdoor 3HAC057966 003 Secure the cabling with a cable strap 8 xx2100002625 Inserting the axis 6 motor cables Note Action 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 brake release tool to the axis 5 motor connector release the brakes and move axis 5 manually to 90 1 Continues on next page Pr...

Page 346: ...rier carefully into position 3 xx1300000485 Secure the carrier with the M4x10 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 4 Continues on next page 346 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved ...

Page 347: ...he purpose of the screw is to secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 2 xx2200001731 xx2200001921 Snap the signal connector...

Page 348: ...e layout as shown in the figure CAUTION Route the signal cabling correctly to avoid cable damage 5 Connection box cover MT100X with gasket Inspect the gasket 6 3HAC079381 003 Graphite White Replace if damaged 3HAC079381 004 ABB Orange xx2200001922 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 348 Product manual IRB 6740 3HAC...

Page 349: ... xx2200001434 Refitting the wrist cover Note Action xx2100002626 Make sure that the cable harness is routed and secured as shown in the figure 1 Continues on next page Product manual IRB 6740 349 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 350: ... 6740 240 3 2 IRB 6740 220 3 2 LID 3HAC078635 004 Graphite White 3HAC078635 005 ABB Orange xx2100001407 Torx pan head screw M6x16 A4 80 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm Foundry Plus xx2000000373 Fit all the screws first then torque tighten Continues on next page 350 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repa...

Page 351: ...432 See Inspecting the cable harness on page 108 Make an overall inspection of the installed cable harness 3 See Updating revolution counters on page 616 Update the revolution counters 4 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 5 Product manual IRB 6740 351 3HAC085701 001 Revision A Copyrigh...

Page 352: ...el Note Article number Spare part L2 3HAC073540 001 Brake release unit Required service parts Note Article number Consumable Includes gasket Replace if damaged 3HAC081189 003 Graphite White 3HAC081189 004 ABB Orange Cover electronics Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 652 Standard toolkit Continues on next page 352 Prod...

Page 353: ...r pressure supply to the robot before entering the safeguarded space 2 Removing the electronic box Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50 2 Continues on nex...

Page 354: ... sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50 2 Disconnect all connectors from the SMB board 3 xx2200001723 Remove the screws that secure the SMB unit 4 Continues on next page 354 Produc...

Page 355: ...nnect the connectors R2 BU1 and R2 BU2 from the brake release board 3 xx2200001728 Remove the brake release unit by removing the screws Put the unit in an ESD bag 4 Refitting the brake release unit Use this procedure to refit the brake release unit Refitting the brake release unit Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety informat...

Page 356: ...d off 1 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 50 2 Cover electronics Check the electronic box gasket 3 3HAC081189 003 Graphite White Replace if damaged 3HAC081189 004 ABB Orange xx2200001724 Fit the SMB unit into the electronic box 4 Continues on next page 356 Product manual IRB ...

Page 357: ...keying 6 xx2200001726 Connect all connectors to the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB If cabling is used for 7th axis option refit the connector R1 SMB7 7 Reconnecting the brake release unit Note Action 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 50 1 Continues on next page Prod...

Page 358: ...e to ESD on page 50 1 Torx pan head screw M6x60 4 pcs Refit the electronic box with the attachment screws 2 Tightening torque 10 Nm xx2200001721 Concluding procedures Note Action See Updating revolution counters on page 616 Update the revolution counters if the battery has been disconnected 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after ins...

Page 359: ...cle number Spare part L2 3HAC043904 001 Serial measurement unit Required service parts Note Article number Consumable Includes gasket Replace if damaged 3HAC081189 003 Graphite White 3HAC081189 004 ABB Orange Cover electronics Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 652 Standard toolkit Continues on next page Product manual ...

Page 360: ... pressure supply to the robot before entering the safeguarded space 2 Removing the electronic box Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50 2 Continues on next...

Page 361: ... Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50 2 Disconnect all connectors from the SMB board 3 xx2200001723 Remove the screws that secure the SMB unit 4 Continues on next page Produ...

Page 362: ...HARGE 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 50 2 Cover electronics Check the electronic box gasket 3 3HAC081189 003 Graphite White Replace if damaged 3HAC081189 004 ABB Orange xx2200001724 Fit the SMB unit into the electronic box 4 Continues on next page 362 Product manual IRB 6740 3HAC085701 001 Revisi...

Page 363: ...g to its keying 6 xx2200001726 Connect all connectors to the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB If cabling is used for 7th axis option refit the connector R1 SMB7 7 Refitting the electronic box Note Action 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 50 1 Continues on next page Pr...

Page 364: ... See Updating revolution counters on page 616 Update the revolution counters 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 2 364 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the SMB unit Continued ...

Page 365: ...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 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC077936 003 Graphite White 3HAC077936 004 ABB Orange Motor unit including connection box and pinion Continues on next page Product manual IRB 6740 365 3HAC085701 001 Revisio...

Page 366: ...de pins in pairs 3HAC15521 2 Guide pin M10x150 Used to push out the motor if necessary Always use removal tools in pairs 3HAC14631 1 Removal tool motor M12 User instructions are enclosed with the tool 3HAC081310 001 Brake release tool Used to rotate the motor pinion Add screw M4 3HAB7887 1 Rotation tool M4 Delivered as a set of calibration tools Required if Axis Calibration is the valid calibratio...

Page 367: ...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 619 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 to...

Page 368: ...g the attachment screws 5 Floor mounted robot Disconnecting the axis 1 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove the motor cover by removing the screws 2 Continues on next page 368 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the ax...

Page 369: ...ttachment screw and then parting the connector 3 xx2200001737 Disconnect the signal cable connector by pulling it out 4 Continues on next page Product manual IRB 6740 369 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 motor Continued ...

Page 370: ...sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Bits extender 3HAC12342 1 Unscrew the attachment screws and washers 2 xx2200001794 Use a bits extender to reach the screws Continues on next page 370 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 motor Continued ...

Page 371: ...pressing the brake release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 5 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for mo...

Page 372: ...r to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Cleaning agent Loctite 7200 Loc tite 7063 Remove any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for c...

Page 373: ...d to the new spare part motor 4 Floor mounted robot Refitting the axis 1 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2200001819 CAUTION The weight of the motor is 19 kg 2 Rotation tool M4 3HAB7887 1 Fit the rotation tool 3 Continues on next page Product manual IRB 6740 373 3HAC085701 001 Revision A Copyright 2023 ABB All right...

Page 374: ...d with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the specified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 5 xx2200001793 Lower the motor into position Make sure that the motor pinion is properly mated...

Page 375: ...he brake release tool 8 See Performing a leak down test on page 178 Perform a leak down test 9 Connecting the motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001738 Continues on next page Product manual IRB 6740 375 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserve...

Page 376: ...n ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page 376 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 R...

Page 377: ...ange 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 378: ... Refit the axis 1 cable protection plates with the attachment screws 1 Hex socket head cap screw M10x16 stainless steel A2 70 3 pcs xx2200001430 Concluding procedure Use this procedure for the concluding refitting Note Action O ring G 1 2 3HAC061327 059 Refit the oil plug with a new o ring 1 Tightening torque 24 Nm xx2200002147 See Calibration on page 609 Re calibrate the robot 2 Continues on next...

Page 379: ...are met when performing the first test run See Test run after installation maintenance or repair on page 96 3 Product manual IRB 6740 379 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 motor Continued ...

Page 380: ...3 Replace the motor 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 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC072099 005 Graphite White 3HAC072099 006 ABB Orange Motor unit including connection box and pinion Continues on next page 380 Product manual IRB 6740 3H...

Page 381: ...ser instructions are enclosed with the tool 3HAC081310 001 Brake release tool 300 mm bits 1 2 3HAC12342 1 Bits extender Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 Used to push out the motor if necessary Always use removal tools in pairs 3HAC14631 1 Removal tool motor M12 Used to rotate the motor pinion Add screw M4 3HAB7887 1 Rotation tool M4 Delivered as a set of calibration too...

Page 382: ...ues 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 619 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the ro...

Page 383: ...box on page 142 Drain the oil from the gearbox 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 5 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove the motor cover by removing the screws 2 Continues ...

Page 384: ...ttachment screw and then parting the connector 3 xx2200001737 Disconnect the signal cable connector by pulling it out 4 Continues on next page 384 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 385: ... gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 Continues on next page Product manual IRB 6740 385 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 386: ... to the motor power connector MP 3 Release the brakes by turning on the brake release tool and pressing the brake release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is sup...

Page 387: ...non threaded hole 7 Removal tool motor M12 3HAC14631 1 Fit a removal tool in the threaded hole Tip Lubricate the guide pins with some grease to make the motor slide better xx2300000043 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 8 The power is only applied for 180 seconds after activation Activate the brake release tool again re lease the...

Page 388: ...tting the motor Use these procedures to refit the axis 2 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 Cleaning agent Loctite 7200 Loc tite 7063 Remove any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts ...

Page 389: ...2100000520 Remove the cover if fitted to the new spare part motor 4 Refitting the axis 2 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2100000593 CAUTION The weight of the motor is 22 kg 2 Continues on next page Product manual IRB 6740 389 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing ...

Page 390: ...7 Lift the motor and put it on the guide pins as close as possible to its final position without pushing the motor pinion into the gear 4 Continues on next page 390 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 391: ... may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Rotation tool M4 3HAB7887 1 Apply the rotation tool 7 Use caution and fit the motor in its final position while at the same time rotating the motor pinion s...

Page 392: ...ve the guide pins and refit the remain ing attachment screws 9 xx2300000044 Tightening torque 50 Nm Tighten the screws 10 Disconnect the brake release tool 11 See Performing a leak down test on page 178 Perform a leak down test 12 Connecting the motor cables Note Action Put the motor cables in place in the open ing 1 Continues on next page 392 Product manual IRB 6740 3HAC085701 001 Revision A Copy...

Page 393: ... secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page Product manual IRB 6740 393 3HAC085701 001 R...

Page 394: ...ange 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 395: ... lock screw that secures the lower arm 1 xx2200001332 Remove the lock screw 2 See Filling oil into the axis 2 gear box on page 144 Refill the gearbox with oil 3 See Calibration on page 609 Re calibrate the robot 4 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 5 Product manual IRB 6740 395 3HAC085...

Page 396: ... service parts Note Article number Consumable Replace if damaged On axis 3 motor 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Connection box cover FS180 with gasket Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 See Type of lubrication in gear boxes on page 135 Lubricating oil Loctite 5800 Flange sealant Required tools and equipment Note Article numb...

Page 397: ...e these procedures to remove the motor Preparations before removing the motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 See Draining the axis 3 gearbox on page 148 Drain the axis 3 gearbox 2 xx2200001810 Unload the upper arm using one of these meth ods Use caution and jog axis 3 to maximum position Release the brakes ...

Page 398: ... Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove the motor cover by removing the screws 2 xx2200001736 Disconnect the power cable connector by first removing the attachment screw and then parting the connector 3 Continues on next page 398 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserv...

Page 399: ...he screws 5 Remove the motor cables from the motor 6 Removing the axis 3 motor Note Action Before removing the motor make sure that the gearbox is completely drained 1 Continues on next page Product manual IRB 6740 399 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 motor Continued ...

Page 400: ...3 motor results in weight transfer of upper arm weight Verify that the upper arm rests against the mechanical stop or installed lifting accessories before releasing the brakes 3 User instructions are enclosed with the tool xx2100000666 DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may oc...

Page 401: ... is used 8 The power is only applied for 180 seconds after activation Activate the brake release tool again re lease the brakes 9 Used to push out the motor if necessary Press the motor out of its position by using the removal tools 10 Always use removal tools in pairs Remove the removal tools CAUTION The weight of the motor is 21 kg 11 xx2100002149 Remove the motor by sliding it out on the guide ...

Page 402: ...Then use Loctite 7063 for cleaning the mating surface 2 Flange sealant Loctite 5800 Apply a continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groove is to catch excess sealant No o ring is used 3 xx2100000520 Remove the cover if fitted to the new spare part motor 4 Refitting the axis 3 motor Note Action Guide pin M10x150 3HAC15...

Page 403: ...e release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 second...

Page 404: ...e attachment screws and washers 7 Bits extender 3HAC12342 1 Use a bits extender in order to reach the screws xx2100002152 Hex socket head cap screw M10x30 12 9 Gleitmo 603 Geomet 500 2 pcs Remove the guide pins and replace with the remaining attachment screws 8 xx2100002153 Tightening torque 50 Nm Tighten the screws 9 Disconnect the brake release tool 10 See Performing a leak down test on page 178...

Page 405: ... secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page Product manual IRB 6740 405 3HAC085701 001 R...

Page 406: ...ange 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 407: ...A4 80 Refit the metal clamp beneath the arm house 2 Tightening torque 10 Nm xx2200002142 See Filling oil into the axis 3 gear box on page 150 Refill the gearbox with oil 3 See Calibration on page 609 Re calibrate the robot 4 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 5 Product manual IRB 6740 ...

Page 408: ...Graphite White 3HAC080508 004 ABB Orange Motor unit including connection box and pinion L2 IRB 6740 240 3 2 IRB 6740 220 3 2 LID 3HAC081177 003 Graphite White 3HAC081177 004 ABB Orange Motor unit including connection box and pinion Required service parts Note Article number Consumable Replace if damaged On axis 4 motor 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Connection box cover FS...

Page 409: ...M4 Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Calibration toolbox Axis Calibra tion Content is defined in section Standard toolkit on page 652 Standard toolkit Removing the motor Use these procedures to remove the motor Preparations before removing the motor Note Acti...

Page 410: ...upply air pressure supply to the robot before entering the safeguarded space 3 See Draining the axis 4 gearbox on page 153 If there is no space to position the upper arm pointed straight up drain the axis 4 gearbox 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 Remove the motor cover by remov...

Page 411: ...ttachment screw and then parting the connector 3 xx2200001737 Disconnect the signal cable connector by pulling it out 4 Continues on next page Product manual IRB 6740 411 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 412: ...ction DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2300000008 Unscrew the attachment screws that secure the motor 2 Continues on next page 412 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 413: ...emoval tool motor M12 3HAC14631 1 Fit removal tools in the threaded holes 4 Used to push out the motor if ne cessary Always use removal tools in pairs xx2300000047 Continues on next page Product manual IRB 6740 413 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 414: ...ith the tool xx2100000666 DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the specified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gearbox the gears may be damaged if ex...

Page 415: ... any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning the mating surface 2 Flange sealant Loctite 5800 Apply a continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groo...

Page 416: ...t guide pins in opposite holes 1 Always use guide pins in pairs xx2100002201 CAUTION The weight of the motor is 12 kg 2 Rotation tool M4 3HAB7887 1 Apply the rotation tool 3 Continues on next page 416 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 417: ...e the spe cified brake release tool to eliminate the risk xx2300000007 Lift the motor and put it on the guide pins as close as possible to its final position without pushing the motor pinion into the gear 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...

Page 418: ... the guide pins and replace with the remaining attachment screws 8 xx2300000011 Tightening torque 50 Nm Tighten the screws 9 Disconnect the brake release tool 10 See Performing a leak down test on page 178 Perform a leak down test 11 Connecting the motor cables Note Action Put the motor cables in place in the open ing 1 Continues on next page 418 Product manual IRB 6740 3HAC085701 001 Revision A C...

Page 419: ... secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page Product manual IRB 6740 419 3HAC085701 001 R...

Page 420: ...ange 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 421: ...See Filling oil into the axis 4 gear box on page 154 Refill the gearbox with oil if drained 1 See Calibration on page 609 Re calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 3 Product manual IRB 6740 421 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair ...

Page 422: ... Article number Consumable Loctite 5800 Flange sealant Loctite 7200 Cleaning agent Loctite 7063 Cleaning agent Replace if damaged On axis 5 motor 3HAC072863 003 Connection box cover with gasket 3HAC057966 003 Cable strap outdoor Required tools and equipment Note Article number Equipment User instructions are enclosed with the tool 3HAC081310 001 Brake release tool Always use guide pins in pairs 3H...

Page 423: ...te Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 xx2200001814 Jog the robot into position Axis 1 no significance Axis 2 suitable working position to replace axis 5 motor for example 25 Axis 3 suitable working position to replace axis 5 motor for example 35 Axis 4 90 Axis 5 no significance Axis 6 no significance With the robot...

Page 424: ...ff 1 xx2000000373 Remove the wrist cover 2 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 xx2100002625 Cut the cable tie 2 Continues on next page 424 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 5 Replacing the axis 5 motor Continu...

Page 425: ...sconnect the signal cable connector 4 xx2200001733 Disconnect the power cable connector by removing the attachment screw 5 Continues on next page Product manual IRB 6740 425 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 5 Replacing the axis 5 motor Continued ...

Page 426: ... using a bits extender 2 xx2100002204 Removal tool motor M12 Fit removal tools in the threaded holes 3 3HAC14631 1 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 4 Used to push out the motor if ne cessary Press the motor out of its position by using the removal tools 5 Always use removal tools in pairs Continues on next page 426 Product manual...

Page 427: ...ds after activation DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 7 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the specified brake release tool to eliminate the risk xx2300000204 Remove the mo...

Page 428: ...continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groove is to catch excess sealant No o ring is used 3 xx2100000520 Remove the cover if fitted to the new spare part motor 4 Refitting the axis 5 motor Note Action Guide pin M10x150 Apply two guide pins in opposite holes 1 3HAC15521 2 CAUTION Whenever parting mating motor and gea...

Page 429: ... motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk CAUTION The weight of the motor is 11 kg All lifting accessories used must be sized accordingly 5 Rotation tool M4 3HAB7887 1 Use caution and lower the motor into posi tion on the guide pins while at the same time rotating the motor pinion slightly 6 xx230...

Page 430: ...rm a leak down test 9 Disconnect the brake release tool 10 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001735 Continues on next page 430 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 5 Replacing th...

Page 431: ... and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms xx2200001734 Connect the signal cable connector Connect in accordance with the markings on the connectors 4 Connection box cover with gasket 3HAC072863 003 Inspect the gasket Replace if damaged 5 xx2200002141 Continues on next p...

Page 432: ... equivalent Loctite 243 Use locking liquid Tightening torque 6 Nm xx2100002495 Cable strap outdoor 3HAC057966 003 Secure the cabling with a cable strap 8 xx2100002625 Refitting the wrist cover Note Action xx2100002626 Make sure that the cable harness is routed and secured as shown in the figure 1 Continues on next page 432 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All ri...

Page 433: ...over and secure with screws 3 Tightening torque 10 Nm Foundry Plus xx2000000373 Fit all the screws first then torque tighten Concluding procedure Note Action See Filling oil into the axis 5 gearbox on page 159 Refill the gearbox with oil if drained 1 See Calibration on page 609 Re calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run See Test run...

Page 434: ...3HAC081093 004 ABB Orange Motor unit including connection box and pinion L2 IRB 6740 240 3 2 IRB 6740 220 3 2 LID 3HAC079162 003 Graphite White 3HAC079162 004 ABB Orange Motor unit including connection box and pinion Required service parts Note Article number Consumable Replace if damaged On axis 6 motor 3HAC079381 003 Graphite White 3HAC079381 004 ABB Orange Connection box cover MT100X with gaske...

Page 435: ...dard toolkit Removing the motor Use these procedures to remove the motor Preparations before removing the axis 6 motor Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 xx2200001818 Jog the robot to a position where axis 5 can be positioned with the axis 6 motor pointing straight up at an acceptable working position With axi...

Page 436: ...1 xx2200001434 Unscrew the attachment screws and re move the motor cover 2 xx2200001730 Remove the connector bracket 3 xx2200001731 Remove the connector screw 4 Disconnect the motor cables 5 Continues on next page 436 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 6 Replacing the axis 6 motor Continued ...

Page 437: ...he tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified ...

Page 438: ... refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Cleaning agent Loctite 7200 Loc tite 7063 Remove any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for clean...

Page 439: ...ool 1 Turn off the brake release tool 2 Connect the tool to the motor power connector MP 3 Release the brakes by turning on the brake release tool and pressing the brake release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 3 User...

Page 440: ...tor pinion is properly mated to the gear of the gearbox the motor pinion does not get dam aged Remove the guide pins 6 Hex socket head cap screw M8x30 12 9 Gleitmo 603 Geomet 500 4 pcs Secure the motor with its attachment screws 7 Tightening torque 24 Nm xx2200001806 See Performing a leak down test on page 178 Perform a leak down test 8 Continues on next page 440 Product manual IRB 6740 3HAC085701...

Page 441: ...ording to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 2 xx2200001731 xx2200001921 Snap the signal connectors to each other in the bracket 3 Torx pan head screw M5x12 Stainless steel A2 70 Refit the connector bracket assembly to the motor CAUTION The cabling is sensitive to mechanical damage Handle it with care to avoid dam age to...

Page 442: ...Replace if damaged 3HAC079381 004 ABB Orange xx2200001922 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Torx pan head screw M5x12 Stainless steel A2 70 6 pcs Refit the motor cover 8 Tightening torque 6 Nm xx2200001434 Continues on next page 442 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 6 ...

Page 443: ...ation information is included in section Calibration on page 609 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 2 Product manual IRB 6740 443 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 8 6 Replacing the axis 6 motor Continued ...

Page 444: ...lancing device 2 Remove the balancing device cradle 3 Drain the axis 1 gearbox 4 Remove the cabling from the base 5 Remove the axis 1 motor 6 Remove the complete arm system complete robot excluding the base and axis 1 gearbox as an assembly 7 Replace the axis 1 gearbox The axis 1 cassette sealing must also be replaced Continues on next page 444 Product manual IRB 6740 3HAC085701 001 Revision A Cop...

Page 445: ...x Included in gearbox spare part but replace if damaged xx2200001407 A 3HAB3772 164 B 3HAC061327 065 O ring Replace if damaged On axis 1 motor 3HAC072864 003 Graphite White 3HAC072864 005 ABB Orange 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Connection box cover FS180 with gasket On axis 1 protection ring 3HAB3772 58 O ring Located at the front ...

Page 446: ...le number Equipment Used to unload or restore a balan cing device User instructions are enclosed with the tool 3HAC074411 001 Hydraulic press equipment balan cing device Used for removing and fitting shaft and bearings User instructions are enclosed with the tool 3HAC028920 001 Dismantle and mounting tool To be used with the press and puller tools See technical specifications in the user instructi...

Page 447: ...moving and fitting cassette sealing on axis 1 3HAC079880 001 Replacement tool for cassette sealing Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Calibration toolbox Axis Calibra tion Content is defined in section Standard toolkit on page 652 Standard toolkit Deciding cal...

Page 448: ...ibration 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 gearbox These procedures describe how to remove the gearbox Removing tools and equipment from the turning disc Note Action This is done to achieve the best stability of the complete arm sys tem when it is resting by itself after removal ...

Page 449: ...the balancing device springs and locking position with the Hydraulic press equipment balancing device Use this procedure to unload and lock the balancing device in unloaded position with the Hydraulic press equipment balancing device 3HAC074411 001 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...

Page 450: ...enclosed with the tool xx0900000813 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 Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingl...

Page 451: ...g accessory to the shackle and raise to unload the weight 3 xx2200001459 Removing the shaft in the front link ear Note Action xx2200001460 Remove the protection plug at the link ear 1 Continues on next page Product manual IRB 6740 451 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 452: ... instruc tions enclosed with the equipment 3 User instructions are enclosed with the tool xx0900000813 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 on next page 452 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Rep...

Page 453: ...e is a risk of damaging the bearing inside The damaged VK cover must be replaced with a new Remove the protection plug from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 VK cover 100x10 3HAA2166 13 Position for screwdriver xx1300000662 Vent hole for air pressure xx2300000003 Wipe off any residual grease inside the re cess 2 Conti...

Page 454: ...d make the balan cing device go free If this is not possible the shaft end must be pulled out a bit with the dismantle and mounting tool see Removing the shaft end cradle on page 249 5 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 6 Continues on next page 454 Product manual IRB 6740 3HAC085701 001 Revision A Copyright ...

Page 455: ...ce during lift of the cradle 1 Lifting eye M16 3HAC14457 4 Fit a lifting eye to each cradle ear 2 xx2300000856 Roundsling 0 5 m Run a roundsling through each lifting eye and at tach to an overhead crane 3 Raise the lifting equipment to secure the weight of the cradle 4 Continues on next page Product manual IRB 6740 455 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1...

Page 456: ... 7 Position for the floor mounted robot Note Action Turn on the power to the robot temporarily 1 xx2300000859 Jog the robot into position Axis 1 no significance Axis 2 45 Axis 3 70 Axis 4 calibration position 0 Axis 5 90 Axis 6 no significance 2 Continues on next page 456 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 ge...

Page 457: ...essure and air pressure are turned off 1 CAUTION The weight of the complete arm system is 865 895 kg depending on robot variant All lifting accessories must be sized accordingly 2 Lifting eye 3HAC16131 1 Fit a lifting eye to the wrist 3 xx2200001522 Roundsling 0 5 m Fit a roundsling to the lifting eye 4 xx2200001523 Continues on next page Product manual IRB 6740 457 3HAC085701 001 Revision A Copyr...

Page 458: ...slowly until the roundsling is stretched approxim ately 65 to carry the weight of the lower arm and frame WARNING Without the roundsling the weight of the lower arm and frame is applied to the axis 3 gear during lifting which risks to damage the gear 7 Continues on next page 458 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the ax...

Page 459: ...sher xx2100002146 Lifting accessory chain 3HAC15556 1 Attach the Lifting accessory chain to an over head crane or similar and then to the lifting eye in the arm house and to a roundsling run through the wrist 10 Roundsling 1 m xx2200001526 Adjust the chain lengths to make the lift as level as possible 11 The figure shows an example of lifting chain lengths Keep chain a shorter than chain b Continu...

Page 460: ... turned off 2 xx2200001398 Hold the mechanical stop pin in a firm grip and remove it by unscrewing the set screw 3 xx2200001430 Foundry Plus Remove the axis 1 cable protection plate by removing the attachment screws 4 See Floor mounted robot Draining the axis 1 gearbox on page 138 Begin draining the axis 1 gearbox Note There will be some oil left in the gear after draining 5 Continues on next page...

Page 461: ... removing the screws 2 xx2200001736 Disconnect the power cable connector by first removing the attachment screw and then parting the connector 3 xx2200001737 Disconnect the signal cable connector by pulling it out 4 Continues on next page Product manual IRB 6740 461 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 462: ...ll supplies for electrical power hydraulic pressure and air pressure are turned off 1 Bits extender 3HAC12342 1 Unscrew the attachment screws and washers 2 xx2200001794 Use a bits extender to reach the screws Continues on next page 462 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 463: ...ressing the brake release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 5 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for mor...

Page 464: ...inion parted from the gear 9 Disconnect the brake release tool 10 Preparations before 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 xx2100000981 Remove the base cover 2 Continues on next page 464 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5...

Page 465: ... the base Note Action xx2200001740 Pull out the robot cable harness through the protection tube 1 Place the cable harness safely on the frame or on the axis 2 motor 2 Continues on next page Product manual IRB 6740 465 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 466: ...1 xx2300000868 Remove six of the seven attachment screws Note Leave the screw closest to the axis 1 motor fitted 2 xx2300000869 Lifting away the complete arm system Note Action Check that the axis 1 gearbox is drained and then remove the draining equipment 1 Continues on next page 466 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing ...

Page 467: ...ise the overhead crane to stretch all lifting accessories 2 Continues on next page Product manual IRB 6740 467 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 468: ...hment screws that hold the frame to the axis 1 gearbox 3 xx2200001405 xx2300000870 Continues on next page 468 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 469: ...de better 4 Always use guide pins in pairs xx2300000871 xx2200001424 CAUTION The weight of the complete arm system is 865 895 kg depending on robot variant All lifting accessories must be sized accord ingly 5 Continues on next page Product manual IRB 6740 469 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 470: ...d resting by itself on the floor make sure it is resting completely stable before remov ing the lifting accessories Do not change the position of the axes from the position de scribed earlier 8 Removing the axis 1 gearbox Note Action xx2200001408 Remove the attachment screws and washers that secure the gearbox to the base 1 Continues on next page 470 Product manual IRB 6740 3HAC085701 001 Revision...

Page 471: ...s of space between the lifting accessory and the surface of the gearbox This is done in order not to damage the surface of the gearbox which is a sealing surface 3 xx2200001410 CAUTION The weight of the gearbox is 85 kg All lifting accessories used must be sized accordingly 4 xx2200001412 Protect the sealing areas on top of the tube to avoid damaging them 5 Continues on next page Product manual IR...

Page 472: ...it needs to be installed in the same orienta tion as removed 6 Lifting accessory chain 3HAC15556 1 Attach the lifting accessory chain to the lifting eyes and lift away the gearbox 7 xx2200001411 Continues on next page 472 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 473: ...aged 1 Guide pin M12x200 3HAC13056 3 Fit guide pins in opposite holes in the base Tip Lubricate the guide pins with some grease to make the gearbox slide better 2 Always use guide pins in pairs xx2200001415 Wipe clean the contact surfaces on the base and the surfaces of the sealing tube from any contamination 3 Put grease on the sealing tube 4 Continues on next page Product manual IRB 6740 473 3HA...

Page 474: ...N Leave a couple of millimeters of space between the lifting accessory and the surface of the gearbox This is done in order not to damage the surface of the gearbox which is a sealing surface 2 xx2200001416 CAUTION The weight of the gearbox is 85 kg All lifting accessories used must be sized accordingly 3 Continues on next page 474 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 A...

Page 475: ...17 O ring A 3HAB3772 164 B 3HAC061327 065 Grease Shell Gadus S2 3HAC042536 001 Check the o ring and lubricate Replace if damaged 5 xx2200001407 Continues on next page Product manual IRB 6740 475 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 476: ...surfaces of the hole in axis 1 gearbox Protection type Foundry Plus 7 xx2100001169 Apply rust preventive to the inner surface of the hole as shown in the figure Removing the protection ring in the frame Note Action Foundry Plus 1 Cut the flange sealant at the protection ring xx2200001610 Remove the protection ring 2 Continues on next page 476 Product manual IRB 6740 3HAC085701 001 Revision A Copyr...

Page 477: ...e Note Check that the gearbox is oriented in the same direction as the old gearbox by checking the orientation of the guiding pin Note Make sure that the o ring is still fitted cor rectly when the gearbox is being fitted 1 Remove the guide pins 2 Remove the lifting accessory and the lifting eyes 3 Continues on next page Product manual IRB 6740 477 3HAC085701 001 Revision A Copyright 2023 ABB All r...

Page 478: ...s before refitting the arm system Note Action Wipe clean the contact surfaces from any contamination 1 Flange sealant Loctite 5800 Protection type Foundry Plus 2 xx2200001609 Apply flange sealant to the mounting interface on the gearbox both inside and outside of the screw holes Apply some grease on the edge of the sealing tube the edge around the gearbox 3 Continues on next page 478 Product manua...

Page 479: ...000905 xx2200001420 Refitting the arm system Note Action CAUTION The weight of the complete arm system is 865 895 kg depending on robot variant All lifting accessories must be sized accord ingly 1 Make sure that all lifting accessories still is fitted correctly on the arm system 2 Continues on next page Product manual IRB 6740 479 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 ...

Page 480: ...ns will enter the correct holes in the frame Note Also check that the guiding pin in the gearbox is aligned with the pin hole in the frame xx2300000013 5 Lower the arm system to align the longest guide pin into the hole 6 xx2200001420 Lower the arm system to align the other guide pin into the hole 7 Continues on next page 480 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All...

Page 481: ...from the front back that the frame is coming down completely level against the gearbox If the frame is somewhat tilted adjust the lifting position with the overhead crane Note While lowering the complete arm system check that the cylindrical pin is fitted cor rectly 9 xx1700002043 Lower the complete arm system into posi tion on top of the gearbox 10 Continues on next page Product manual IRB 6740 4...

Page 482: ...e axis 1 gearbox 11 Tightening torque standard torque 300 Nm Tightening torque for lubricated screws Molykote Gleitmo or equivalent with allen head screws on page 650 xx2200001421 Continues on next page 482 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 483: ...ews on page 650 Remove the two guide pins and refit remain ing attachment screws Tighten the remaining accessible attach ment screws 12 xx2200001403 xx2200001405 xx2300000870 Continues on next page Product manual IRB 6740 483 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 484: ...80 001 Fit the first part of the mounting tool to the frame 2 xx2100001188 xx2100001189 Fit the cassette sealing on the tool with the plain side facing upwards groove down wards 3 xx2100001191 Fit the second part of the mounting tool on top of the sealing 4 Continues on next page 484 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing t...

Page 485: ...d the axis 1 tube upper edge at four 4 locations The measurement is approximately 9 mm 7 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h Protection type Foundry Plus Apply rust preventive to the outer surface of the gearbox tube and outer surface of the frame hole all the way down to the cassette sealing as shown in the figure 8 xx2100001170 xx2100001172 Contin...

Page 486: ...ction DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Cleaning agent Loctite 7200 Loc tite 7063 Remove any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning the mating surface ...

Page 487: ... to the new spare part motor 4 Floor mounted robot Refitting the axis 1 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2200001819 CAUTION The weight of the motor is 19 kg 2 Rotation tool M4 3HAB7887 1 Fit the rotation tool 3 Continues on next page Product manual IRB 6740 487 3HAC085701 001 Revision A Copyright 2023 ABB All rights...

Page 488: ... with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the specified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 5 xx2200001793 Lower the motor into position Make sure that the motor pinion is properly mated ...

Page 489: ...k down test on page 178 Perform a leak down test 9 Refilling oil in the gearbox Note Action See Changing the oil in axis 1 gearbox on page 137 Refill oil in the gearbox 1 Refitting the cable harness in the base Note Action xx2200001924 Run the robot cable harness through the frame recess and down through the protec tion tube 1 Continues on next page Product manual IRB 6740 489 3HAC085701 001 Revis...

Page 490: ...e cables are facing the base cover when connected 3 Screw dimension for R1 MP M6x25 A2 70 Connect connectors R1 MP and R1 SMB 4 Tightening torque for R1 MP 10 Nm Tightening torque for R1 SMB 10 Nm xx2100001109 Screw dimension M6x16 Connect the earth cable 5 Washer dimension 6 4x17x3 Tightening torque 10 Nm xx2200001790 Continues on next page 490 Product manual IRB 6740 3HAC085701 001 Revision A Co...

Page 491: ...es in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001738 Connect the motor cables Note Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 6740 491 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 492: ...t is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page 492 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Conti...

Page 493: ...nge 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 494: ...cal stop Note Action Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended dry ing time is 24h Protection type Foundry Plus Apply rust preventive on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 1 xx2100001139 Continues on next page 494 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing...

Page 495: ...ame and only tighten slightly by hand 2 Feel that the stop pin can move some millimeters in vertical direction This verifies that the screw is inserted in the groove and not against the flange 3 Tighten the screw with tightening torque xx2200001500 Preparations before refitting the cradle and the balancing device Note Action Turn on the power to the robot temporarily 1 xx2300000906 Jog axis 2 to t...

Page 496: ...ord ingly 1 xx2300000858 Lift the cradle and lower into mounting position 2 Hex socket head cap screw M16x50 12 9 Gleitmo 603 Geomet 500 Refit the cradle screws and washers 3 Tightening torque standard torque 300 Nm Tightening torque for lub ricated screws Molykote Gleitmo or equivalent with allen head screws on page 650 xx2300000857 Continues on next page 496 Product manual IRB 6740 3HAC085701 00...

Page 497: ...ndry Plus Apply Mercasol on matching surfaces on the shaft end in the cradle and the balan cing device See the figure 2 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 3 xx2200001469 Lift the balancing device into position in the cradle 4 Continues on next page Product manual IRB 6740 497 3HAC085701 001 Revision A Copyri...

Page 498: ...rews insert them on both sides and tighten by hand 7 Washer 3HAC047681 001 The screws are not possible to torque tighten at this point since the front ear is not fastened to the lower arm Locking liquid Loctite 2400 or equivalent Loctite 243 xx2200001475 Refitting the front shaft of the balancing device Note Action Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if ...

Page 499: ...200001918 Align the balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 5 xx2200001917 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 next page Product manual IRB 6740 499 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Repl...

Page 500: ...ectly will cause serious injury Read and follow enclosed user instructions for the tool Hex socket head cap screw M16x70 8 8 A3F Apply locking liquid on the first threads of the screw 8 Washer Steel 17x25x3 Locking liquid Loctite 2400 or equivalent Loctite 243 xx2200001916 Tightening torque 200 Nm Secure the shaft with screw and washer 9 xx2200001461 Continues on next page 500 Product manual IRB 6...

Page 501: ... Refit the two screws and wipe clean from residual grease 12 Remove the lifting accessory from the balancing device 13 Securing the shaft ends Note Action Tightening torque 280 Nm Secure both shaft end screws with tighten ing torque 1 xx2200001471 Continues on next page Product manual IRB 6740 501 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 ...

Page 502: ...te Action User instructions are enclosed with the tool Restore the balancing device according to instructions for the press equipment 1 xx0900000813 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 on next page 502 Product manual IRB 6740 3HAC085701 001 Revision ...

Page 503: ...ation maintenance or repair on page 96 3 Refitting the covers for Foundry Plus and floor mounted robots Note Action Torx pan head screw M6x16 A4 80 4 pcs Protection type Foundry Plus Refit the axis 1 cable protection plates with the attachment screws 1 Hex socket head cap screw M10x16 stainless steel A2 70 3 pcs xx2200001430 Concluding procedure Note Action Remove the lifting accessories 1 Continu...

Page 504: ...all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 3 504 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 505: ...terial nearby the robot If needed run axis 1 into a position that gives the required space The figure shows an example xx2300000026 Note Keeping the cable harness and DressPack fitted on the robot during gearbox replacement is only a recommendation If it is not possible to put the lower and upper arm close enough to the robot the cable harness and DressPack in the base and in the frame must be rem...

Page 506: ...kets inside the lower arm and on the frame 4 Remove the upper and lower arm mounted together as an assembly 5 Remove the axis 2 motor 6 Replace the axis 2 gearbox 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 6740 via myABB Business Portal www abb com myABB Continues on next page 506 Product manual IRB 6740 3H...

Page 507: ...aulic cylinder M12 2 pcs 3HAC16131 1 Lifting eye SA 10 8 NA1 Lifting shackle Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer Lifting instruction 3HAC15880 2 enclosed 3HAC15556 1 Lifting accessory chain Length 1 5 m Roundsling 1 5 m Length 1 m Roundsling 1 m User instructions are enclosed with the tool 3HAC081310 001 Brake release tool 300 mm bits 1 2 3HA...

Page 508: ...g Replace if damaged On axis 2 motor 3HAC072864 003 Graphite White 3HAC072864 005 ABB Orange 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Connection box cover FS180 with gasket Used on oil plug Always replace when refitting oil plug 3HAC061327 059 O ring G 1 2 Isopropanol Cleaning agent Shell Gadus S2 3HAC042536 001 Grease Mercasol 3110 Waxcoat Re...

Page 509: ...w 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 619 If no previous reference values exist and no new reference values can be created then reference calibration is not pos...

Page 510: ...ocking position with the Hydraulic press equipment balancing device Use this procedure to unload and lock the balancing device in unloaded position with the Hydraulic press equipment balancing device 3HAC074411 001 Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 510 Product manual IRB 6740 3HAC085701 00...

Page 511: ...enclosed with the tool xx0900000813 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 Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingl...

Page 512: ...g accessory to the shackle and raise to unload the weight 3 xx2200001459 Removing the shaft in the front link ear Note Action xx2200001460 Remove the protection plug at the link ear 1 Continues on next page 512 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 513: ...3 User instructions are enclosed with the tool xx0900000813 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 Note Action xx2200001462 Put down the balancing device and let it rest on the frame 1 Continues on next page Product manual IRB 6740 513 3HAC085701 001 Revision A C...

Page 514: ...ric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 3 See Draining the axis 2 gearbox on page 143 Begin draining the gearbox 4 Attaching lifting accessories to the lower and upper arm Note Action CAUTION The weight of the complete upper and lower arm together is 535 565 kg depending on robot vari ant All lifting accessories used must be...

Page 515: ...insert a M12x50 securing screw not more than 10 15 mm into the screw hole shown in the figure 5 xx2100001415 xx2100001412 Example where securing screw is not needed xx2100001469 Stretch the roundsling between the wrist and the lower arm by slowly jogging the axis 3 Note Make sure the roundsling is stretched in order to carry the weight of the lower arm 6 Continues on next page Product manual IRB 6...

Page 516: ...y chain to an over head crane or similar then to the lifting eye in the arm house and to a roundsling run through the wrist 9 Roundsling 1 m xx2200001619 Adjust the chain lengths to make the lift as level as possible The figure shows an example of lifting chain lengths Keep chain a shorter than chain b Raise the overhead crane to stretch the chains and roundslings 10 Verify that the roundsling bet...

Page 517: ...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 1 xx2200001388 Loosen the cable bracket from the frame by removing the nuts Let it hang loose 2 Disconnecting the axis 2 motor cables Use this procedure to disconnect the motor cables Note Action DANGER Make sure that all suppl...

Page 518: ...tachment screw and then parting the connector 3 xx2200001737 Disconnect the signal cable connector by pulling it out 4 Continues on next page 518 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 519: ...gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 Continues on next page Product manual IRB 6740 519 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued...

Page 520: ...to the motor power connector MP 3 Release the brakes by turning on the brake release tool and pressing the brake release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supp...

Page 521: ...on threaded hole 7 Removal tool motor M12 3HAC14631 1 Fit a removal tool in the threaded hole Tip Lubricate the guide pins with some grease to make the motor slide better xx2300000043 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 8 The power is only applied for 180 seconds after activation Activate the brake release tool again re lease the ...

Page 522: ... and lifting away the lower and upper arms un separated Step 1 Use this procedure for the first step of removing and lifting away the lower and upper arm un separated Note Action Guide pin M16x150 Guide pin M16x200 3HAC13120 2 3HAC13120 3 Remove two attachment screws in opposite holes and replace them with guide pins Tip Use different lengths on the guide pins to simplify guidance 1 Always use gui...

Page 523: ...needed move axis 1 into a position that gives the required space Note Keeping the cable harness and DressPack fitted on the robot during gearbox replace ment is only a recommendation If it is not possible to put the lower and upper arm close enough to the robot the cable har ness and DressPack in the base and in the frame must be removed first 1 CAUTION The weight of the complete upper and lower a...

Page 524: ... away the arms The cable harness is still partly con nected xx2100001103 Lift the arm system and lay it down safely on the boards Use a higher block as support under the wrist unit when the arms are put down on the boards CAUTION Check that the cable bracket underneath the arm housing is not damaged 4 Continues on next page 524 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB A...

Page 525: ...idance Tip Lubricate the guide pins with some grease to make the lower arm slide better xx2300000664 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 weight of the gearbox is 97 kg All lifting accessories used must be sized accordingly 3 Continues on next page Product manual IRB 6740 525 3HAC085701 001 R...

Page 526: ...fully threaded Remove the two protection plugs and use removal tools to press the gearbox out of position 5 xx2300000702 Continues on next page 526 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 527: ...om the guide pins and remove the gearbox 8 Refitting the gearbox Use these procedures to refit the gearbox Preparations before refitting the axis 2 gearbox Note Action CAUTION The weight of the gearbox is 97 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 6740 527 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 R...

Page 528: ...ropanol Wipe clean the contact surfaces on both the gearbox and the frame from any con tamination Note Also wipe clean the o ring groove 4 O ring 3HAC061327 067 Check the o ring 5 xx2100001132 Replace if damaged Continues on next page 528 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 529: ... Apply rust preventive to the gearbox sur face shown in the figures 7 xx2100001105 Refitting the axis 2 gearbox Use this procedure to refit the gearbox Note Action CAUTION The weight of the gearbox is 97 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 6740 529 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Repla...

Page 530: ...x slide better xx2300000663 Lift the gearbox and let it rest on the guide pins CAUTION Use stoppers on the guide pins 3 Remove the lifting accessory DANGER There is a risk that the gearbox may glide out and fall down if it is too far out to on the guide pins and no stoppers are used 4 Continues on next page 530 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserve...

Page 531: ... and fit the remain ing attachment screws and washers 6 Tightening torque standard torque 120 Nm Tightening torque for lubricated screws Molykote Gleitmo or equivalent with allen head screws on page 650 Tighten the attachment screws 7 Continues on next page Product manual IRB 6740 531 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Conti...

Page 532: ...me grease to make the lower arm slide better CAUTION The weight of the complete upper and lower arm together is 535 565 kg depend ing on robot variant All lifting accessories used must be sized accordingly 2 Attach the lifting accessories to the arm assembly if not already fitted 3 xx2300000027 Use caution and slowly lift the lower and upper arm together Make sure not to stretch any of the cables ...

Page 533: ... the hole pattern does not match use the adjustment tool in the axis 2 gear and ro tate until a matching hole pattern is achieved xx1300000819 xx2300000028 Slide the arms into position on the guide pins 6 Continues on next page Product manual IRB 6740 533 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 534: ... 300 Nm Tightening torque for lubricated screws Molykote Gleitmo or equivalent with allen head screws on page 650 Tighten the attachment screws 9 Remove the lifting accessories 10 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 534 Product manual IRB 6740 3HAC085701...

Page 535: ...1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groove is to catch excess sealant No o ring is used 3 xx2100000520 Remove the cover if fitted to the new spare part motor 4 Refitting the axis 2 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2100000593 CAUTION The weight of the motor is 22 kg ...

Page 536: ... Lift the motor and put it on the guide pins as close as possible to its final position without pushing the motor pinion into the gear 4 Continues on next page 536 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 537: ...may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Rotation tool M4 3HAB7887 1 Apply the rotation tool 7 Use caution and fit the motor in its final position while at the same time rotating the motor pinion sl...

Page 538: ...he guide pins and refit the remain ing attachment screws 9 xx2300000044 Tightening torque 50 Nm Tighten the screws 10 Disconnect the brake release tool 11 See Performing a leak down test on page 178 Perform a leak down test 12 Connecting the axis 2 motor cables Note Action Put the motor cables in place in the open ing 1 Continues on next page 538 Product manual IRB 6740 3HAC085701 001 Revision A C...

Page 539: ...secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page Product manual IRB 6740 539 3HAC085701 001 Re...

Page 540: ...nge 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 541: ... arm 1 Torx pan head screw M6x16 A4 80 Secure the upper and lower cable clamps inside the lower arm with the attachment screws Note The screws are reached from the outside of the lower arm 2 Tightening torque 6 Nm xx2100001104 Note Check that the cabling will stay a little bit twisted between the cable clamps Do not change the position of the brackets xx1300000595 Continues on next page Product ma...

Page 542: ... air pressure supply to the robot before entering the safeguarded space 3 Refitting the front shaft of the balancing device Note Action Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 1 Lifting accessory chain 3HAC15556 1 Remove all residue of Loctite in the screw hole of the shaft 2 Wipe all contact surfaces inside the recess clean from contamin...

Page 543: ...e link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 5 xx2200001917 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 next page Product manual IRB 6740 543 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 544: ...ectly will cause serious injury Read and follow enclosed user instructions for the tool Hex socket head cap screw M16x70 8 8 A3F Apply locking liquid on the first threads of the screw 8 Washer Steel 17x25x3 Locking liquid Loctite 2400 or equivalent Loctite 243 xx2200001916 Tightening torque 200 Nm Secure the shaft with screw and washer 9 xx2200001461 Continues on next page 544 Product manual IRB 6...

Page 545: ...ing the Hydraulic press equipment balancing device Note Action User instructions are enclosed with the tool Restore the balancing device and remove the press equipment according to instruc tions for the press equipment xx0900000813 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 t...

Page 546: ...ve the lifting accessory from the balancing device 1 See Filling oil into the axis 2 gear box on page 144 Refill oil to the axis 2 gearbox 2 See Calibration on page 609 Calibrate the robot 3 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 96 4 546 Product manual IRB 6740 3HAC085701 001 Revision A Copy...

Page 547: ...lace the axis 3 gearbox 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 6740 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Includes o ring 3HAC082815 003 Graphite White 3HAC082815 004 ABB Orange Gearbox Required service parts Note Article number Consumable 3HAC061327 066 O r...

Page 548: ...HAC14631 1 Removal tool motor M12 Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 For lifting the gearbox 3HAC081585 001 Lifting accessory for gear Used to push out the gearbox if necessary Screws M10x80 fully threaded Used to rotate the gear for matching hole pattern with frame 3HAC080331 001 Adjustment tool for gear Used to rotate the motor pinion Add screw M4 3HAB7887 1 Rotation to...

Page 549: ...re 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 619 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 calibr...

Page 550: ...upper arm resting against the mechanical stop approximately 70 Axis 4 0 Axis 5 90 Axis 6 0 3 xx2200001811 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 4 xx2200001432 Remove the cable bracket underneath the tube shaft 5 Continues on next page 550 Product manual IRB 6740 3HAC085701 001 Revision A Copyright...

Page 551: ... hydraulic pressure and air pressure are turned off 1 xx2000000373 Remove the wrist cover 2 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 Product manual IRB 6740 551 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis...

Page 552: ... xx2200001730 Remove the connector bracket 3 xx2200001731 Remove the connector screw 4 Disconnect the motor cables 5 Continues on next page 552 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 553: ... the carri er Note The screw is located at the bottom of the carrier 2 xx1300000666 Lift out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 3 Continues on next page Product manual IRB 6740 553 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 554: ...upplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2100002625 Cut the cable tie 2 xx2100002495 Remove the motor cover by removing the screws 3 Continues on next page 554 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 555: ...by removing the screws 6 Remove the motor cables 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 6740 555 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 556: ...by first removing the attachment screw and then parting the connector 3 xx2200001737 Disconnect the signal cable connector by pulling it out 4 Continues on next page 556 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 557: ...mage the gasket 1 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 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 2 Continues on next page Product manual IRB 6740 557 3HAC085701 001 Revision A Copyright 2023 ABB All right...

Page 558: ...axis 4 metal clamp inside the arm tube Note The screw is reached from outside the up per arm 4 xx2300000032 xx2200002142 Remove the arm house metal clamp 5 Continues on next page 558 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 559: ...st xx2300000036 Person 1 working at the side hole 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 7 xx230000003...

Page 560: ...2196 xx2100002146 Lifting accessory chain 3HAC15556 1 Attach the Lifting accessory chain to an overhead crane or similar then to the lifting eye in the arm house and to a roundsling run through the wrist 3 Roundsling 1 m xx2100002145 Adjust the chain lengths to make the lift as level as possible The figure shows an example of lifting chain lengths Keep chain b shorter than chain a Raise the liftin...

Page 561: ... sure that the gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the upper arm will be movable and falls down if not secured Verify that the upper arm is secured as previously de scribed before continuing 2 Continues on next page Product manual IRB 6740 561 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearb...

Page 562: ...mechanical stop or installed lifting accessories before releasing the brakes 3 User instructions are enclosed with the tool xx2100000666 DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake rel...

Page 563: ...is used 8 The power is only applied for 180 seconds after activation Activate the brake release tool again re lease the brakes 9 Used to push out the motor if necessary Press the motor out of its position by using the removal tools 10 Always use removal tools in pairs Remove the removal tools CAUTION The weight of the motor is 21 kg 11 xx2100002149 Remove the motor by sliding it out on the guide p...

Page 564: ...6 Leave one of the remaining attachment screws fitted remove the other screws 2 Removing the upper arm Note Action xx1400002197 Note Make sure the lift is done completely leveled In case of necessary adjustments use the shortening loops on the lifting ac cessory chain and make sure to place the chain the right way through the loops 1 Continues on next page 564 Product manual IRB 6740 3HAC085701 00...

Page 565: ...one in order to keep the axis 3 gearbox in a vertical position and to get the best position to replace the axis 3 gearbox if applicable 4 Removing the axis 3 gearbox Use this procedure to remove the gearbox Note Action Guide pin M12x150 Guide pin M12x200 3HAC13056 2 3HAC13056 3 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some gr...

Page 566: ...er below the gearbox 4 xx2300000149 Remove the remaining attachment screw and loosen the gearbox with help of the removal tools Only pull out the gearbox a little bit on the guide pins DANGER There is a risk that the gearbox may glide out and fall down if it is too far out to on the guide pins and no stoppers are used 5 Continues on next page 566 Product manual IRB 6740 3HAC085701 001 Revision A C...

Page 567: ...etting it slide out on the guide pins 8 xx2300000202 Remove the gearbox 9 Refitting the gearbox Use these procedures to refit the axis 3 gearbox Preparations before refitting the axis 3 gearbox Note Action CAUTION The weight of the gearbox is 56 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 6740 567 3HAC085701 001 Revision A Copyright 2023 AB...

Page 568: ...of both the gearbox and the upper arm from any con tamination 4 O ring 3HAC061327 066 Check the o ring 5 xx2100001237 Replace if damaged Grease Shell Gadus S2 3HAC042536 001 Lubricate the contact surface inside the upper arm with grease 6 xx2100002775 Continues on next page 568 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axi...

Page 569: ...Lift the gearbox and let it rest on the guide pins 2 Remove the lifting accessory DANGER There is a risk that the gearbox may glide out and fall down if it is too far out to on the guide pins and no stoppers are used 3 Hex socket head cap screw M12x50 12 9 Gleitmo 603 Geomet 500 32 pcs Slide the gearbox into position and fit the attachment screws and washers 4 xx2300000154 Continues on next page P...

Page 570: ...s in the axis 3 gearbox Tip Lubricate the guide pins with some grease to make the upper arm slide better 2 Always use guide pins in pairs xx2300000212 Securing the upper arm Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 375 405 kg depending on robot variant All lifting accessories used must be sized accordingly 1 See Attaching the lifting accessories to the upper...

Page 571: ...12x40 12 9 Gleitmo 603 Geomet 500 39 pcs Insert all but two of the screws and wash ers 5 Washer Steel 13x19x1 5 39 pcs xx2300000206 xx2300000205 Remove the guide pins and fit the two re maining screws and washers 6 Tightening torque standard torque 120 Nm Tightening torque for lubricated screws Molykote Gleitmo or equivalent with allen head screws on page 650 Tighten the attachment screws 7 Contin...

Page 572: ...ing the mating surface 2 Flange sealant Loctite 5800 Apply a continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groove is to catch excess sealant No o ring is used 3 xx2100000520 Remove the cover if fitted to the new spare part motor 4 Refitting the axis 3 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposit...

Page 573: ... release button on the tool The power for brake release is only applied for 180 seconds after activa tion DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds...

Page 574: ... Gleitmo 603 Geomet 500 2 pcs Fit two of the attachment screws and washers 7 Bits extender 3HAC12342 1 Use a bits extender in order to reach the screws xx2100002152 Hex socket head cap screw M10x30 12 9 Gleitmo 603 Geomet 500 2 pcs Remove the guide pins and replace with the remaining attachment screws 8 xx2100002153 Tightening torque 50 Nm Tighten the screws 9 Disconnect the brake release tool 10 ...

Page 575: ... the robot 2 Person 1 working at the back Run the cable harness through the cable guide and then into and through the upper arm tube Tip This step is best performed by two persons 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 ...

Page 576: ...ide the wrist Together Move the cable harness past the axis 5 motor and into the wrist 4 xx2300000035 Person 2 working at the wrist xx2300000041 Torx pan head screw M6x16 A4 80 Refit the metal clamp axis 4 inside the arm tube Note The screw is reached from outside the up per arm 5 Tightening torque 10 Nm xx2300000033 xx2300000032 Continues on next page 576 Product manual IRB 6740 3HAC085701 001 Re...

Page 577: ...tening torque 10 Nm Refit the back cover with the attachment screws Foundry Plus Tighten the two screws closest to the outlet first shown in figure to avoid deformation xx2100002636 Reconnecting the axis 3 and axis 4 motor cables Note Action Put the motor cables in place in the open ing 1 Continues on next page Product manual IRB 6740 577 3HAC085701 001 Revision A Copyright 2023 ABB All rights res...

Page 578: ...secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 4 xx2200001736 Continues on next page 578 Product manual IRB 6740 3HAC085701 001 Re...

Page 579: ...nge 3HAC074336 004 Graphite White threaded connection 3HAC074336 005 ABB Orange threaded connection Axis 3 Connection box cover FS180 with gasket 3HAC072864 004 Graphite White 3HAC072864 005 ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 580: ... routed correctly to each motor according to the figure and according to the markings on the connectors 1 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 xx2200001735 Continues on next page 580 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB ...

Page 581: ...and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms xx2200001734 Connect the signal cable connector Connect in accordance with the markings on the connectors 4 Connection box cover with gasket 3HAC072863 003 Inspect the gasket Replace if damaged 5 xx2200002141 Continues on next pa...

Page 582: ... Cable strap outdoor 3HAC057966 003 Secure the cabling with a cable strap 8 xx2100002625 Inserting the axis 6 motor cables Note Action 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 brake release tool to the axis 5 motor connector release the brakes and move axis 5 manually to 90 1 Continues on next page 58...

Page 583: ...rier carefully into position 3 xx1300000485 Secure the carrier with the M4x10 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 4 Continues on next page Product manual IRB 6740 583 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved ...

Page 584: ...he purpose of the screw is to secure the mating of the connectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 2 xx2200001731 xx2200001921 Snap the signal connector...

Page 585: ... layout as shown in the figure CAUTION Route the signal cabling correctly to avoid cable damage 5 Connection box cover MT100X with gasket Inspect the gasket 6 3HAC079381 003 Graphite White Replace if damaged 3HAC079381 004 ABB Orange xx2200001922 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 6740 585 3HAC0...

Page 586: ... xx2200001434 Refitting the wrist cover Note Action xx2100002626 Make sure that the cable harness is routed and secured as shown in the figure 1 Continues on next page 586 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 587: ...001407 Torx pan head screw M6x16 A4 80 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm Foundry Plus xx2000000373 Fit all the screws first then torque tighten Refitting cable brackets Use this procedure to refit the cable brackets Note Action Remove the lifting accessories 1 Move the cable harness and DressPack back to the correct side of the robot 2 Continues on next page Pr...

Page 588: ...rm 3 Torx pan head screw M6x16 A4 80 Refit the metal clamp to the arm house 4 Tightening torque 10 Nm xx2200001433 Torx pan head screw M6x16 A4 80 Refit the metal clamp beneath the arm house 5 Tightening torque 10 Nm xx2200002142 Continues on next page 588 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 589: ...procedures Note Action Torx pan head screw M6x16 A4 80 Refit the metal clamp to the arm house 1 Tightening torque 10 Nm xx2200001433 See Filling oil into the axis 3 gearbox on page 150 Refill oil in the gearbox 2 See Calibration on page 609 Calibrate the robot 3 Continues on next page Product manual IRB 6740 589 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replac...

Page 590: ...re met when performing the first test run See Test run after installation maintenance or repair on page 96 4 590 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 591: ...ange Gearbox L2 Includes o ring IRB 6740 240 3 2 IRB 6740 220 3 2 LID 3HAC079353 002 Graphite White 3HAC079353 003 ABB Orange Gearbox Required service parts Note Article number Consumable Replace if damaged 3HAB3772 25 O ring Replace if damaged On axis 6 motor 3HAC079381 003 Graphite White 3HAC079381 004 ABB Orange Connection box cover MT100X with gasket Used on oil plug Always replace when refitt...

Page 592: ...ble Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robo...

Page 593: ... page 163 Drain the gearbox 3 Remove all equipment fitted on the turning disc 4 Jog the robot into position Axis 1 no significance Axis 2 suitable working position to replace axis 6 gearbox for example 25 Axis 3 suitable working position to replace axis 6 gearbox for example 20 Axis 4 0 Axis 5 55 Axis 6 0 5 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to ...

Page 594: ...rning disc 2 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 594 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 595: ... xx2200001730 Remove the connector bracket 3 xx2200001731 Remove the connector screw 4 Disconnect the motor cables 5 Continues on next page Product manual IRB 6740 595 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 596: ...30 3 0 LID Unscrew the attachment screws that secure the axis 6 gearbox 1 xx2300000667 IRB 6740 240 3 2 IRB 6740 220 3 2 LID xx2200001804 Continues on next page 596 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 597: ... 2 Guide pin M6x150 3HAC080345 001 Fit guide pins 3 Always use guide pins in pairs xx2200001821 Continues on next page Product manual IRB 6740 597 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 598: ...ol incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gear box the gears may be...

Page 599: ...dures 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 Cleaning agent Isopropanol Wipe clean the contact surfaces of both gearbox and wrist from any contamination 2 Continues on next page Product manual IRB 6740 599 3HAC085701 001 Revision A Copyright 2023 A...

Page 600: ...urface inside the wrist with grease 4 xx2100002791 Flange sealant Loctite 5800 Protection type Foundry Plus 5 xx2100002233 Apply flange sealant on the surface shown in the figure Continues on next page 600 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 601: ...ser instructions for the tool 6 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk Refitting the axis 6 gearbox Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive for...

Page 602: ...00000666 Make sure that the motor pinion is properly mated to the gear of the gearbox CAUTION Be careful not to damage motor pinion or gears Tip Verify that the oil plug is removed so the air can be pressed out during fitting of the gearbox IRB 6740 240 3 2 IRB 6740 220 3 2 LID xx2200001803 Continues on next page 602 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights r...

Page 603: ...tmo or equivalent with allen head screws on page 650 IRB 6740 310 2 8 IRB 6740 260 3 0 IRB 6740 270 2 8 LID IRB 6740 230 3 0 LID xx2300000667 IRB 6740 240 3 2 IRB 6740 220 3 2 LID xx2200001804 Disconnect the brake release tool 6 See Performing a leak down test on page 178 Perform a leak down test 7 Jog axis 5 to horizontal position 8 See Filling oil into the axis 6 gearbox on page 164 Refill oil i...

Page 604: ...nectors and the position ing of the connector in the connection box It is normal that the connector can be moved back and forth after the screw has been tightened according to the torque specification and in some connection boxes that the screw is not even fully inser ted when it bottoms 2 xx2200001731 xx2200001921 Snap the signal connectors to each other in the bracket 3 Continues on next page 60...

Page 605: ... layout as shown in the figure CAUTION Route the signal cabling correctly to avoid cable damage 5 Connection box cover MT100X with gasket Inspect the gasket 6 3HAC079381 003 Graphite White Replace if damaged 3HAC079381 004 ABB Orange xx2200001922 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 6740 605 3HAC0...

Page 606: ...1 Mercasol 3110 Waxcoat Recom mended drying time is 24h Protection type Foundry Plus Apply rust preventive to the surface shown in the figure 2 xx2100002232 xx2100002169 Fit the turning disc to the wrist Orient the disc according to the synchronization marks 3 Continues on next page 606 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 5 Repair 5 9 4 Replacin...

Page 607: ...1 5 IRB 6740 220 3 2 LID Tightening torque standard torque 35 Nm Tightening torque for lubric ated screws Molykote Gleitmo or equivalent with allen head screws on page 650 xx2200001807 Concluding procedure Note Action See Calibration on page 609 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or r...

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Page 609: ... generic 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 ...

Page 610: ...ccuracy has the option information printed on its name plate OmniCore To regain 100 Absolute accuracy perform ance the robot must be recalibrated for abso lute accuracy after repair or maintenance that affects the mechanical structure Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6740 It is the recommended ...

Page 611: ...s after replacements that do not include taking apart the robot structure standard calibration is sufficient The Absolute Accuracy option varies according to the robot mounting position This is printed on the robot name plate for each robot The robot must be in the correct mounting position when it is recalibrated for absolute accuracy References Article numbers for the calibration tools are liste...

Page 612: ... counter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 616 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...

Page 613: ...the position of the synchronization marks and the synchronization position for each axis Synchronization marks IRB 6710 IRB 6720 IRB 6730 IRB 6740 xx2200002087 Continues on next page Product manual IRB 6740 613 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 6 Calibration 6 2 1 Synchronization marks and synchronization position for axes ...

Page 614: ...xx2200002088 614 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 6 Calibration 6 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 615: ... in gears and so on Positive directions are shown in the graphic below Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions xx2200002089 Product manual IRB 6740 615 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 6 Calibration 6 2 2 Calibration movement dire...

Page 616: ...creen tap Calibrate 1 Select Calibration from the menu 2 The Mechanical Units page displays a list of available mechanical units Note This step is required only if you are not already in the Mechanical Unit page when you open Calibrate Note The Mechanical Unit page is displayed only if there are more than one mechanical unit available Otherwise the calibration summary page for the available mechan...

Page 617: ...ution counter for the selected axes is updated CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury Check the synchronization position very carefully after each update See Checking the synchronization position on page 632 10 Product manual IRB 6740 617 3HAC085701 001 Revision A Copyright 2023 ABB All rights...

Page 618: ...ovable 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 ins...

Page 619: ...technical data about the tool installed A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB 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 t...

Page 620: ...s allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 System containing SafeMove SafeMove will lose its synchronization to the controller if a new calibration is done New calibration values have to be downloaded to SafeMove and a new SafeMove calibration has to be done Make sure that the user rights admit to change the safety settings and to synchronize S...

Page 621: ...damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Calibration toolbox Ax is Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube inser...

Page 622: ...d solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a ca...

Page 623: ...pin and a bushing for the movable calibration tool are located on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure xx2300000256 Continues on next page Product manual IRB 6740 623 3HAC085701 001 Revision A...

Page 624: ...Replace damaged parts with new Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushings 3HAC064875 001 axes 1 2 3 and 4 3HAC059487 001 axes 5 and 6 Protection cover and plug set 624 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Cont...

Page 625: ...cover and plug set Overview of the calibration procedure on the FlexPendant The actual instructions of how to perform the calibration 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...

Page 626: ...l affect the calibration value 2 Starting the calibration procedure Use this procedure to start the Axis Calibration routine on the FlexPendant Note Action Tap the calibration icon and enter the calibration main page 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question Note For RobotWare 7 the mechanical unit page is displayed...

Page 627: ...calibration tool is in contact the robot axis needs to be jogged in order to release the calibration tool Jogging the axis in wrong direction will cause the calibration tool to break Directions of axis movement is shown in Calibration movement directions for all axes on page 615 Axis Calibration with SafeMove option To be able to run Axis Calibration SafeMove needs to be unsynchronized The Axis Ca...

Page 628: ...es 1 2 3 and 4 3HAC059487 001 axes 5 and 6 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 3HAC064875 001 axes 1 2 3 and 4 3HAC059487 001 axes 5 and 6 628 Product manual IRB 6...

Page 629: ...ibration to save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset val...

Page 630: ...ce ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the ...

Page 631: ...ition 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 613 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 ...

Page 632: ...rrectly 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 Tap Jog 1 From the Mechanical unit list select a mechanical unit 2 From the Motion mode section select an axis set that need to be jogged 3 For example to jog axis 2 select the axis set Axis 1 3 Follow the screen instruction o...

Page 633: ...ms 2 Divide the fault chain in two 3 Check communication parameters and cables 4 Check that the software version is compatible with the hardware Work systematically 1 Take a look around to make sure that all screws connectors and cables are secured and that the robot and other parts are clean not damaged and correctly fitted 2 Replace one thing at a time 3 Do not replace units randomly 4 Make sure...

Page 634: ...ed Check all connections to the replaced part power supplies that the correct part has been fitted the last repair documents The robot has recently been repaired Check software versions compatibilities between hardware and software options and their configuration The robot recently had a software upgrade Check connections software versions The robot has recently been moved from one site to another...

Page 635: ...f the oil spill is small this step is sufficient Wipe off the oil or grease see Cleaning the IRB 6740 on page 172 2 Monitor the robot over time to see if new oil or grease occurs Check the gearbox oil level 3 Robots performing certain ex tremely heavy duty work cycles may be fitted with vented oil plugs These are not fitted to normal duty robots but can be purchased from your local ABB representat...

Page 636: ...parts If the noise is emitted from a gearbox the following can also apply Overheating Recommended actions The following actions are recommended Information Action CAUTION Allow hot parts to cool down 1 Verify that the service is done according to the maintenance schedule 2 If a bearing is emitting the noise determine which one and make sure that it has suffi cient lubrication 3 If possible disasse...

Page 637: ...ounding equipment Possible causes The symptom can be caused by Faulty brake Faulty power supply to the brake Recommended actions The following actions are recommended Information Action Determine which motor s causes the robot to collapse 1 See the circuit diagram Check the brake power supply to the col lapsing motor during the Motors OFF state 2 If found faulty the motor must be replaced as a com...

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Page 639: ...ry in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robot and cont...

Page 640: ... and their respective use throughout the product Dispose components properly according to local regulations to prevent health or environmental hazards Example application Material Wrist house tilt house covers connection box mo tor housing Aluminium Serial measurement board Batteries Lithium Calibration protection cap and plug and couplings connectors and nuts in cable harness Brass zink alloys St...

Page 641: ... for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxygen transfer ...

Page 642: ...orch 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 A used robot does not have the same performance as on delivery Springs brakes bearings and other parts might be worn or broken 642 Pro...

Page 643: ...se procedures in the step by step in structions below DANGER Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Action on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissio...

Page 644: ... 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 Cut a hole in the housing as shown in the figure 4 The measurements shown below are maxim um values 400 m m 200 mm xx0700000391 Use a cutting torch with a lo...

Page 645: ...chapter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 6740 645 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 9 Reference information 9 1 Introduction ...

Page 646: ...f machines Part 1 General requirements normative reference from ISO 10218 1 IEC 60204 1 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity standard for industrial environments IEC 61000 6 2 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments IEC 61000 6 4 Safety of machinery Safety related parts of control systems Part 1 Gen...

Page 647: ...y 39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual IRB 6740 647 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 9 Reference information 9 3 Unit conversion ...

Page 648: ...carded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Generally screws are lubricated with Gleitmo 603 mixed with Geomet 500 or Geomet 702 in proportion 1 3 Geomet thickness varies according to screw dimensions refer to the following Geomet thickness Lubricant Dimension 3 5 μm Gleitmo 603 Geomet 500 M6 M20 any length ex...

Page 649: ...is do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 Tightening torque for oil lubricated screws with slotted or cross recess head screws The following table specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws Note A special torque specified in the repair maintena...

Page 650: ... for screws lubricated with Molycote 1000 Gleitmo 603 or equivalent with allen head screws Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 lubricated i Tightening torque Nm Class 10 9 lubricated i Dimension 8 M5 14 M6 35 28 M8 70 55 M10 120 96 M12 300 235 M16 550 460 M20 950 790 M24 i Lubricated with ...

Page 651: ...ccessory 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 Product manual IRB 6740 651 3HAC085701 001 Revision A Copyright 2023 ABB All ...

Page 652: ...r and hexagon bit SW10 Bit holder dimension 5 16 14x18 mm Used for screw access in narrow locations 1 xx2200001085 Socket head cap 2 5 17 mm 1 Torx socket no 10 30 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 shorte...

Page 653: ... toolkit on page 652 and of special tools listed directly in the instructions and also gathered in this section Special tools Note If the replacing procedure is not listed in the table below only standard tools are needed for the procedure Continues on next page Product manual IRB 6740 653 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 9 Reference information 9 7 Special tools ...

Page 654: ...ment tool for cassette sealing 3HAC079880 001 1 xx2100002289 Replacement tool for arm house cover 3HAC079878 001 1 1 1 1 1 1 Dismantle and mounting tool 3HAC028920 001 2 2 2 2 2 2 2 2 Removal tool motor M12 3HAC14631 1 2 Removal tool motor M10 3HAC14972 1 2 Screws M8x75 fully threaded 2 Screws M10x80 fully threaded 1 1 1 1 1 1 1 1 Bits extender 3HAC12342 1 1 1 xx2200001085 Bit holder and hexagon b...

Page 655: ... 1 1 Hydraulic pump 80 MPa 3HAC13086 1 1 1 1 1 1 1 Hydraulic cylinder 3HAC11731 1 Lifting accessories 1 Roundsling 0 5 m 1 1 1 1 Roundsling 1 m 1 Roundsling 1 5 m 1 Roundsling 2 m 1 1 xx2100002415 Lifting accessory for gear 3HAC081585 001 1 1 1 Fender washer 1 1 1 1 1 1 1 1 xx1200001241 Lifting accessory chain 3HAC15556 1 1 2 2 xx1200001242 Lifting eye 3HAC16131 1 2 Lifting eye M16 3HAC14457 4 1 1...

Page 656: ...1 2 Guide pin M12x150 3HAC13056 2 1 Guide pin M12x200 3HAC13056 3 1 Guide pin M16x120 3HAC062397 001 1 Guide pin M16x250 3HAC062398 001 Brake release 1 1 1 1 1 1 1 1 1 1 1 xx2100000666 Brake release tool 3HAC081310 001 Calibration tools 1 1 1 1 1 1 1 1 1 1 Calibration toolbox Axis Calibration 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Adjustment and fixing tools 1 1 1 1 1 1 1 1 Ro...

Page 657: ...iece of lifting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories The instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 6740 657 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved 9 Reference information 9 8 Lifting accessories and lifting instructions...

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Page 659: ...alancing device front eye 170 Brake power supply faulty 637 brake release unit replacing 352 brake releasing 75 brakes testing function 33 C cabinet lock 27 cable harness inspecting 108 refitting 325 removing 306 cabling between robot and controller 93 calibrating robot 618 roughly 616 calibrating robot 618 calibration Absolute Accuracy type 610 rough 616 standard type 610 verification 631 when to...

Page 660: ...2 installation equipment 78 installation procedure 55 instructions for assembly 51 integrator responsibility 26 intervals for maintenance 99 L labels robot 19 leak down test 178 leaking sealing 635 lifting robot 66 67 lifting accessory 651 lifting accessory robot 64 lifting robot with lifting accessory 64 limitation of liability 15 lithium disposal 640 Lithium disposal 640 loads on foundation 38 l...

Page 661: ...g 78 labels 19 lifting 66 67 protection class 40 protection types 40 symbols 19 technical data 37 working range 41 S safety brake testing 33 ESD 50 fire extinguishing 27 release robot axes 32 signals 17 signals in manual 17 symbols 17 symbols on robot 19 test run 96 safety devices 27 safety signals in manual 17 safety standards 646 scales on robot 613 schedule of maintenance 99 screw joints 648 se...

Page 662: ...vice 189 193 202 215 219 220 222 234 249 450 454 456 496 497 511 complete arm system 457 469 479 robot 65 69 73 upper and lower arm 514 523 532 upper arm complete 560 570 wrist 289 working range 48 robot 41 wrist replacing 282 X xx replacing 53 Z zero position checking 632 662 Product manual IRB 6740 3HAC085701 001 Revision A Copyright 2023 ABB All rights reserved Index ...

Page 663: ......

Page 664: ... 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong New 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 3HAC085701 001 Rev A en Copyright 2023 ABB All rights reserved Specifications subject to change without notice ...

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