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4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.

Required equipment

Note

Article number

Equipment, etc.

-

Leak-down tester

-

Leak detection spray

Performing a leak-down test

Note

Action

Finish the refitting procedure of the motor or gear in
question.

1

Remove the upper oil plug on the gear and replace
it with the leak-down tester.

2

Regulators, which are included in the leak-down test,
may be required.

Correct value:

Use caution, apply compressed air and raise the
pressure 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. This is quite normal.

Wait for approximately 8-10 minutes and make sure
that no pressure loss occurs.

5

If any pressure drop occurred, then localize the leak
as described in step

6

If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.

7

When the leak has been localized, take the necessary
measures to correct the leak.

8

198

Product manual - IRB 6700

3HAC044266-001 Revision: N

© Copyright 2013 - 2018 ABB. All rights reserved.

4 Repair

4.2.1 Performing a leak-down test

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Summary of Contents for IRB 6700 Series

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

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ...2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 IRB 6700 300 2 70 IRB 6700 245 3 00 IRC5 Document ID 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved Specifications subject to change without notice ...

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

Page 5: ...ase 38 1 4 Safety signals and symbols 38 1 4 1 Safety signals in the manual 40 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Unpacking 48 2 2 1 Pre installation procedure 52 2 2 2 Working range 58 2 2 3 Risk of tipping stability 59 2 2 4 Main dimensions 61 2 3 On site transportation 61 2 3 1 Robot transportation precautions 65 2 3 2 Securing ...

Page 6: ...nging oil axis 1 gearbox 165 3 4 3 Changing oil axis 2 gearbox 170 3 4 4 Changing oil axis 3 gearbox 176 3 4 5 Changing oil axis 4 gearbox 180 3 4 6 Changing oil axis 5 gearbox 184 3 4 7 Changing oil axis 6 gearbox 189 3 4 8 Replacing the SMB battery 192 3 5 Lubrication activities 192 3 5 1 Lubricating the spherical roller bearing balancing device 194 3 6 Cleaning activities 194 3 6 1 Cleaning the...

Page 7: ...1 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 664 4 8 3 Replacing the axis 2 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 701 4 8 4 Replacing the axis 2 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 738 4 8 5 Replacing the axis 3 gearbox 776 4 8 6 Replacing the axis 6 gearbox 787 5 Calibration 787 5 1 Introduction to calibration ...

Page 8: ... joints 828 8 5 Weight specifications 829 8 6 Standard toolkit 830 8 7 Special tools 835 8 8 Lifting accessories and lifting instructions 837 9 Spare parts 837 9 1 Spare part lists and illustrations 839 10 Circuit diagrams 839 10 1 Circuit diagrams 841 Index 8 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved Table of contents ...

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

Page 10: ...on i 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC021313 001 Product manual IRC5 IRC5 with main computer DSQC 639 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC16578 1 Operating manual Calibration Pendulum 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050948 001 Technical reference manual System parameters i This manual contains all s...

Page 11: ...ring it to a track motion carriage see Orienting and securing the robot on page 80 Updated base plate drawings and added information regarding guide pins see Securing the base plate on page 69 Thread lines were missing Now added in figure Figure updated so locating hole is shown at 12 o clock D The following updates are done in this revision Information regarding how to read the procedures in this...

Page 12: ...on with SafeMove option on page 806 F The following updates are done in this revision Removal tools for removing the motors are updated New article numbers for the tools G Published in release R16 2 The following updates are made in this revi sion Drawing of base plate is not available for purchase faulty inform ation removed in Securing the base plate on page 69 Type B motors are introduced throu...

Page 13: ...for Axis Calibration on page 800 Added sections in General procedures on page 198 Corrected the length of attachment screws for axis 1 and axis 2 motors Guide tool for refitting the axis 1 gearbox is added to the repair procedure and list of special tools Safety restructured Changed specification for axis 2 position before usage of distance tool on the balancing device The procedure for replacing ...

Page 14: ...ioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ...

Page 15: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 6700 15 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved Product documentation Continued ...

Page 16: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 17 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a different...

Page 17: ...arried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is respo...

Page 18: ...orking in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure that...

Page 19: ...view The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 6700 19 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 20: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 20 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 21: ... may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury 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 Product manu...

Page 22: ...troller before proceeding work Note Switch off all main power switches in a MultiMove system Spot welding cabinet Wait for 5 minutes to let the capacitors discharge after the power has been switched off DANGER Even if the main switch is switched off the capacitors can cause electric shock if not given the time to discharge 22 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 AB...

Page 23: ...afety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pur...

Page 24: ...odifications to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as...

Page 25: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 26: ...fore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ...

Page 27: ...in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of the...

Page 28: ...manipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pr...

Page 29: ...risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 7...

Page 30: ...e live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 30 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 31: ...nics Safe handling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and mus...

Page 32: ... your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 32 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 33: ...re must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause a...

Page 34: ...as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 34 Product manual IRB 6700 3HAC044266 001 Revision N Cop...

Page 35: ...losion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures ...

Page 36: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 37: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vol...

Page 38: ...e instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or deat...

Page 39: ...d conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 6700 39 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 40: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of c...

Page 41: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRB 6700 41 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights re...

Page 42: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 42 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 43: ...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 Product manual IRB 6700 43 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...0001242 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 44 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...hat 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 Product manual IRB 6700 45 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

Page 46: ...This page is intentionally left blank ...

Page 47: ...portant that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 before performing any installation work Note If the IRB 6700 is connected to power always make sure that the robot is connected to protective...

Page 48: ...uired is suitable to handle the weight of the robot as specified in Weight robot on page 49 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 51 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 51 7 Before taking the robot to its installation ...

Page 49: ... robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values ...

Page 50: ... recommended Minimum resonance frequency Due to foundation stiffness consider robot mass including equipment i For information about compensating for founda tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode i The minimum resonance frequency given should be interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation transl...

Page 51: ...nstant temper ature Maximum ambient humidity i At low environmental temperature below 10 C a warm up phase is recommended to be run with the robot Otherwise there is a risk that the robot stops or runs with lower performance due to temperature dependent oil and grease viscosity Protection classes robot The table shows the available protection types of the robot with the corresponding protection cl...

Page 52: ...oftware i Working range for variants IRB 6700 300 2 70 and 245 3 00 85 to 65 when axis 3 is within 70 to 45 85 to 58 when axis 3 is within 70 to 180 ii Working range 120 to 120 for robots with LeanID option 780 4 iii Working range 220 to 220 for robots with LeanID option 780 4 Working range axis 5 and axis 6 for LeanID option 780 4 Allowed working area for axis 6 related to axis 5 position is show...

Page 53: ... IRB 6700 Illustration working range IRB 6700 205 2 80 This illustration shows the unrestricted working range of the robot 308 3259 1281 2039 958 2794 Reach Handling capacity Robot type 2 80 m 205 kg IRB 6700 Continues on next page Product manual IRB 6700 53 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 54: ... IRB 6700 Illustration working range IRB 6700 150 3 20 This illustration shows the unrestricted working range of the robot 1604 2445 1067 3200 713 3665 Reach Handling capacity Robot type 3 20 m 150 kg IRB 6700 Continues on next page 54 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 55: ... IRB 6700 Illustration working range IRB 6700 155 2 85 This illustration shows the unrestricted working range of the robot 1352 2106 994 2848 529 3312 Reach Handling capacity Robot type 2 85 m 155 kg IRB 6700 Continues on next page Product manual IRB 6700 55 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 56: ...IRB 6700 Illustration working range IRB 6700 245 3 00 This illustration shows the unrestricted working range of the robot 2097 1518 1057 2967 596 3399 Reach Handling capacity Robot type 3 00 m 245 kg IRB 6700 Continues on next page 56 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 57: ...205 2 80 3056 IRB 6700 175 3 05 3200 IRB 6700 150 3 20 2601 IRB 6700 200 2 60 2848 IRB 6700 155 2 85 2720 IRB 6700 300 2 70 2967 IRB 6700 245 3 00 Product manual IRB 6700 57 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 58: ...able position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position 45 2 0 6 5 70 890 50 570 55 xx1300000356 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 58 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 ...

Page 59: ... 85 C Radius ax1 back 700 mm IRB 6700 300 2 70 and 245 3 00 J H G F LeanID F E D A LeanID A Robot variant 186 209 1 182 5 1820 1670 1135 2300 350 200 IRB 6700 235 2 65 209 186 1 182 5 1820 1670 1280 2445 350 200 IRB 6700 205 2 80 186 209 1 592 5 2230 2080 1135 2300 350 200 IRB 6700 175 3 05 186 209 1 592 5 2230 2080 1280 2445 350 200 IRB 6700 150 3 20 193 197 5 1 142 5 1773 1623 1125 2276 350 200 ...

Page 60: ...55 2 85 187 222 5 1212 5 1878 5 1718 5 1145 2321 380 220 IRB 6700 300 2 70 186 222 5 1462 5 2128 5 1968 5 1145 2321 380 220 IRB 6700 245 3 00 60 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 2 4 Main dimensions Continued ...

Page 61: ... any compensation claim Method 1 recommended method Transportation according to method 1 is strongly recommended by ABB xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 Always remove the tool before transportation of the robot Always place the robot in the ABB recommended transport position described in section Risk of tipping stability on page 58 ...

Page 62: ...he ABB recommended transport position for robot with tool described in sub section Transport position with a transport support on page 63 Always use the recommended transport support described in sub section Recommended transport support on page 64 IRB 6700 A B D C xx0800000037 Transport Support A Hexagon socket head cap screw M16x140 B Threaded bar M10x200 C Nut M10 D Continues on next page 62 Pr...

Page 63: ... robot with tool must follow these instructions IRB 6700 xx0800000040 Continues on next page Product manual IRB 6700 63 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Robot transportation precautions Continued ...

Page 64: ...18 60 12 R 2 0 30 A 5 IRB 6700 2 65 2 8 3 05 3 00 3 2 2 85 2 60 Lower Variant arm L 1135 1280 1135 1280 1125 1125 A 1000 1160 630 860 817 1004 B 21 21 21 21 21 21 2 70 B 1145 1145 1000 817 6 6 xx1300001603 64 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Robot transportation precautions Continued ...

Page 65: ...ols DANGER Releasing the brakes is a hazardous action that may cause injury and damage property It must be done with great care and only when absolutely necessary Fitting the transport support Illustration for fitting the transport support A B xx0800000062 Continues on next page Product manual IRB 6700 65 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and comm...

Page 66: ...ansport position with a transport support on page 63 Use the brake release for axis 3 to reach the final resting position on the transport support see the section Manually releasing the brakes on page 85 3 CAUTION Do not attempt to tighten any attachment screws without first releasing the brakes This can seriously damage the robot Tighten all the attachment screws A and B in the figure with the br...

Page 67: ...ulator to the plat form foundation 3 See on page See Product manual IRC5 Connect the manipulator to the controller 4 See Product manual IRC5 Configure the safety settings 5 See Product manual IRC5 How to start and run the robot is described in the product manual for the controller 6 Install required equipment if any Signal lamp option on page 102 7 Make sure all safety requirements are met when pe...

Page 68: ...g All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 68 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 68 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 AB...

Page 69: ...042 A A 1 6 1 5 A 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 72 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 6700 69 3HAC044266 001 Revision N Copyright 2013 20...

Page 70: ...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 70 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Securing the base plate Continued ...

Page 71: ...16 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 Color RAL 9005 Thickness 80 100 µm Weight 360 kg A Continues on next page Product manual IRB 6700 71 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3...

Page 72: ...s Cylindrical guide pin x2 A M5 x 40 Tightening torque 6 Nm x2 B Note All screws and pins are delivered in a plastic bag together with the base plate Continues on next page 72 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Securing the base plate Continued ...

Page 73: ...0 79 attachment screws and washers for securing the robot to the base plate 3HAC051821 001 Base plate Content is defined in section Standard toolkit on page 829 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 6700 ...

Page 74: ...he base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces on the base plate to make sure the base plate is level...

Page 75: ... number Equipment Contains fork lift pockets and all required hardware for installation User instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700 3HAC047054 003 Fork lift accessory set Required documents Document number Document 3HAC048484 002 Directions for use Fork lift accessory for IRB 6700 Lifting the robot Note Action Lift the robot according to the...

Page 76: ...00 205 2 80 Roundsling 2 m Roundsling 2 5 m IRB 6700 175 3 05 Roundsling 2 m Roundsling 2 5 m IRB 6700 150 3 20 Roundsling 2 m Roundsling 2 m IRB 6700 200 2 60 Roundsling 2 m Roundsling 2 5 m IRB 6700 155 2 85 Roundsling 2 5 m Roundsling 2 m IRB 6700 300 2 70 Roundsling 2 5 m Roundsling 2 5 m IRB 6700 245 3 00 Roundsling 2 5 m 4 pcs C Lifting eye M20 4 pcs D Continues on next page 76 Product manua...

Page 77: ...lift the robot with roundslings Jogging the robot to lifting position Note Action 45 2 0 6 5 70 890 50 570 55 xx1300000356 Jog the robot into position Axis 1 calibration position 0 Axis 2 45 Axis 3 65 Axis 4 no significance Axis 5 70 Axis 6 no significance WARNING The robot is likely to be mechanically un stable if not secured to the foundation 1 Continues on next page Product manual IRB 6700 77 3...

Page 78: ...es and fasten them in an overhead crane CAUTION If the lifting eyes have sharp edges that might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes 2 Roundsling 2 5 m 4 pcs xx1300001572 Continues on next page 78 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 2 Liftin...

Page 79: ... strained at lifting It only secures for tipping 4 CAUTION The IRB 6700 robot weighs 1300 kg All lifting accessories used must be sized accordingly 5 WARNING Personnel must not under any circum stances be present under the suspended load 6 Raise the overhead crane to lift the robot CAUTION Make sure that the roundsling running from the front left corner is positioned on the correct side of the bra...

Page 80: ...ws the hole configuration used when positioning and securing the robot D D 8x 30 8x 53 4x 45 H7 4 x 3 x 4 5 1 6 8 x 4 9 5 0 3 A 0 12 A 800 4x 90 5 2 5 4 x 1 5 D D E E 2x 25 H8 2 0 2 5 H 8 2 x 4 5 2 4 5 2 x 0 12 E E A A xx1300000243 Description Pos Holes for guide pins x2 A Continues on next page 80 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Inst...

Page 81: ...4 M24 x 100 installation on base plate foundation Suitable screws lightly lubricated 8 pcs Quantity 8 8 Quality 90 v 0 9 Screw tightening yield point utilization factor v according to VDI2230 4 mm flat washer Suitable washer 550 Nm screws lubricated with Molykote 1000 Tightening torque 600 725 Nm typical 650 Nm screws none or lightly lubricated Continues on next page Product manual IRB 6700 81 3HA...

Page 82: ...ogether with the base plate 1 See Lifting the robot with roundslings on page 76 Lift the robot 2 Move robot close to its installation location 3 Make sure the robot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 81 Note Lightly lubricate screws before as sembly Fit the...

Page 83: ...ylindrical guide pin A Note There are versions with a flattened cylindrical guide pin in left rear of the base Continues on next page Product manual IRB 6700 83 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Orienting and securing the robot Continued ...

Page 84: ...n line turned 90 or 180 xx1500000320 Description Pos Cylindrical guide pin A Adapter for guide pin fitted to the carriage at delivery C Distance plate fitted to the carriage at delivery D Note There are versions with a flattened cylindrical guide pin in left rear of the base It is important that the flattened pin is aligned in correct direction 84 Product manual IRB 6700 3HAC044266 001 Revision N ...

Page 85: ...nit on page 85 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 86 1 DANGER When releasing the holding brakes the robot axes may move ve...

Page 86: ... controller power must be supplied to connector R1 MP on the robot in order to enable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 86 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 I...

Page 87: ... robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot Prod...

Page 88: ...cables used on the robot must be designed and fitted not to damage the robot and or its parts Frame hip load Extra load can be fitted on the frame Description JH 100 kgm2 Permitted extra load on frame JH JH0 M4 x R2 Recommended position see the fol lowing figure where JH0 is the moment of inertia of the equipment R is the radius m from the center of axis 1 M4 is the total mass kg of the equipment ...

Page 89: ... 50 kg with a distance a 500 mm from the center of gravity in the axis 3 extension a A M1 M1 xx1400002019 Mass center A Continues on next page Product manual IRB 6700 89 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 8 Fitting equipment to the robot Continued ...

Page 90: ...Center of gravity 50 kg A Continues on next page 90 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 8 Fitting equipment to the robot Continued ...

Page 91: ...1 3 4 x M 8 M12 20 52 5 H H 150 150 109 J K K A A J 2x M12 19 M12 19 C L Axis 4 B B A B E L H J M K C D F G 12 N B B xx1300000263 Allowed position for attachment holes M12 through Be careful not to touch the cables when drilling A Continues on next page Product manual IRB 6700 91 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 8 Fitting eq...

Page 92: ... 102 43 143 315 437 365 650 5 400 270 R 204 5 IRB 6700 200 2 60 210 95 102 43 143 315 437 365 650 5 400 270 R 204 5 IRB 6700 155 2 85 215 5 98 5 117 12 152 405 467 376 652 5 450 310 R 230 IRB 6700 300 2 70 215 5 98 5 117 12 152 405 467 376 652 5 450 310 R 230 IRB 6700 245 3 00 i Smallest circumscribed radius axis 4 Continues on next page 92 Product manual IRB 6700 3HAC044266 001 Revision N Copyrig...

Page 93: ... 303 5 320 255 186 208 5 80 403 418 433 R 456 IRB 6700 175 3 05 13 8 500 303 5 320 255 186 208 5 80 408 423 438 R 456 IRB 6700 150 3 20 13 8 500 303 5 320 255 193 197 113 395 410 425 R 440 IRB 6700 200 2 60 13 8 500 303 5 320 255 193 197 113 395 410 425 R 440 IRB 6700 155 2 85 15 523 5 273 5 350 265 187 222 5 80 423 438 453 R 468 IRB 6700 245 3 00 15 523 5 273 5 350 265 187 222 5 80 423 438 453 R ...

Page 94: ... 0 100 H7 0 0 035 0 02 A xx1300000280 Thread length 18 mm A The turning disc for robot variants IRB 6700 200 2 60 and IRB 6700 155 2 85 was redesigned when Axis Calibration was introduced for IRB 6700 Prior to Axis Calibration the holes on the disc were through On the current turning disc the holes are not through Fastener quality Use suitable screws and tightening torque for your application scre...

Page 95: ... 200 h8 8 100 H7 1x45 100 H7 0 07 E 0 3 E F F E xx1300000290 Thread length 18 mm A Fastener quality Use suitable screws and tightening torque for your application screws with quality class 12 9 are recommended Product manual IRB 6700 95 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 4 8 Fitting equipment to the robot Continued ...

Page 96: ... may be restricted Axis 1 hardware mechanical stop and software Axis 2 software Axis 3 software This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant manuals are included in the installation procedures 96 Product manual IRB 6700 3HAC044266 001 Revision N Copyrig...

Page 97: ...nical stops axis 1 The illustration shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 A B C B xx1300001971 Attachment screws M12x70 quality 12 9 Gleitmo 603 2 pcs per additional mechanical stop A Movable mechanical stop B Mechanical stop pin axis 1 C Continues on next page Product manual IRB 6700 97 3HAC044266 001 Revision N Copyright 2013 ...

Page 98: ...essure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Tightening torque 60 Nm Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 97 2 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software w...

Page 99: ...ow voltage signals and high voltage power supply protective ground Customer cables option 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 Connection point robot Connection point cabinet...

Page 100: ...er A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1500001600 Continues on next page 100 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and c...

Page 101: ...ithout cables If equipping the robot with cooling fans use the cabling specified below The cables for cooling fans listed below are used together with a distributing cable also specified below Connection point Art no Cable Distributing cable R1 FAN SW2 3 3HAC022723 001 Harness cooling 7 m Inside cabinet A43 X10 and A43 X11 Distributing cable R1 FAN SW2 3 3HAC022723 004 Harness cooling 15 m Inside ...

Page 102: ...mbly instruction delivered with the signal lamp Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller 102 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 7 1 Signal lamp option ...

Page 103: ... IRB 6700Inv on ABB Library Note Article number Spare part Only available for the axis 1 motor Can not be used together with protec tion type Foundry Plus Includes fan unit fan cable harness customer connection plate and re quired fasteners 3HAC051149 001 Fan unit set Required tools and equipment Note Article number Equipment Content is defined in section Stand ard toolkit on page 829 Standard too...

Page 104: ...air pressure supply to the robot before entering the robot working area 2 xx1800000157 Remove the metal sheet frame from the fan unit assembly by loosening the six screws 3 xx1800000159 Loosen the two tightening screws so they don t damage the motor surface during installation 4 Continues on next page 104 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved...

Page 105: ...th the two tightening screws Tighten them properly so that the box is firmly attached to the motor 6 Connecting the fan cabling Note Action xx1800000161 Remove the rear cover plate 1 xx1800000162 Fit the customer connection plate 2 Continues on next page Product manual IRB 6700 105 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 7 2 Installi...

Page 106: ... adjustment 3 xx1300000542 Loosen the frame cable clamp by unscrewing the screws 4 Cable straps xx1800000164 Run the cabling up through the base and frame Make a loop of the fan cable and use cable straps to strap it to the other cables 5 xx1800000166 Secure the cable bracket inside the frame with the two enclosed nuts 6 Continues on next page 106 Product manual IRB 6700 3HAC044266 001 Revision N ...

Page 107: ...able clamp with the screws 9 xx1800000167 Connect the connector R1 SW2 3 to the base of the robot Make sure that the cabling run through the frame and base is not twisted and runs freely from the robot cabling 10 xx1800000161 Refit the rear cover plate to the robot base 11 Continues on next page Product manual IRB 6700 107 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Ins...

Page 108: ...gs by using the Modify Controller System Wizard in the System Builder of RobotStu dio Read more about modifying the system in Operating manu al RobotStudio Modify the settings in RobotWare to include the cooling fans 1 108 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 2 Installation and commissioning 2 7 2 Installing the motor cooling fan option Cont...

Page 109: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 110: ...This page is intentionally left blank ...

Page 111: ...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 17 before performing any service work Note If t...

Page 112: ...rs More frequent running means more frequent maintenance activities Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot and define the optimal ABB support to maintain your robot working Contact your local ABB Custo...

Page 113: ...leaning activities Cleaning the IRB 6700 on page 194 x Cleaning the robot Inspection activities Inspecting the motor seal on page 116 x Inspecting the motor seal ii Inspect the oil level in the actual gearbox if there is a suspected leakage after an oil change or a maintenance or repair activity where draining and filling oil is required Inspecting the oil level in gearboxes Inspecting the balanci...

Page 114: ...ng device on page 192 x v Lubricating the balancing device bearings Overhaul x Overhaul of complete robot i Operating hours counted by the DTC Duty time counter ii Only valid for robots that are equipped with Type B motors Type B motors include evacuation on the motor flange to indicate failure of primary sealing between the gearbox and the motor Robots with protection type Foundry Plus have a sig...

Page 115: ...movement most material handling applications ii Severe chemical or thermal environments or similar environments can result in shortened life expectancy iii Examples of extreme usage in regard to movement press tending very severe palletizing applications major use of axis 1 movement iv The given life for the balancing device is based on a test cycle of 4 000 000 cycles that starts from the initial...

Page 116: ...e evacuation hole is located on each motor flange The figure shows axis 1 motor as an example xx1500001057 Plug in the evacuation hole Robots with protection type Standard have a protection filter installed in the evacuation hole Robots with protection type Foundry Plus have a transparent plug sight glass installed in the evacuation holes xx1800000102 xx1800000101 Transparent plug Foundry Plus Pro...

Page 117: ...risks during work with gearbox lubricants oil or grease on page 36 2 xx1500001057 Do a leakage check of the sight glass evacuation hole of each motor If any oil is available on the sight glass or if any oil has been spilled out from the evacuation hole replacement of the motor is recommended 3 Replacing of motors is described in the repair chapter Motors on page 503 Product manual IRB 6700 117 3HA...

Page 118: ...ated as shown in the figure xx1200000950 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continues on next page 118 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil level in axis 1 gearbox ...

Page 119: ...les Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6700 119 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil level in axis...

Page 120: ...ea 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 2 Make sure that the oil temperature is 25 C 10 C 3 Continues on next page 120 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 2 ...

Page 121: ...00000692 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Check the oil level Required oil level is 58 mm 5 mm below the sealing surface of the oil plug 5 Continues on next page Product manual IRB 6700 121 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil level in axis 1 gearbox Co...

Page 122: ...to drain or fill with oil is found in section Changing oil axis 1 gearbox on page 158 Tightening torque 24 Nm Refit the oil plug 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 9 122 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights...

Page 123: ...kit on page 829 Standard toolkit Required consumables Note Article number Consumables Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6700 123 3HAC044266 001 Revision N Copyright 2013...

Page 124: ...age 36 2 Make sure that the oil temperature is 25 C 10 C 3 xx1200000952 Open the oil plug 4 Check the oil level 5 Required oil level is 0 15 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubric ation in gearboxes Add or drain oil if required 6 Further information about how to drain or fill with oil is found in section Chan ging oil axis 2 gearbox...

Page 125: ...first test run These are further detailed in the section First test run may cause injury or damage on page 26 8 Product manual IRB 6700 125 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the oil level in axis 2 gearbox Continued ...

Page 126: ...200 2 60 IRB 6700 155 2 85 xx1200000955 IRB 6700 300 2 70 IRB 6700 245 3 00 xx1500001645 Tightening torque 24 Nm Required tools Note Article number Equipment etc Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page 126 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 4 Inspecting the oil le...

Page 127: ...libration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Make sure that the oil temperature is 25 C 10 C 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or gre...

Page 128: ...on in gearboxes Add or drain oil if required 7 Further information about how to drain or fill with oil is found in section Changing oil axis 3 gearbox on page 170 Tightening torque 24 Nm Refit the oil plug 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 9 128 Product...

Page 129: ...ormation about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Inspecting the oil level in axis 4 gearbox Use this procedure to inspect the oil level in the gearbox Note Action Run the robot to calibration position 1 Continues on next page Pro...

Page 130: ...evel is 0 10 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 7 Further information about how to drain or fill with oil is found in section Changing oil axis 4 gearbox on page 176 Tightening torque 24 Nm Refit the oil plug 8 DANGER Make sure all safety requirements are met when performing the fir...

Page 131: ...ormation about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Inspecting the oil level in axis 5 gearbox Use this procedure to inspect the oil level in the gearbox Note Action Run the robot to calibration position 1 Continues on next page Pro...

Page 132: ...evel is 0 10 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 7 Further information about how to drain or fill with oil is found in section Changing oil axis 5 gearbox on page 180 Tightening torque 24 Nm Refit the oil plug 8 DANGER Make sure all safety requirements are met when performing the fir...

Page 133: ...it on page 829 Standard toolkit Required consumables Note Article number Consumable Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6700 133 3HAC044266 001 Revision N Copyright 2013 2...

Page 134: ...supply air pressure supply to the robot before entering the robot working area 2 Make sure that the oil temperature is 25 C 10 C 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 4 xx1600002049 Open the oil plug 5 Continues on next page 134 Produ...

Page 135: ...l plug hole Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 8 Further information about how to drain or fill with oil is found in section Changing oil axis 6 gearbox on page 184 Tightening torque 24 Nm Refit the oil plug 9 DANGER Make sure all safety requirements are met when performing the first test run These are furthe...

Page 136: ... device is located at the top rear of the frame as shown in the figure The figure also shows the inspection points further described in the instructions xx1300000413 Piston rod inside balancing device A Link ear B Rear attachments of the balancing device rear bearing C Required tools Visual inspection no tools are required Continues on next page 136 Product manual IRB 6700 3HAC044266 001 Revision ...

Page 137: ...aused by the springs inside the cylinder 2 How to replace the device is detailed in section Repla cing the balancing device on page461 This section also specifies the spare part number If dissonance is detected perform maintenance accord ing to given instructions in Maintenance kit complete Check for dissonance from the piston rod squeaking may indicate worn plain bearings internal contamin ation ...

Page 138: ...e robot air pressure supply to the robot Before entering the robot working area 3 Check the area around the o ring and radial sealings at the front ear for leakage 4 The o ring and radial sealings are in cluded in the Maintenance kit bear ings and seals already assembled with sealing spacers and sealing rings Article number for the kit is specified in Required material on page 137 Replace o ring a...

Page 139: ...he robot working area 1 xx1300000423 Check that there are no obstacles inside the frame that could prevent the balancing device from moving freely Keep the areas around the balancing device clean and free from objects such as service tools 2 Product manual IRB 6700 139 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the balancing device Continue...

Page 140: ... 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 robot working area 1 Continues on next page 140 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the cable harness ...

Page 141: ...r cables visually for any damage 4 Check the connectors at the base visually for any damage 5 xx1300001094 Check the cabling going through the protec tion tube to detect possible cable chafing by using your hands inside the tube to feel the cables Ensure that the cables are un damaged Remove any objects that may cause pos sible cable chafing Replace damaged cabling if any 6 See Removing the cable ...

Page 142: ... to be inspected The symbols are described in section Safety symbols on product labels on page 40 Illustration 1 H J N N E F F F E E E E B K M Continues on next page 142 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels ...

Page 143: ...0 55 6 5 4x IRB 6700 m 1160 1600 kg 2557 3527 lbs 3HAC 046732 001 00 4x 2000kg 2 5 m 1x 2000 kg 2 m 2 5 m 1x 2000 kg 2 m 45 20 70 890 50 570 55 6 5 xx1300001084 Instruction label Lifting of robot C Continues on next page Product manual IRB 6700 143 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels Continued ...

Page 144: ...526 1 04 xx1300001086 Warning label Do not dismantle Stored energy H 3HAC 4431 1 06 xx1300001087 Warning label Heat J 29454489 16 xx1700000984 3HAC 9191 1 02 xx1300001088 Warning label Tip risk when loosening bolts K Continues on next page 144 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels Continu...

Page 145: ...p See user documentation 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 entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare parts on pag...

Page 146: ...ing mechanical stop pin Use this procedure to inspect the axis 1 mechanical stop pin Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 146 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the axis...

Page 147: ... damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop Product manual IRB 6700 147 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the axis 1 mechanical stop pin Continued ...

Page 148: ...t Note Article number Equipment etc IRB6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 3HAC055744 001 Movable mechanical stop axis 1 Limits the robot working range by 15 Includes attachment screws and an as sembly drawing Mechanical stop Attachment screws M12x70 quality 12 9 Gleitmo 603 and washers Document for mechanical stop Continues on next page 148 Product manual IRB 6700 3HAC04426...

Page 149: ...power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Shown in figure Location of mechanical stops on page 148 Make sure no additional stops are damaged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 60 Nm Article number is specified in Required equipment on page148 If any damage ...

Page 150: ...s fitted to the robot as shown in the figure A B Fork lift pocket 4 pcs A Hex socket head cap screw M20x60 quality steel 8 8 A3F 2 pcs per fork lift device B Required equipment Note Article number Equipment 3HAC047054 003 Fork lift accessory set Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page 150 Product manual IRB 6700 3HAC044266 001 Revision N C...

Page 151: ...ther type of damage 3 Make sure fork lift device set is properly attached 4 Correct tightening torque fork lift devices 280 Nm Article number is specified in Required equipment on page148 If any damage is detected the fork lift device and attachment screws must be replaced Correct attachment screws M20x60 quality steel 8 8 A3F 2 pcs per addi tional mechanical stop 5 Product manual IRB 6700 151 3HA...

Page 152: ...rs The procedure below details how to inspect the dampers Note A damaged damper must be replaced Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Continues on next page 152 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 ...

Page 153: ...deformation 3 Spare part number is found in Product manual spare parts IRB 6700 IRB 6700Inv If any damage is detected the damper must be replaced with a new one Attachment screws M6x60 4 Locking liquid Loctite 243 Product manual IRB 6700 153 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 14 Inspecting the dampers Continued ...

Page 154: ...e 837 Signal lamp kit Content is defined in section Stand ard toolkit on page 829 Standard toolkit Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Inspect that signal lamp is lit when motors are put in operation MOTORS ON 1 Continues on next page 154 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Main...

Page 155: ...54 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting cable connections measuring the voltage in the connectors of motor axis 3 24V inspecting the cabling Replace the cabling if a fault is detected 3 Product manual IRB 6700 155 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 3 15 Inspecting the si...

Page 156: ...arboxes available for registered users on myABB Business Portal www mypo rtal abb com Before starting any inspection maintenance or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the la...

Page 157: ...x axis 6 F Equipment Note Equipment Includes pump with outlet pipe Oil dispenser Use the suggested dispenser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring Product manual IRB 6700 157 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 158: ...for ventilation on manipulator types IRB 6700 300 2 70 IRB 6700 245 3 00 Tightening torque 24 Nm Tightening torque 24 Nm Consumables Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page156 Required tools and equipment Note Article number Equipment etc The capacity of the vessel must ...

Page 159: ...re supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 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 p...

Page 160: ...er Note There will be some oil left in the gear after draining 6 WARNING Used oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page813 for more in formation 7 Remove the oil dispenser 8 Refit the protective cap on the nipple Tightening torque 24 Nm Refit the vent hole plug 9 Continues on next page 160 Product manual IRB 6700 3HAC044266 001 Revision N C...

Page 161: ...ox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 2 xx1200000948 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 3 Continues on next page Product manual IRB 6700 161 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights re...

Page 162: ...ed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil with the oil dis penser Note The amount of oil to be filled depends on the amount previously being drained 5 Continues on next page 162 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox Continued ...

Page 163: ... 155 2 85 xx1200000950 Required oil level 58 mm 5 mm below the sealing surface of the oil plug xx1300000692 IRB 6700 300 2 70 IRB 6700 245 3 00 xx1500001655 Continues on next page Product manual IRB 6700 163 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox Continued ...

Page 164: ...g oil always wipe the robot clean from all surplus oil The robot color can otherwise be discolored 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 10 164 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 2...

Page 165: ... etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 156 Oil dispenser Content is defined in section Standard toolkit on page 829 Standard toolkit Required consumable Note Material Information about the oil is found in Technical refer ence manual Lubr...

Page 166: ...ral safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 2 CAUTION The gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 3 xx1200000951 Remove the protective cap from the nipple of the oil hole and connect the oil dis...

Page 167: ...e in formation 7 Vent hole plug tightening torque 24 Nm Refill oil or 1 Remove the oil dispenser 2 Refit the protective cap on the nipple 3 Refit the vent hole plug 8 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 robot working ...

Page 168: ...nser 3 xx1200000952 Remove the plug from the vent hole Note The vent hole is opened to let air out during the filling process 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 5 Continues on next page 168 Product manual IRB 6700 3HAC044266 0...

Page 169: ...ispenser 7 Refit the protective cap on the nipple Tightening torque 24 Nm Refit the level plug 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 9 Product manual IRB 6700 169 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 3 Chan...

Page 170: ...nipple Used for both draining and filling with an oil dispenser Tightening torque 24 Nm Tightening torque 24 Nm Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 156 Oil dispenser Content is...

Page 171: ...lectric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 3 CAUTION The gearbox can contain an excess pres sure that can be hazardous O...

Page 172: ...lug from the vent hole WARNING Open the vent hole while using the dis penser to avoid damaging vital parts in the gear 6 xx1500001645 IRB 6700 300 2 70 IRB 6700 245 3 00 Suck out the oil with the oil dispenser Note There will be some oil left in the gear after draining 7 Continues on next page 172 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maint...

Page 173: ...ff all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 3 xx1200000954 Remove the protective cap from the nipple of the oil h...

Page 174: ... 5 xx1500001645 IRB 6700 300 2 70 IRB 6700 245 3 00 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 6 Continues on next page 174 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 ...

Page 175: ...und in Inspecting the oil level in axis 3 gearbox on page 127 Remove the oil dispenser 8 Refit the protective cap on the nipple Tightening torque 24 Nm Refit the level plug 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 10 Product manual IRB 6700 175 3HAC044266 001 ...

Page 176: ...age 156 Oil dispenser Content is defined in section Standard toolkit on page 829 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page156 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearbox...

Page 177: ...box can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 4 Place the oil collecting vessel underneath the oil drain plug 5 xx1200000956 Remove the oil plug from the drain hole and let the oil run into the vessel 6 xx1200000957 Remove the oil plug from the fill level hole Note The level hole is opened to speed up the drainage 7 Co...

Page 178: ...ng the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 3 xx1200000957 Open the fill level plug 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note...

Page 179: ...n page 129 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 8 Product manual IRB 6700 179 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 5 Changing oil axis 4 gearbox Continued ...

Page 180: ...age 156 Oil dispenser Content is defined in section Standard toolkit on page 829 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page156 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearbox...

Page 181: ... plug carefully in order to let the excess pressure out 4 xx1200000958 Remove the oil plug from the drain hole and let the oil run into the vessel 5 Place the oil collecting vessel underneath the oil drain plug 6 xx1200000959 Remove the oil plug from the fill level hole Note The fill hole is opened to speed up the drainage 7 WARNING Used oil is hazardous material and must be disposed of in a safe ...

Page 182: ...everal safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 3 xx1200000959 Open the fill level plug 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously be...

Page 183: ... 5 gearbox on page 131 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 8 Product manual IRB 6700 183 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 6 Changing oil axis 5 gearbox Conti...

Page 184: ...56 Oil dispenser Content is defined in section Standard toolkit on page 829 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page156 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearboxes Dr...

Page 185: ...earbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 4 Place the oil collecting vessel underneath the oil drain plug 5 xx1200000962 Remove the oil plug from the drain hole and let the oil run into the vessel 6 xx1200000963 Remove the oil plug from the fill hole Note The fill hole is opened to speed up the drainage 7 Contin...

Page 186: ...tering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lub ricants oil or grease on page 36 3 xx1200000963 Open the fill plug 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note T...

Page 187: ...the oil plug IRB 6700 300 2 70 IRB 6700 245 3 00 45 mm 5 mm below the sealing surface of the oil plug xx1300000693 More information is found in Inspecting the oil level in axis 6 gearbox on page 134 Method 2 Rotate axis 5 77 Required oil level is 0 10 mm below the oil plug hole Tightening torque 24 Nm Refit the oil plug 7 Continues on next page Product manual IRB 6700 187 3HAC044266 001 Revision N...

Page 188: ...ing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 8 188 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axis 6 gearbox Continued ...

Page 189: ...tions for batteries Safety risks during handling of batteries on page35 Location of SMB battery The SMB battery SMB serial measurement board is located on the frame as shown in the figure below xx1200001069 Required tools Note Article number Equipment Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page Product manual IRB 6700 189 3HAC044266 001 Revisi...

Page 190: ... working area 2 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the sec tion The unit is sensitive to ESD on page 31 3 xx1200001069 Remove the SMB battery cover by unscrewing the attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardou...

Page 191: ... on page 31 2 xx1200001069 Connect the battery cable and install the battery pack into the SMB battery recess 3 Secure the SMB battery cover with its attachment screws 4 See Updating revolution counters on page 794 Update the revolution counters 5 DANGER Make sure all safety requirements are met when performing the first test run These are further described in the section First test run may cause ...

Page 192: ...2F 2 pcs A End cover B Radial sealing with dust lip 50x68x8 2 pcs C O ring 85x3 D Spherical roller bearing E Washer F Consumables Note Article number Equipment etc Tribol GR 100 0 PD 50 ml 3HAA1001 294 Grease Used for lubrication of the spherical roller bearing Continues on next page 192 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 5...

Page 193: ...t edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 204 2 Grease 3HAA1001 294 xx1300000783 Unscrew both screws in link ear and fill the bearing with grease from the upper hole until the grease appears in the lower hole 3 Refit the two screws and wipe clean from residual grease 4 Product manual IRB 6700 193 3HAC044266 001 Revision N Copyright 201...

Page 194: ... activities on page 116 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot Always check that all ...

Page 195: ...r cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus Wash or Foundry Prim...

Page 196: ...ooling fans Inspect the air supply inlet of the the motor cooling fans Clean to remove any contamination that could hinder the air supply 196 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 3 Maintenance 3 6 1 Cleaning the IRB 6700 Continued ...

Page 197: ...perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 821 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sur...

Page 198: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 199: ...o any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the...

Page 200: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 200 Product manual IRB 6...

Page 201: ... correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page201 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreign...

Page 202: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 203: ... the tool parts are needed in each procedure The procedure specifies which tool part to be used The complete tool set 3HAC028920 001 as follows A xx1700000383 Part A hydraulic cylinder is ordered separately 3HAC11731 1 Hydraulic pump is ordered separately 3HAC13086 1 Product manual IRB 6700 203 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 2 4 Dismantle and mount...

Page 204: ...52 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 204 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights re...

Page 205: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 206: ...ccessories to variants IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 How to attach lifting accessories to variants IRB 6700 300 2 70 245 3 00 see section 4 3 2 Attaching lifting accessories to complete arm system Definition of the complete arm system The complete arm system consists of the following parts of the robot upper arm wrist lower arm frame Continues on next page 206 Prod...

Page 207: ... 2 000 kg Roundsling 1 5 m Length 1 m lifting capacity 1 000 kg Roundsling 1 m Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page Product manual IRB 6700 207 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories t...

Page 208: ...ntering the robot working area 2 Attaching lifting accessories to the arm system Use this procedure to attach the lifting accessories Valid for variants IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION The comple...

Page 209: ...e roundsling to the shackle on the wrist 6 Jog axis 3 slowly until the roundsling is stretched approximately 58 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 Product manual IRB 6700 209 3HAC044266 001 Revision N Copyright 2013 20...

Page 210: ...5556 1 Attach the Lifting accessory chain to an over head crane or similar and then to the lifting eye in the arm house and to a roundsling run through the wrist 9 Roundsling 1 m Length 1 m lift ing capacity 1 000 kg xx1200001236 210 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to complete arm system IRB ...

Page 211: ...How to attach lifting accessories to variants IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 see section 4 3 1 Attaching lifting accessories to complete arm system Definition of the complete arm system The complete arm system consists of the following parts of the robot upper arm wrist lower arm frame including the balancing device Continues on next page Product manual IRB 6700 211...

Page 212: ...Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer SA 10 8 NA1 Lifting shackle Continues on next page 212 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting accessories to complete arm system IRB 6700 300 2 70 245 3 00 Continued ...

Page 213: ... Axis 5 90 Axis 6 calibration position 0 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Attaching the lifting accessories to the arm system Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION The complete arm system weighs 130...

Page 214: ...er washer underneath 4 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Continues on next page 214 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting accessories to complete arm system IRB 6700 300 2 70 245 3 00 Continued ...

Page 215: ...ill prevent the roundsling from gliding A B C D A Upper arm B Shackle C Roundsling D Hole in frame 1 Lifting shackle SA 10 8 NA1 Connect the roundsling with a shackle 2 Use caution and jog axis 3 slowly to stretch the roundsling Note Make sure the roundsling is stretched so it can carry the weight of the frame 3 Continues on next page Product manual IRB 6700 215 3HAC044266 001 Revision N Copyright...

Page 216: ...rane or similar and then to the lifting eye in the arm house and to the lifting eye in the wrist 4 216 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting accessories to complete arm system IRB 6700 300 2 70 245 3 00 Continued ...

Page 217: ...to attach lifting accessories to variants IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 How to attach lifting accessories to variants IRB 6700 300 2 70 245 3 00 see section 4 3 4 Attaching lifting accessories to an unseparated lower and upper arm Attachment points of lifting accessory xx1200001254 Continues on next page Product manual IRB 6700 217 3HAC044266 001 Revision N Copyrig...

Page 218: ...his procedure to jog the robot into position Valid for variants IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Note Action Note When jogging the axis 2 into position check that the balancing device ear and the ear on the lower arm is not colliding 1 xx1200001250 Jog the robot into position Axis 1 no significance as long as the robot is s...

Page 219: ... 85 Note Action CAUTION The lower and upper arms together weigh accord ing to variants 510 kg All lifting accessories used must be sized accord ingly 1 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist 2 Lifting shackle SA 10 8 NA1 xx1200001234 Fit a lifting shackle in the wrist lifting eye 3 Continues on next page Product manual IRB 6700 219 3HAC044266 001 Revision N Copyright 2...

Page 220: ... of the lower arm so that the roundsling runs on the left side of the most lower of the four bosses This will prevent the roundsling from gliding 6 Attach the roundsling to the shackle on the wrist 7 Stretch the roundsling between the wrist and the lower arm by slowly jogging the axis 3 Note Make sure the roundsling is stretched in order to carry the weight of the lower arm 8 DANGER Turn off all e...

Page 221: ...be attached to the shackle on the arm house 12 Lifting accessory chain 3HAC15556 1 Attach the Lifting accessory chain to an over head crane or similar then to the lifting eye in the arm house and to a roundsling run through the wrist 13 Roundsling 1 m Length 1 m lift ing capacity 1 000 kg xx1200001254 Raise the overhead crane to stretch the chains and roundslings 14 Verify that the roundsling betw...

Page 222: ...r R2 MP2 axis 2 motor pin 2 pin 5 222 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 3 Attaching lifting accessories to an un separated lower and upper arm IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 Continued ...

Page 223: ...accessories to variants IRB 6700 300 2 70 245 3 00 How to attach lifting accessories to variants IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 see section 4 3 3 Attaching lifting accessories to an unseparated lower and upper arm Attachment points of lifting accessory xx1400002104 Continues on next page Product manual IRB 6700 223 3HAC044266 001 Revision N Copyright 2013 2018 ABB A...

Page 224: ...ching lifting accessories to the lower and upper arm Robot position Note Action Note When jogging the axis 2 into position check that the balancing device ear and the ear on the lower arm is not colliding 1 xx1200001250 Jog the robot into position Axis 1 position the axis 1 to be able to put down the arm system after removal Axis 2 60 Axis 3 70 approximately Axis 4 90 Axis 5 0 90 if DressPack is i...

Page 225: ...ly 1 Lifting eye 3HAC16131 1 xx1400002106 Fit a lifting eye to the wrist 2 xx1200001251 In order to secure the roundsling from gliding when lifting With no DressPack cable package installed Insert a M12x50 securing screw not more than 10 15 mm into the screw hole shown in the figure With DressPack cable package installed Use the ball joint housing in the same way 3 Continues on next page Product m...

Page 226: ... Connect both ends of the roundsling with a shackle 6 Stretch the roundsling between the upper 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 7 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 8 Continues on next page 22...

Page 227: ... to the lifting eye in the arm house and to the lifting eye in the wrist 10 Raise the overhead crane to stretch the chains and roundslings 11 Verify that the roundsling between the wrist and the lower arm is stretched To release the brake connect the 24 VDC power supply 12 Connect to connector R2 MP2 axis 2 motor pin 2 pin 5 Product manual IRB 6700 227 3HAC044266 001 Revision N Copyright 2013 2018...

Page 228: ...diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page 228 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 3 5 Attaching lifting access...

Page 229: ...pper arm Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 360 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 465 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 1 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist 2 Continues on next page Product manual IRB 6700 229 3HAC044266 001 Revision N Co...

Page 230: ...rm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm house and in the wrist 4 Raise the lifting accessories to take the weight of the upper arm 5 xx1400002197 In case of necessary adjustments use the shortening loops on the lifting accessory chain to find the level position 6 230 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB ...

Page 231: ...the figure xx1300001096 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page Product manual IRB 6700 231 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness ...

Page 232: ... harness in the carrier being un wound or placed in the wrong position Depending on what tool is used the other axes may need to be jogged to another position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx1400000208 Note If only the manipulator harness shall be removed the DressPack cable package ca...

Page 233: ...raulic pressure and air pressure are turned off 1 xx1400000355 If DressPack is installed Remove the bracket with the com plete ball joint housing still fitted as shown in the figure This is done to be able to reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 Continues on next page Prod...

Page 234: ... at tached to the plate 5 Choose figure depending on which plate is installed on the robot xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate xx1300000490 Continues on next page 234 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 235: ...only for replacing the motor the cabling does not need to be loosened from the plate 6 xx1300000489 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 6700 235 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Remov...

Page 236: ...x1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page 236 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 237: ...r cables by holding the cables with one hand at the motor and the other at the carrier 7 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700 237 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cab...

Page 238: ...the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 238 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 239: ...le is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Disconnecting the axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Cont...

Page 240: ...amaged Tip Make a note in which direction the cable gland hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page 240 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 241: ...g or not to loose the inserts fitted on the cover 1 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 2 xx1700000690 If used loosen the insert 3 Continues on next page Product manual IRB 6700 241 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 242: ...e This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 5 xx1300000557 Remove the side cover on the arm tube 6 Continues on next page 242 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 243: ...e arm tube Note The screw is reached from outside the up per arm 7 xx1700000339 xx1300000543 Remove the arm house metal clamp 8 Continues on next page Product manual IRB 6700 243 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 244: ...acket is replaced by the cable guide xx1300001973 Cable guide 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page 244 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 245: ...ormed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12 Person 2 working at the back xx1400002561 Note To be able to remove the cable harness with the DressPack tube fitted the tube needs to be pulled out a little th...

Page 246: ...e sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1300000561 Remove the base cover 2 xx1300000591 Disconnect connectors R1 MP R1 SMB 3 xx1400000366 If used disconnect the DressPack hoses in the base 4 Continues on next page 246 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the...

Page 247: ...facilitate removal of the DressPack hoses 6 xx1400000088 If used use caution and pull out the DressPack hoses through the protection tube in the base Note There is no need to pull out the DressPack cables at this point 7 Continues on next page Product manual IRB 6700 247 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 248: ...achment screws three M10x30 and two of the M5x12 screws 2 xx1400000724 Foundry Plus Remove the two protection plates 3 Disconnecting the axis 1 and axis 2 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 248 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights...

Page 249: ...the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 6700 249 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 250: ...turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 31 2 xx1300000829 Open the small cover on the SMB cover disconnect the battery cable and remove the battery 3 xx1300000669 Remove the SMB cover CAUTION Clean cover from metal residues before opening Metal residues can ...

Page 251: ...regard to the brake release board 3 xx1300000670 Remove the connectors X8 X9 and X10 from the brake release board 4 Removing the cable harness in the base Note Action If equipped with DressPack pull out the DressPack cables through the protection tube and place them carefully over the balancing device 1 xx1300000732 Pull out the robot cable harness through the protection tube 2 Place the cable har...

Page 252: ...the metal clamp frame 1 xx1200001237 Cut the cable tie inside the frame recess 2 xx1300001114 Disconnect connectors on the SMB unit 3 Continues on next page 252 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 253: ...crew the attachment screws that hold the SMB BU cover from inside the SMB recess 5 xx1300000560 Use caution and pull out the cable harness from the SMB recess Note The parts are sealed with Sikaflex Remove the part carefully 6 Continues on next page Product manual IRB 6700 253 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 254: ...er arm Note Action xx1300000540 Loosen the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp loc ated on the inside of the lower arm by re moving the attachment screws Note The screws are reached from the outside of the lower arm 1 xx1300000733 Use caution and pull the cable harness out 2 254 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reser...

Page 255: ...er insert Replace if damaged 3HAC055411 001 Cable protection PU rubber Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 829 Standard toolkit Consumables Note Article number Consumable Used to lubricate o rings 3HAB3537 1 Grease D 84 5x3 21522012 429 O ring Used on the SMB BU cover Continues on next page Product manual IRB 6700 25...

Page 256: ...hexagon If only ordering the o ring order the same profile that is currently installed in the connection box Robot position If the robot axes have been re positioned after the cable harness has been removed make sure to restore the initial robot position before refitting the cable harness See Preparations before removing the cable harness on page 232 Refitting the cable harness base frame and lowe...

Page 257: ...e cable harness through the lower arm 3 xx1300000734 Secure the axis 2 lower arm cable bracket Note Do not secure the axis 3 lower arm cable bracket at this point Note Screws are reached from the outside of the lower arm 4 xx1300000735 Run the cable harness into the hole in the frame in this order R1 MP R1 SMB R2 MP2 R2 MP1 5 Continues on next page Product manual IRB 6700 257 3HAC044266 001 Revisi...

Page 258: ...t be in line with its position on the base plate Make sure that the R1 SMB cable will run on the correct side of the R1 MP1 see the figure 2 Make sure that the markings on the cables are facing the base cover when connected 3 Tightening torque for R1 SMB 10 Nm xx1300000591 Connect connectors R1 MP and R1 SMB 4 Continues on next page 258 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2...

Page 259: ...otection tube in the base 7 Make sure that the hoses are running cor rectly and are not twisted xx1400000078 If used fit the bracket that hold the DressPack to the frame 8 xx1200000052 If used connect the DressPack cable package on the base plate 9 Continues on next page Product manual IRB 6700 259 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the c...

Page 260: ...e figure shows the position of the o ring Wipe clean the contact surfaces of the cover as well as the hole it shall fit in 2 Apply Sikaflex on the o ring before as sembly 3 xx1300000560 Run the SMB BU cables into the SMB re cess 4 Continues on next page 260 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Conti...

Page 261: ... running through the hole in the frame by carefully moving the SMB BU cover on its screws while at the same time checking the position of the cable harness through the hole Note The cables must be placed so that they don t rub against any part of the robot 6 Screws 3 pcs xx1300000655 Secure the SMB BU cover with its attach ment screws from inside the SMB BU re cess 7 Continues on next page Product...

Page 262: ...ll supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 31 2 Continues on next page 262 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refi...

Page 263: ...to position and fit the bracket that secures the SMB unit 5 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 Continues on next page Product manual IRB 6700 263 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reser...

Page 264: ...is option refit the connector R2 FB7 to the SMB cover and tighten with 6 Nm 8 Reconnecting the axis 1 and axis 2 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page 264 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 265: ...le Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 3 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Continues on next page Product manual IRB 6700 265 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights...

Page 266: ...ads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Refitting the cable harness lower arm Note Action xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also ...

Page 267: ...the lower arm 3 xx1300000595 Before fitting the remaining axis 3 lower arm cable bracket inside the lower arm check that it will stay twisted a little between the metal clamps after fitting as shown in the figure Do not change the po sition of the brackets 4 Continues on next page Product manual IRB 6700 267 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refit...

Page 268: ...w to refit the cable harness in upper arm and wrist Refitting the cable harness upper arm Note Action xx1300000541 Refit the metal clamp on top of the arm house 1 xx1300000543 Refit the arm house metal clamp 2 Arrange the cables between the cable clamps in the upper arm 3 Continues on next page 268 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repa...

Page 269: ...A B C D xx1400000382 A Gasket B Cable guide C Washer D Cover Foundry Plus Make sure that the gasket underneath the cover is correctly fitted Replace if dam aged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 5 Continues on next page Product manual IRB 6700 269 3HAC044266 00...

Page 270: ...back of the robot Together Use caution and move the cable harness into the arm tube 6 Person 2 working at the back xx1400000356 Note The cable harness is best placed at the upper right hand side of the DressPack tube if used through the arm tube Do not run the cable harness into the DressPack tube Note Do not run the cable harness into the DressPack tube if one is fitted xx1300000820 Continues on ...

Page 271: ...ke a hold of the cable harness from inside the wrist Together Move the cable harness past the axis 5 motor and into the wrist 7 Person 2 working at the wrist xx1300000746 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 8 xx1700000339 Continues on next page Product manual IRB 6700 271 3HAC044266 001 Revision N Copyright 2013 2018 ...

Page 272: ... side cover 9 xx1700000690 If used refit the insert that guides the DressPack cable package through the hole in the upper arm 10 xx1400000092 If used refit the tube containing the DressPack into the insert 11 Continues on next page 272 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 273: ...000045 DressPack or Foundry Plus Refit the cover with the tube guiding ring fitted Note Foundry Plus Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 13 Continues on next page Product manual IRB 6700 273 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 274: ...01973 14 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 274 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 275: ...cular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product man...

Page 276: ...ecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001016 Refit the cable gland cover by performing the following steps Slide the cable gland cover onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 Continues on next page 27...

Page 277: ...hexagon pro file xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page Product manual IRB 6700 277 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 278: ...are two versions of the heat protec tion plates Secure the cable harness with cable straps to the heat protection plate Note If replacing a type A motor with a type B motor the heat protection plate must be replaced with plates suited for the type B motor See Type A vs type B motors on page 819 7 Choose figure depending on which plate is installed on the robot xx1500001029 xx1300000489 Continues o...

Page 279: ...he robot Fit the heat protection plate with the screws 8 Screws M5x12 xx1500001030 xx1300000490 Continues on next page Product manual IRB 6700 279 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 280: ...be in position 90 or as close as possible for a correct installation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 Continues on next page 280 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights rese...

Page 281: ...e attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page Product manual IRB 6700 281 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 282: ...01095 Make sure the gasket is undamaged Replace if damaged 8 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page 282 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 283: ... cover axis 5 gearbox B Washers 10 pcs in gasket holes Inspect the gasket Replace if damaged Foundry Plus and Foundry Prime Make sure that the gasket is undam aged on the cover Replace if dam aged Put washers in the holes of the gas ket Use attachment screws made of stainless steel to fit the wrist cover 2 Continues on next page Product manual IRB 6700 283 3HAC044266 001 Revision N Copyright 2013 ...

Page 284: ...sPack cable package on the wrist 5 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 6 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performi...

Page 285: ...nv SMB unit DSQC633C Product manual spare parts IRB 6790 See Product manual spare parts IRB 6700 IRB 6700Inv Battery pack Product manual spare parts IRB 6790 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page Product manual IRB 6700 285 3HAC044266 001 Revision N Copyright 2013 2018 ABB Al...

Page 286: ...e and remove the battery 3 xx1300000669 Remove the SMB cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Disconnecting and removing the SMB unit Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The u...

Page 287: ...upper lip of the R2 G connector to release the lock while pulling the connector upwards 4 xx1700000993 xx1300000731 Pull out the SMB unit and put it in an ESD bag 5 Refitting the SMB unit Refitting the SMB unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700 287 3HAC044266 001 Re...

Page 288: ...he SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB 4 xx1300000730 Push in the SMB unit carefully into position and fit the bracket that secures the SMB unit 5 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 Continues on next page 28...

Page 289: ...the SMB battery Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 31 1 Reconnect the battery cable 2 xx1300000829 Place the battery in the recess 3 Refit the battery cover 4 Continues on next page Product manual IRB 6700 289 3HAC044266 001 Revision N Copyright 2013 201...

Page 290: ...1 DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 26 2 290 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the SMB Continued ...

Page 291: ...Brake release unit Product manual spare parts IRB 6790 See Product manual spare parts IRB 6700 IRB 6700Inv Battery pack Product manual spare parts IRB 6790 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page Product manual IRB 6700 291 3HAC044266 001 Revision N Copyright 2013 2018 ABB All ...

Page 292: ...on page 31 2 xx1300000743 Remove the push button guard from the SMB cover The push button guard must be removed to ensure a correct refitting of the brake release unit 3 xx1300000742 Remove the SMB cover 4 The battery can stay connected to avoid the need of synchronizing the robot CAUTION If the battery stays connected put or hold the SMB cover in a safe position The battery cable connectors can o...

Page 293: ...w the robot cabling is positioned in regard to the brake release board 3 xx1300000670 Remove the connectors X8 X9 and X10 from the brake release board 4 Removing the brake release unit Note Action xx1300000744 Unscrew the attachment screws that secure the brake release unit bracket 1 Remove the bracket with the brake release unit fitted 2 Remove the brake release unit from the bracket 3 Continues ...

Page 294: ...xx1700000978 Reconnect the connectors X8 X9 and X10 to the brake release unit Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 4 Verify that the robot cabling is positioned correctly according to previously taken picture notes WARNING Screened cables must not get in contact with the brake release board after installation Eliminate ...

Page 295: ...ot stay in any locked position 9 Reconnect the battery if it has been disconnected 10 See Updating revolution counters on page 794 Update the revolution counters if the battery has been disconnected 11 DANGER Make sure all safety requirements are met when performing the first test run These are further de scribed in First test run may cause injury or damage on page 26 12 Product manual IRB 6700 29...

Page 296: ... Spare part Note Spare part number Spare part See Product manual spare parts IRB 6700 IRB 6700Inv Upper arm Product manual spare parts IRB 6790 Consumables Parts needed to be replaced after removal Note Article number Equipment etc Used to lubricate o rings 3HAB3537 1 Grease Continues on next page 296 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 R...

Page 297: ...C15880 2 en closed 3HAC15556 1 Lifting accessory chain Used for putting down removed parts from robot Pallet Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Always use guide pins in pairs 3HAC13056 4 Guide pin M12x200 Always use guide pins in pairs 3HAC13120 2 Guide pin M16x150 Always use guide pins in pairs 3HAC13120 3 Guide pin M16x200 Used to release the motor brakes 24 VDC power s...

Page 298: ...n Reference calibration routine on page 799 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Re...

Page 299: ...he founda tion Axis 2 60 Axis 3 60 Axis 4 90 Axis 5 90 Axis 6 No significance 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover to retrieve access to the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all...

Page 300: ... reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 xx1300002247 Remove the wrist cover 4 Continues on next page 300 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 301: ...plate 5 Choose figure depending on which plate is installed on the robot xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate xx1300000490 Continues on next page Product manual IRB 6700 301 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 302: ...le package Remove the DressPack cable package from the upper arm if used How to remove the DressPack cable package is described in more detail in the product manual IRB 6700 DressPack For article number see References on page 10 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on...

Page 303: ... the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 6700 303 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 304: ...cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001080 Unscrew the attachment screws and re move the motor cover 2 Continues on ...

Page 305: ...ld the cable bracket 4 xx1300000485 Unscrew the M4 screw that holds the carri er Note The screw is located at the bottom of the carrier 5 Continues on next page Product manual IRB 6700 305 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 306: ...he axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 306 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm C...

Page 307: ... damaged Tip Make a note in which direction the cable gland hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 6700 307 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 308: ...ing or not to loose the inserts fitted on the cover 1 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 2 xx1700000690 If used loosen the insert 3 Continues on next page 308 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 309: ...ne This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 5 xx1300000557 Remove the side cover on the arm tube 6 Continues on next page Product manual IRB 6700 309 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 310: ...the arm tube Note The screw is reached from outside the up per arm 7 xx1700000339 xx1300000543 Remove the arm house metal clamp 8 Continues on next page 310 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 311: ...racket is replaced by the cable guide xx1300001973 Cable guide 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page Product manual IRB 6700 311 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 312: ...rformed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12 Person 2 working at the back xx1400002561 Note To be able to remove the cable harness with the DressPack tube fitted the tube needs to be pulled out a little ...

Page 313: ...ting eye to the wrist 2 Lifting eye 3HAC16131 1 Fit a lifting eye in the arm house with a fender washer underneath xx1400002196 3 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Lifting accessory chain 3HAC15556 1 xx1200001308 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm ...

Page 314: ...hment screws M12 in opposite holes and replace them with guide pins Note Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M12x200 3HAC13056 4 Always use guide pins in pairs xx1300000659 Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1300000747 Leave one of the remaining attachment screws fitted remove the...

Page 315: ... remaining attachment screws fitted remove the other screws 2 Preparations before removing the upper arm IRB 6700 300 2 70 IRB 6700 245 3 00 Note Action Guide pin M16x150 3HAC13120 2 Remove two attachment screws in opposite holes and replace them with guide pins Note Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M16x200 3HAC13120 3 Alway...

Page 316: ...re 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 316 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 317: ...000059 Lift the upper arm and place it on the pre pared area CAUTION Only valid when the upper arm is removed due to replacement of the axis 3 gearbox If the cable harness is still fitted or partly fitted use caution when lifting the upper arm over to the other side of the robot in order not to cause any damage to the cable harness 3 Continues on next page Product manual IRB 6700 317 3HAC044266 00...

Page 318: ...t surfaces 1 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1700001880 Foundry Plus Apply Mercasol on the surface on the lower arm as shown in the figure CAUTION Keep the sealing surfaces clean from Mer casol 2 Guide pin M12x150 3HAC13056 2 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 3 Guide pin M12x200 3HAC13056 4 Fit two guide p...

Page 319: ...e to make the upper arm slide better Always use guide pins in pairs xx1700000056 Securing the upper arm IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 360 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 465 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be si...

Page 320: ...uide pins in the lower arm 3HAC067547 001 ii 3HAC067545 001 iii Screws Insert all nine M16 screws and 25 of the 27 M12 screws 6 M16 9 pcs M12 25 of 27 pcs xx1400000359 xx1300000659 Remove the guide pins and fit the two re maining M12 screws 7 Tightening torque depends on screw dimen sion Secure the upper arm by tightening the at tachment screws 8 Tightening torque M16 300 Nm Tightening torque M12 ...

Page 321: ...nstalled to the upper arm 4 Rotation tool In order to release the brakes connect the 24 VDC power supply Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm Pinion If the axis 3 motor is not installed to the upper arm 5 3HAC067546 001 i Use the pinion to rotate the axis 3 gearbox to find the corr...

Page 322: ... lifting accessories to the upper arm on page 228 Attach the lifting accessories if not already fitted 2 Lift the upper arm and bring it towards the lower arm 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool Connect the 24 VDC power supply to re lease the brakes Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find ...

Page 323: ...700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 ii IRB 6700 200 2 60 IRB 6700 155 2 85 iii IRB 6700 300 2 70 IRB 6700 245 3 00 Refitting the cable harness upper arm Note Action xx1300000541 Refit the metal clamp on top of the arm house 1 Continues on next page Product manual IRB 6700 323 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replaci...

Page 324: ... run the cable harness through the inside of the robot 4 A B C D xx1400000382 A Gasket B Cable guide C Washer D Cover Foundry Plus Make sure that the gasket underneath the cover is correctly fitted Replace if dam aged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 5 Continu...

Page 325: ...e back of the robot Together Use caution and move the cable harness into the arm tube 6 Person 2 working at the back xx1400000356 Note The cable harness is best placed at the upper right hand side of the DressPack tube if used through the arm tube Do not run the cable harness into the DressPack tube Note Do not run the cable harness into the DressPack tube if one is fitted xx1300000820 Continues o...

Page 326: ...Take a hold of the cable harness from inside the wrist Together Move the cable harness past the axis 5 motor and into the wrist 7 Person 2 working at the wrist xx1300000746 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 8 xx1700000339 Continues on next page 326 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 201...

Page 327: ...he side cover 9 xx1700000690 If used refit the insert that guides the DressPack cable package through the hole in the upper arm 10 xx1400000092 If used refit the tube containing the DressPack into the insert 11 Continues on next page Product manual IRB 6700 327 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 328: ...00000045 DressPack or Foundry Plus Refit the cover with the tube guiding ring fitted Note Foundry Plus Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 13 Continues on next page 328 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 329: ...able package How to refit the DressPack cable package is described in more detail in the product manual IRB 6700 DressPack For article number see References on page 10 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page Product manual IRB 6700 329 3HAC044266 001 Revision N Copyright 2013 2018 ABB All ...

Page 330: ...file Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 3 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Continues on next page 330 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All righ...

Page 331: ...t screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Connecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual ...

Page 332: ...e connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 332 Product manual IRB 6700 3HAC044266 001 Revisi...

Page 333: ...e are two versions of the heat protec tion plates Secure the cable harness with cable straps to the heat protection plate Note If replacing a type A motor with a type B motor the heat protection plate must be replaced with plates suited for the type B motor See Type A vs type B motors on page 819 7 Choose figure depending on which plate is installed on the robot xx1500001029 xx1300000489 Continues...

Page 334: ... the robot Fit the heat protection plate with the screws 8 Screws M5x12 xx1500001030 xx1300000490 Continues on next page 334 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 335: ...t be in position 90 or as close as possible for a correct installation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 Continues on next page Product manual IRB 6700 335 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights re...

Page 336: ...The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page 336 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 337: ...0001095 Make sure the gasket is undamaged Replace if damaged 8 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page Product manual IRB 6700 337 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 338: ...Hold the cover angled See figure 2 Catch any part of the cable harness hanging down 3 Lift the cover still held in an angle 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 2 Remove the lifting accessories 3 Concluding procedure Note Action Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools ...

Page 339: ...en performing the first test run These are further described in First test run may cause injury or damage on page 26 2 Product manual IRB 6700 339 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 340: ...on the axis 5 gearbox It is strictly forbidden to do any repair work on the axis 5 gearbox xx1300002248 Location of the wrist The wrist is located as shown in the figure xx1300000597 Continues on next page 340 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist ...

Page 341: ...ength 1 m lifting capacity 1 000 kg Roundsling 1 m Used for putting down removed parts from robot Pallet Used for protection Cardboard Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Used to release the motor brakes 24 VDC power supply Required if Calibration Pendulum is the valid calibration method for the robot 3HAC15716 1 Calibration Pendulum toolkit Delivered as a set of calibrati...

Page 342: ... 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 799 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Ope...

Page 343: ...r supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 Prepare a pallet with cardboard in front of the robot or where it is possible to be used for putting down the wrist unit on 6 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover to retrieve access to the axis 5 and axis 6 motor cables Note Action DANGER Make ...

Page 344: ...to reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 xx1300002247 Remove the wrist cover 4 Continues on next page 344 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 345: ...e plate 5 Choose figure depending on which plate is installed on the robot xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate xx1300000490 Continues on next page Product manual IRB 6700 345 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 346: ...te only for replacing the motor the cabling does not need to be loosened from the plate 6 xx1300000489 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 346 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Re...

Page 347: ... 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page Product manual IRB 6700 347 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 348: ...otor cables by holding the cables with one hand at the motor and the other at the carrier 7 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 348 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the...

Page 349: ...ve the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 6700 349 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 350: ...RB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 140 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 1 Roundsling 1 m Length 1 m lifting capa city 1 000 kg xx1300000673 Attach a roundsling to the wrist as shown in the figure CAUTION It is very important that the roundsling is placed as shown in the figure to keep the wrist balanced when it is remov...

Page 351: ...ke the wrist slide better 2 Always use guide pins in pairs xx1300000748 xx1300000749 Remove the remaining attachment screws 3 xx1300000750 Pull out the wrist a bit onto the guide pins This is done to be able to remove the cable harness from the wrist in a safe way CAUTION Make sure that the cabling does not get damaged 4 Continues on next page Product manual IRB 6700 351 3HAC044266 001 Revision N ...

Page 352: ...edures describes how to refit the wrist Preparations before refitting the wrist Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Wipe clean all contact surfaces 2 Continues on next page 352 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued...

Page 353: ...nect the 24 VDC power supply release the brakes and move the axis manually into that position 5 Connect to R2 MP5 connector pin 2 pin 5 Attaching the lifting accessories to the wrist Note Action CAUTION The weight of the complete wrist is 125 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 140 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 1 ...

Page 354: ...axis 5 gearbox 2 Note Make sure the roundsling is stretched so it can carry the weight of the wrist 3 Refitting the wrist Note Action xx1300000770 Lift the wrist and insert the guide pins into the holes of the arm tube Tip Leave a small opening between wrist and arm tube This will make it easier to run the cable harness back into the wrist 1 xx1300000769 Run the cabling into the wrist unit Be care...

Page 355: ...ashers 4 xx1300000748 Remove the guide pins and replace them with the remaining attachment screws and washers 5 Tightening torque 120 Nm Tighten the attachment screws 6 Continues on next page Product manual IRB 6700 355 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 356: ...er onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 Continues on next page 356 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacin...

Page 357: ...001013 Refit the motor cover with its attachment screws Note Do not refit the screws that will hold the heat protection plate at this point Note Do not reuse the self threading attachment screws it will damage the threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 Continues on next page Product manual IRB 6700 357 3HAC044266 001 Revision N ...

Page 358: ...motor the heat protection plate must be replaced with plates suited for the type B motor See Type A vs type B motors on page 819 7 Choose figure depending on which plate is installed on the robot xx1500001029 xx1300000489 Continues on next page 358 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 359: ...on the robot Fit the heat protection plate with the screws 8 Screws M5x12 xx1500001030 xx1300000490 Continues on next page Product manual IRB 6700 359 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 360: ...ust be in position 90 or as close as possible for a correct installation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 Continues on next page 360 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights ...

Page 361: ...p The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page Product manual IRB 6700 361 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 362: ...200001095 Make sure the gasket is undamaged Replace if damaged 8 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page 362 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 363: ... A B xx1400000383 A Protection plugs 2 on wrist cover and 2 on cover axis 5 gearbox B Washers 10 pcs in gasket holes Inspect the gasket Replace if damaged Foundry Plus and Foundry Prime Make sure that the gasket is undam aged on the cover Replace if dam aged Put washers in the holes of the gas ket Use attachment screws made of stainless steel to fit the wrist cover 2 Continues on next page Product...

Page 364: ... wrist 5 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 6 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run Thes...

Page 365: ...anual spare parts IRB 6790 Consumables Note Article number Equipment etc Mercasol 3110 Waxcoat Re commended drying time is 24h 3HAC034903 001 Rust preventive Used on Foundry Plus Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 829 Standard toolkit Continues on next page Product manual IRB 6700 365 3HAC044266 001 Revision N Copyr...

Page 366: ...robot working area 2 Remove any equipment fitted to the turning disc 3 Removing the turning disc Note Action xx1300000492 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 Remove the screws and washers that se cure the turning disc 1 xx1300002302 IRB 6700 200 2 60 IRB 6700 155 2 85 Remove the screws and washers that se cure the turning disc 2 Continues on next page 366 Produc...

Page 367: ...e the screws and washers that se cure the turning disc 3 xx1300000493 Remove the turning disc 4 Continues on next page Product manual IRB 6700 367 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 3 Replacing the turning disc Continued ...

Page 368: ...1500000874 xx1500000873 Compatible synchronization mark plate is in stalled Incompatible synchronization mark plate is installed No action required Replace the plate Fitting the axis 6 synchronization mark plate There are different attachment holes on the plate used for different robot variants See table below IRB 6700 300 2 70 IRB 6700 245 3 00 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 0...

Page 369: ...n See Replacing the synchronization mark plate on page 368 If new turning disc spare part is installed verify that the correct synchronization mark plate for axis 6 is installed on the wrist 1 Wipe clean the contact surfaces 2 A B xx1400000385 Foundry Plus Apply Mercasol on the surfaces on turning disc and axis 6 gearbox as shown in the figure 3 Tightening torque 35 Nm IRB 6700 235 2 65 IRB 6700 2...

Page 370: ...s M10x25 Steel 12 9 Gleitmo 603 21 pcs Secure the turning disc with its attachment screws and washers Washers Steel 11x17x25 21 pcs xx1400002195 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 26 1 370 Product manual IRB 6700 3HAC044266 001 Revision ...

Page 371: ... Consumables Note Article number Equipment etc Mercasol used on Foundry Plus Rust preventive Removing the process turning disc Use these procedures to remove the process turning disc Preparations before removing the process turning disc Note Action Run the robot to a position most comfort able for the removal of the process turning disc 1 Continues on next page Product manual IRB 6700 371 3HAC0442...

Page 372: ...turning disc Note Action IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 Remove the 24 M8 screws and washers that secure the process turning disc 1 IRB 6700 200 2 60 155 2 85 Remove the nine M10 screws and three washers that secure the process turning disc 2 Continues on next page 372 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 4 Replacin...

Page 373: ...h standard turning disc but is also valid for the process turning disc The design of the turning disc spare part might require replacement of the axis 6 synchronization mark plate if the existing plate is not compatible with the new turning disc Continues on next page Product manual IRB 6700 373 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 4 Replacing the proc...

Page 374: ...ate is installed No action required Replace the plate Fitting the axis 6 synchronization mark plate There are different attachment holes on the plate used for different robot variants See table below IRB 6700 300 2 70 IRB 6700 245 3 00 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 xx1500000878 xx1500000877 Use the holes at the back end ...

Page 375: ...onization mark plate on page 373 If new turning disc spare part is installed verify that the correct synchronization mark plate for axis 6 is installed on the wrist 1 Wipe clean the contacts surfaces 2 A B Foundry Plus Apply Mercasol on the surfaces on the process turning disc and axis 6 gearbox as shown in the figure 3 The figure show standard turning disc Surfaces to apply Mercasol on are the sa...

Page 376: ...l 12 9 Gleitmo 603 21 pcs Secure the process turning disc with its attachment screws and washers Washers Steel 11x17x25 21 pcs Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 26 1 376 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2...

Page 377: ...ncing device 2 Remove the shaft in the balancing device front link ear 3 Remove the cabling from the upper and lower arm 4 Remove the upper arm 5 Replace the lower arm Spare part Note Spare part number Spare part See Product manual spare parts IRB 6700 IRB 6700Inv Lower arm Product manual spare parts IRB 6790 Continues on next page Product manual IRB 6700 377 3HAC044266 001 Revision N Copyright 20...

Page 378: ...in a locked position after the balancing device springs has been unloaded with the help of the robot itself DANGER Never use this tool to unload or restore a balancing device 3HAC030662 001 Distance tool SA 10 8 NA1 Lifting shackle Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Used for removing and fitting shaft and bearings 3HAC028920 001 Dismantle and mounting too...

Page 379: ...erence calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for ...

Page 380: ...lower arms 3 Position of the robot in the continued process Note Action Jog the robot to Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 0 1 24 VDC power supply xx1200001081 Connect the 24 VDC power supply release the brakes and move the axis 5 manually into 90 Connect to R2 MP5 connector pin 2 pin 5 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to ...

Page 381: ...lancing device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 This is done in order to compress the bal ancing device springs inside the balancing device before fitting the Distance tool Jog axis 2 to 30 or 30 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressur...

Page 382: ...ings making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance tool stay fitted during the continued procedure 8 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 9 Preparations before removing the shaft...

Page 383: ...5 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 185 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 4 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 5 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory chain to the shackle and raise to unload the weight 6 Continues on next page Product manual IRB 6700 383 3HAC04...

Page 384: ...sible to the center of the VK cover and pull it out xx1200001278 Remove the VK cover 1 xx1200001279 M16x70 quality steel 8 8 A3F Unscrew the attachment screw and washer 2 Continues on next page 384 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 385: ...001281 Put down the balancing device and let it rest on the frame 4 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover to retrieve access to the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700 385 3HAC044266 001 Revi...

Page 386: ... reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 xx1300002247 Remove the wrist cover 4 Continues on next page 386 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 387: ...plate 5 Choose figure depending on which plate is installed on the robot xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate xx1300000490 Continues on next page Product manual IRB 6700 387 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 388: ...p If removing the plate only for replacing the motor the cabling does not need to be loosened from the plate 6 xx1300000489 Removing cable brackets Note Action xx1200001184 Unscrew the screws that hold the bracket and let it hang free 1 Continues on next page 388 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Con...

Page 389: ...te and let the DressPack hang free 3 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 6700 389 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 390: ... the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 390 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 391: ...tion and pull out the motor cables 6 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page Product manual IRB 6700 391 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved...

Page 392: ...otor 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page 392 Product manual IRB 6700 3HAC044266 001 Revision N Copyrig...

Page 393: ... xx1200001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page Product manual IRB 6700 393 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 394: ...13 Pull out the carrier from its position 6 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 7 Continues on next page 394 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 395: ...ing or not to loose the inserts fitted on the cover 1 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 2 xx1700000690 If used loosen the insert 3 Continues on next page Product manual IRB 6700 395 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 396: ...ne This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 5 xx1300000557 Remove the side cover on the arm tube 6 Continues on next page 396 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 397: ...the arm tube Note The screw is reached from outside the up per arm 7 xx1700000339 xx1300000543 Remove the arm house metal clamp 8 Continues on next page Product manual IRB 6700 397 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 398: ...racket is replaced by the cable guide xx1300001973 Cable guide 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page 398 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 399: ...rformed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12 Person 2 working at the back xx1400002561 Note To be able to remove the cable harness with the DressPack tube fitted the tube needs to be pulled out a little ...

Page 400: ...it a lifting eye to the wrist 2 Lifting eye 3HAC16131 1 Fit a lifting eye in the arm house with a fender washer underneath xx1400002196 3 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Lifting accessory chain 3HAC15556 1 xx1200001308 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in ...

Page 401: ...hment screws M12 in opposite holes and replace them with guide pins Note Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M12x200 3HAC13056 4 Always use guide pins in pairs xx1300000659 Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1300000747 Leave one of the remaining attachment screws fitted remove the...

Page 402: ... remaining attachment screws fitted remove the other screws 2 Preparations before removing the upper arm IRB 6700 300 2 70 IRB 6700 245 3 00 Note Action Guide pin M16x150 3HAC13120 2 Remove two attachment screws in opposite holes and replace them with guide pins Note Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M16x200 3HAC13120 3 Alway...

Page 403: ...re 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 Product manual IRB 6700 403 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 404: ...000059 Lift the upper arm and place it on the pre pared area CAUTION Only valid when the upper arm is removed due to replacement of the axis 3 gearbox If the cable harness is still fitted or partly fitted use caution when lifting the upper arm over to the other side of the robot in order not to cause any damage to the cable harness 3 Continues on next page 404 Product manual IRB 6700 3HAC044266 00...

Page 405: ...fore removing the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Open the ball joint housings on the lower arm and remove the DressPack 2 xx1300000540 Loosen the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp loc ated on the inside of the lower arm by re moving the attachment screws Note The scre...

Page 406: ... IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Note Action Raise the lifting accessory to unload the lower arm 1 Guide pin M16x150 3HAC13120 2 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the lower arm slide better 2 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx13000...

Page 407: ...IRB 6700 300 2 70 IRB 6700 245 3 00 Note Action Raise the lifting accessory to unload the lower arm 1 Guide pin M16x150 3HAC13120 2 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the lower arm slide better 2 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1400002181 Continues on next page Product ...

Page 408: ...r arm Preparations before refitting the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1700001879 Apply Mercasol on the surface on the lower arm as shown in the figure CAUTION Keep the sealing surfaces clean from Mer casol 2 Cont...

Page 409: ...RB 6700 245 3 00 4 Always use guide pins in pairs xx1400002189 Fit two guide pins in opposite holes in the axis 2 gearbox Tip Lubricate the guide pins with some grease to make the lower arm slide better CAUTION The lower arm weighs 145 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 160 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 5 Attach ...

Page 410: ...e hole pattern of the lower arm and gearbox does not match Remove the motor cover Apply the rotation tool on the motor shaft Connect the 24 VDC power supply Release the brakes Rotate pinion and gear with the rota tional tool until the holes matches Connect 24 VDC the power supply to con nector R2 MP2 pin 2 pin 5 3 24 VDC power supply xx1300000819 xx1300000790 Fit one attachment screw in one of the...

Page 411: ...e them with the remaining attachment screws 7 Tightening torque M16 300 Nm Secure the remaining attachment screws 8 Remove the lifting accessory from the lower arm 9 Securing the lower arm to the axis 2 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Note Action Lift the lower arm onto the guide pins and slide it into position 1 Continues on next page Product manual IRB 6700 411 3HAC044266 001 Revisio...

Page 412: ...ing it for security and lower the lifting accessory a little 3 Tightening torque M16 300 Nm Secure the lower arm by fitting and tighten ing the accessible screws 4 Attachment screws M16x50 quality steel 12 9 Gleitmo 21 pcs Washers steel 17x25x3 21 pcs xx1400002190 Disconnect the 24 VDC power supply if used 5 xx1400002181 Remove the guide pins and replace them with the remaining attachment screws 6...

Page 413: ... Keep the sealing surfaces clean from Mer casol 2 Guide pin M12x150 3HAC13056 2 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 3 Guide pin M12x200 3HAC13056 4 Fit two guide pins in opposite M12 holes in the axis 3 gearbox Tip Lubricate the guide pins with some grease to make the upper arm slide better Always use guide pins in pairs xx1700000058 Continues on next page Produ...

Page 414: ...e to make the upper arm slide better Always use guide pins in pairs xx1700000056 Securing the upper arm IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 360 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 465 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be si...

Page 415: ...uide pins in the lower arm 3HAC067547 001 ii 3HAC067545 001 iii Screws Insert all nine M16 screws and 25 of the 27 M12 screws 6 M16 9 pcs M12 25 of 27 pcs xx1400000359 xx1300000659 Remove the guide pins and fit the two re maining M12 screws 7 Tightening torque depends on screw dimen sion Secure the upper arm by tightening the at tachment screws 8 Tightening torque M16 300 Nm Tightening torque M12 ...

Page 416: ...nstalled to the upper arm 4 Rotation tool In order to release the brakes connect the 24 VDC power supply Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm Pinion If the axis 3 motor is not installed to the upper arm 5 3HAC067546 001 i Use the pinion to rotate the axis 3 gearbox to find the corr...

Page 417: ... lifting accessories to the upper arm on page 228 Attach the lifting accessories if not already fitted 2 Lift the upper arm and bring it towards the lower arm 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool Connect the 24 VDC power supply to re lease the brakes Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find ...

Page 418: ...he cable harness lower arm Note Action xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cable harness through the inside of the robot 1 xx1300000733 Run the upper end of the cable harness up through th...

Page 419: ... that it will stay twisted a little between the metal clamps after fitting as shown in the figure Do not change the po sition of the brackets 4 xx1300000558 Refit the axis 3 lower arm metal clamp located on the inside of the lower arm Note The screws are reached from the outside of the lower arm 5 Continues on next page Product manual IRB 6700 419 3HAC044266 001 Revision N Copyright 2013 2018 ABB ...

Page 420: ...tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cable harness through the inside of the robot 4 Continues on next page 420 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Re...

Page 421: ...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 6 Person 2 working at the back xx1400000356 Note The cable harness is best placed at the upper right hand side of the DressPack tube if used throu...

Page 422: ...Take a hold of the cable harness from inside the wrist Together Move the cable harness past the axis 5 motor and into the wrist 7 Person 2 working at the wrist xx1300000746 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 8 xx1700000339 Continues on next page 422 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 201...

Page 423: ...he side cover 9 xx1700000690 If used refit the insert that guides the DressPack cable package through the hole in the upper arm 10 xx1400000092 If used refit the tube containing the DressPack into the insert 11 Continues on next page Product manual IRB 6700 423 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 424: ...00000045 DressPack or Foundry Plus Refit the cover with the tube guiding ring fitted Note Foundry Plus Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 13 Continues on next page 424 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 425: ...0001973 14 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 6700 425 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 426: ...ircular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 426 Produ...

Page 427: ...nnecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001016 Refit the cable gland cover by performing the following steps Slide the cable gland cover onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 Continues on next page ...

Page 428: ...1 hexagon pro file xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 428 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 429: ...e are two versions of the heat protec tion plates Secure the cable harness with cable straps to the heat protection plate Note If replacing a type A motor with a type B motor the heat protection plate must be replaced with plates suited for the type B motor See Type A vs type B motors on page 819 7 Choose figure depending on which plate is installed on the robot xx1500001029 xx1300000489 Continues...

Page 430: ... the robot Fit the heat protection plate with the screws 8 Screws M5x12 xx1500001030 xx1300000490 Continues on next page 430 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 431: ...t be in position 90 or as close as possible for a correct installation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 Continues on next page Product manual IRB 6700 431 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights re...

Page 432: ...The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page 432 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 433: ...0001095 Make sure the gasket is undamaged Replace if damaged 8 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page Product manual IRB 6700 433 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 434: ...ble harness with cable straps to the heat protection plate 1 Choose figure depending on which plate is installed on the robot xx1500001029 xx1300000489 Continues on next page 434 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 435: ...0490 xx1600002061 Make sure that the cable harness is placed so it will not be damaged when the wrist cover is fitted 3 xx1300000596 Cable layout in the wrist with Type A mo tors Continues on next page Product manual IRB 6700 435 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 436: ...ver tilted See figure 2 Put the cable harness on the cover 3 Lift the cover still tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 5 How to refit the DressPack cable package is described in the product manual IRB 6700 DressPack For article number see References on page 10 If the robot is equipped with DressPack cable package Refit the distance t...

Page 437: ...DressPack in the ball joint housings on the lower arm 9 Refitting the front shaft of the balancing device Note Action Turn the power to the robot on temporarily 1 Continues on next page Product manual IRB 6700 437 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 438: ...ve all residue of Loctite in the screw hole of the shaft 5 Wipe all contact surfaces inside the recess clean from contamination 6 xx1300000784 Align the balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 7 A B C A xx1400000368 A Front link ear B Shaft C Mercasol red dotted lines Foundry Plus Apply Mercasol on the surfaces on the shaft and fro...

Page 439: ...HAC11731 1 Dismantle and mounting tool 3HAC028920 001 xx1700002238 The item numbers refer to mark ings on the tools xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 11 Tightening torque 180 Nm xx1200001279 Secure the shaft with screw and washer 12 Continues on next page Product manual IRB 6700 439 3HAC044266 001 Revision N Copyright...

Page 440: ...e 14 Refit the two screws and wipe clean from residual grease 15 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 xx1200001283 Refit the cable bracket if not already refit ted 2 Continues on next page 440 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Co...

Page 441: ... by jogging the robot only use the hydraulic press tool Dismantle and mounting tool 3HAC028920 001 3 This is done in order to compress the spring unit inside the balancing device be fore refitting or removal of the distance tool Jog axis 2 to 30 or 30 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 A xx...

Page 442: ...bot 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 26 3 442 Product manual IRB 6700 3HAC044266 001 Revision N Copyr...

Page 443: ... lip 50x68x8 2 pcs C O ring 85x3 D Spherical roller bearing E Washer F Summary of the replacement procedure This is a brief summary of the replacement procedure containing the major actions to be performed 1 Unload the balancing device 2 Replace the spherical roller bearing 3 Restore the balancing device Continues on next page Product manual IRB 6700 443 3HAC044266 001 Revision N Copyright 2013 20...

Page 444: ...estore a balancing device 3HAC030662 001 Distance tool Used to unload or restore a balancing device 3HAC020902 001 Hydraulic press tool balan cing device Used for removing and fitting shaft and bearings 3HAC028920 001 Dismantle and mounting tool To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa Used to secure lowe...

Page 445: ...rent methods using two different tools Distance tool or Hydraulic press tool balancing device The situations when to use which tool are very different The method described in this procedure describes how to use the Distance tool 3HAC030662 001 The Distance tool can not be used to unload or restore the pressure of the balancing device spring unit The Distance tool is only used to keep the balancing...

Page 446: ...ncing device This tool is used to unload or restore a balancing device which cannot be done with the help of the robot itself This press tool shall also be used if the tool shall be fitted on or be removed from a balancing device not fitted on the robot Use this tool 3HAC020902 001 Hydraulic press tool balan cing device xx1300000672 if the balancing device shall be unloaded or restored after it ha...

Page 447: ...device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 This is done in order to compress the bal ancing device springs inside the balancing device before fitting the Distance tool Jog axis 2 to 30 or 30 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply...

Page 448: ... it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance tool stay fitted during the continued procedure 8 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 9 Preparations before removing the spherical roller...

Page 449: ...e supply to the robot before entering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 4 CAUTION The weight of the balancing device exclud ing cradle is 140 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 185 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 5 Continues on next page Product manual IRB 6...

Page 450: ...emoving the shaft in the front link ear Note Action It is possible to drive a screwdriver or similar through the VK cover as close as possible to the center of the VK cover and pull it out xx1200001278 Remove the VK cover 1 Continues on next page 450 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ...

Page 451: ...0378 The numbers in the figure refers to the marked tool pieces respectively 3 Hydraulic pump 80 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 xx1200001280 xx1200001281 Put down the balancing device and let it rest on the frame 4 Continues on next page Product manual IRB 6700 451 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearin...

Page 452: ...radial sealing with a screwdriver 2 xx1300000775 Remove the o ring 3 Dismantle and mounting tool 3HAC028920 001 xx1300000840 A Spherical roller bearing B Radial sealing C Washer Apply the dismantle and mounting tool and pull the spherical roller bearing out together with the radial sealing and washer 4 Continues on next page 452 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018...

Page 453: ...0000839 Put the radial sealing on the Press tool J Note Make sure that the sealing is turned accord ing to the figure 3 xx1300000777 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 Product manual IRB 6700 453 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6...

Page 454: ...1700000379 6 xx1300000775 Refit the o ring 7 Loctite 243 3HAB7116 1 xx1300000774 Apply Locking liquid on the screws and secure the end cover with the radial sealing ring 8 Continues on next page 454 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 455: ...g device Note Action DANGER Do not use the Distance tool 3HAC030662 001 to unload or restore the pressure of the balancing device spring unit This tool is only used to lock the spring unit in a compressed position after axis 2 has been jogged to 30 or 30 Fitting and removal of the tool shall only be done with axis 2 in this position To unload or restore a new balancing device or if the spring unit...

Page 456: ...ic power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 4 Lifting accessory chain 3HAC15556 1 Remove all residue of Loctite in the screw hole of the shaft 5 Wipe all contact surfaces inside the recess clean from contamination 6 xx1300000784...

Page 457: ...where Mercasol is ap plied 9 Hydraulic pressure 250 bar Press the shaft in with the hydraulic press tool 10 Hydraulic pump 80 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 Dismantle and mounting tool 3HAC028920 001 xx1700002238 The item numbers refer to mark ings on the tools Continues on next page Product manual IRB 6700 457 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4...

Page 458: ...he VK cover 13 Grease 3HAA1001 294 xx1300000783 Unscrew both screws in link ear and fill the bear ing with grease from the upper hole until the grease appears in the lower hole 14 Refit the two screws and wipe clean from residual grease 15 Continues on next page 458 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roll...

Page 459: ...ready refit ted 2 xx1200001116 Remove the locking screw M16x120 3 xx1400000372 Foundry Plus Apply Mercasol in the hole for the locking screw 4 Jog axis 2 to 30 or 30 5 Continues on next page Product manual IRB 6700 459 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 460: ...nce tool 7 Screws M10 quality 12 9 Apply flange sealant and refit the cover plate on the back of the balancing device 8 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 577 xx1300000554 460 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 461: ...re containing the major actions to be performed 1 Unload the balancing device 2 Replace the balancing device Spare part Note Spare part number Spare parts See Product manual spare parts IRB 6700 IRB 6700Inv Balancing device Product manual spare parts IRB 6790 Continues on next page Product manual IRB 6700 461 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 2 Repl...

Page 462: ...d to unload or restore a balancing device 3HAC020902 001 Hydraulic press tool balan cing device Used for removing and fitting shaft and bearings 3HAC028920 001 Dismantle and mounting tool To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa To be used with the press tool 3HAC11731 1 Hydraulic cylinder Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain...

Page 463: ...prings has been un loaded with the help of the robot itself 3HAC030662 001 Distance tool xx1400000726 DANGER Never use this tool to unload or restore a balancing device This tool is used to unload or restore a balancing device which cannot be done with the help of the robot itself This press tool shall also be used if the tool shall be fitted on or be removed from a balancing device not fitted on ...

Page 464: ...cing device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 This is done in order to compress the bal ancing device springs inside the balancing device before fitting the Distance tool Jog axis 2 to 30 or 30 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure s...

Page 465: ...ngs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance tool stay fitted during the continued procedure 8 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 9 Preparations before removing the balanc...

Page 466: ...fore entering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 4 Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 185 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 1 Con...

Page 467: ...evice 2 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle and raise to unload the weight 3 Continues on next page Product manual IRB 6700 467 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 468: ...hole in the center of the VK cover there is a risk of damaging the bearing inside The damaged VK cover must be replaced with a new Remove the protection screw from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 Vent hole for air pressure xx1700002189 Wipe off any residual grease inside the re cess 2 Continues on next page 468 Prod...

Page 469: ...meters just long enough for the balancing device to go free 5 Removing the shaft in the front link ear Note Action It is possible to drive a screwdriver or similar through the VK cover as close as possible to the center of the VK cover and pull it out xx1200001278 Remove the VK cover 1 Continues on next page Product manual IRB 6700 469 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights r...

Page 470: ...1700000378 The numbers in the figure refers to the marked tool pieces respectively 3 Hydraulic pump 80 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 xx1200001280 xx1200001281 Put down the balancing device and let it rest on the frame 4 Continues on next page 470 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing dev...

Page 471: ...alancing device fitted to the robot 2 Refitting the balancing device Use this procedure to refit the balancing device Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 185 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordi...

Page 472: ...020902 001 1 How to unload a new balancing device a spare part not yet fitted to the robot is described in Unloading the balancing device on page 492 Before a new spare part balancing device is fitted the springs must be unloaded us ing the Hydraulic press tool balancing device 3HAC020902 001 2 Refitting the rear shafts Perform this procedure on both sides Note Action DANGER Turn off all electric ...

Page 473: ... on matching surfaces on the axis and balancing device See the fig ure 5 xx1300000664 Fit the retaining ring 6 M16x70 quality steel 12 9 Gleitmo 603 Apply Loctite 243 on the screws and secure the shafts on both sides 7 Tightening torque 280 Nm xx1300000663 Continues on next page Product manual IRB 6700 473 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 2 Replaci...

Page 474: ...e further detailed in the section First test run may cause injury or damage on page 26 12 Refitting the front shaft of the balancing device Note Action Turn the power to the robot on temporarily 1 Use caution and jog the robot to the calibration position if not already done 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the ro...

Page 475: ... the hole in the lower arm Note Verify that the link ear is correctly turned 7 A B C A xx1400000368 A Front link ear B Shaft C Mercasol red dotted lines Foundry Plus Apply Mercasol on the surfaces on the shaft and front ear 8 xx1200001280 Lubricate the shaft and place it to the front ear Note Foundry Plus Do not lubricate surfaces where Mercasol is ap plied 9 Continues on next page Product manual ...

Page 476: ...r to mark ings on the tools xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 11 Tightening torque 180 Nm xx1200001279 Secure the shaft with screw and washer 12 xx1200001278 Fit the VK cover 13 Continues on next page 476 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 2 Repla...

Page 477: ...m residual grease 15 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 xx1200001283 Refit the cable bracket if not already refit ted 2 xx1200001116 Remove the locking screw M16x120 3 Continues on next page Product manual IRB 6700 477 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancin...

Page 478: ... before entering the robot working area 6 Remove the Distance tool 7 Screws M10 quality 12 9 Apply flange sealant and refit the cover plate on the back of the balancing device 8 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 577 xx1300000554 478 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing ...

Page 479: ...ing includ ing VK covers VK covers can be ordered separately 3HAA2166 28 2 pcs 3HAC045822 001 Maintenance set cradle Consumables Note Article number Equipment Located at the cradle of the balancing device 2 pcs required 3HAA2166 28 VK cover 90x12 Loctite 243 3HAB7116 1 Locking liquid Shell Gadus S2V220 AC 3HAB3537 1 Grease Continues on next page Product manual IRB 6700 479 3HAC044266 001 Revision ...

Page 480: ...ancing device with the help of the robot and lock the balancing device springs in a compressed position using the Distance tool 3HAC030662 001 Note Action DANGER Do not use the Distance tool 3HAC030662 001 to unload or restore the pressure of the balancing device springs This tool is only used to lock the spring unit in a com pressed position after axis 2 has been jogged to 30 or 30 Fitting and re...

Page 481: ...maged if more tightening torque than 45 Nm is used risking that the Distance tool is not properly fitted 5 Attachment screws M10 quality 12 9 4 pcs A xx0800000480 A Distance tool 3HAC030662 001 Turn the power on temporary 6 This is done to compress the balancing device springs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing...

Page 482: ...t of the lower arm in order to avoid acci dents or damage 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 4 CAUTION The weight of the balancing device exclud ing cradle is 140 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 ...

Page 483: ...e and raise to unload the weight 7 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 6700 483 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continued ...

Page 484: ...inside The damaged VK cover must be replaced with a new Remove the protection screw from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 Vent hole for air pressure xx1700002189 Wipe off all residual grease inside the re cess 2 xx1300000663 Unscrew the attachment screw securing the shaft 3 Continues on next page 484 Product manual I...

Page 485: ...nce IRB 6700 300 2 70 245 3 00 7 Apply the press tool and pull out the shaft end with the groove ball bearing Refitting the bearing cradle Use these procedures to refit the bearing in the cradle Refitting the shaft end and rear bearings Note Action Wipe clean all contact surfaces from resid ual grease and other contamination inside the recess 1 Continues on next page Product manual IRB 6700 485 3H...

Page 486: ...ounting tool 3HAC028920 001 xx1700002296 The item number refers to marking on the tool Apply a threaded bar into the hole in the balancing device 4 xx1300000830 IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 Use caution and put sealing ring radial sealing spacer and groove ball bearing onto the shaft end manually 5 Continues on next page 486 Product manual IRB 6700 3HAC044266 001 R...

Page 487: ...ut radial sealing and groove ball bearing onto the shaft end manually 6 Put the shaft end with the fitted parts on the threaded bar 7 Manually press the shaft end into the cradle a little 8 Continues on next page Product manual IRB 6700 487 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continued ...

Page 488: ...the cradle and balancing device and use it as a dis tance tool 10 Use caution and press the shaft end in po sition 11 Remove the press tool and the threaded bar 12 xx1700000343 Fit the retaining ring bore 13 Loctite 243 3HAB7116 1 Apply locking liquid on the attachment screw 14 Continues on next page 488 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved ...

Page 489: ...device 15 Fit a VK cover to protect the bearing 16 Remove the lifting accessories Note Action Remove the lifting accessories 1 Concluding procedure Note Action xx1300000664 Refit the retaining ring bore 1 Continues on next page Product manual IRB 6700 489 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continu...

Page 490: ... 3HAA1001 294 xx1300000832 Unscrew both screws and refill grease from the inner hole See figure 3 xx1300000833 Refit the screws 4 Wipe clean from residual grease 5 Remove the Distance tool 6 Continues on next page 490 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continued ...

Page 491: ... Loctite 577 xx1300000554 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 8 Product manual IRB 6700 491 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continued ...

Page 492: ...2 to calibration position lock axis 2 with a M16 lock screw How to secure the lower arm is described in the current repair activity for example removal of the balancing device DANGER There is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property Continues on next page 492 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 A...

Page 493: ...g E Bolt 4 pcs F Pin attached to the fix plate G Required equipment Note Article number Equipment etc Used to unload or restore a balancing device 3HAC020902 001 Hydraulic press tool balan cing device To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa Continues on next page Product manual IRB 6700 493 3HAC044266 00...

Page 494: ...pin is shown in the figure Press tool and hydraulic cylinder on page 493 The bolt is shown in the figure Press tool and hydraulic cylinder on page493 Fit the correct press device and moving pin to the press tool Secure with the bolt press device Note Make sure the bolt is secured properly 2 xx1300000554 Remove the rear cover of the balancing device by unscrewing the attachment screws DANGER DO NOT...

Page 495: ... until the marking on the moving pin indicates the cor rect position in level with the pressure block 7 Turn the fix plate to position Closed in order to lock the tool in loaded condition 8 Hydraulic cylinder 3HAC11731 1 Hydraulic pump 80 MPa 3HAC13086 1 Do not apply more pressure than neces sary it could damage bearings and sealings at the shaft Unload the hydraulic cylinder 9 The hydraulic cylin...

Page 496: ...ress tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 Press block A Hydraulic cylinder B Press device C Bolt press device D Moving pin with marking E Continues on next page 496 Product manual IRB 6700 3HAC044266 001 Revision N Copyright...

Page 497: ...74 Press block A Hydraulic cylinder B Press device C Bolt press device D Moving pin with marking E Bolt 4 pcs F Pin attached to the fix plate G Refit the hydraulic cylinder to the press tool in case it has been removed 1 Press with the cylinder and the hydraulic pump until the fix plate is movable again Turn the pin on the fix plate to position Open CAUTION Do not apply more pressure than neces sa...

Page 498: ...cal fittings Loctite 577 xx1300000554 DANGER The rear cover of the balancing device is a safety device for the piston rod during operation Make sure the cover is properly secured before commissioning of the ro bot 7 498 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 5 Restoring the balancing device Continued ...

Page 499: ...nd equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 829 Standard toolkit Required consumables Note Article number Consumable Loctite 243 3HAB7116 1 Locking liquid Mercasol 3110 Waxcoat Recom mended drying time is 24h 3HAC034903 001 Foundry plus Rust preventive Continues on next page Product manual IRB 6700 499 3HAC044266 001 Revision N Copyright 20...

Page 500: ...o go free from the axis 1 oil plug draining when removed 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1300000476 Hold the mechanical stop pin in a firm grip use caution and remove it by unscrewing the set screw cup point CAUTION The mechanical stop weighs 5 kg and may unexpectedly fall down when th...

Page 501: ...drying time is 24h xx1400000378 Foundry Plus Apply Mercasol on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 1 xx1300000477 Fit the stop pin 2 Continues on next page Product manual IRB 6700 501 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 6 Replacing the stop pin Continued ...

Page 502: ...ocking liquid on the set screw and secure the stop pin 3 Set screw M10x20 xx1300000476 502 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 6 6 Replacing the stop pin Continued ...

Page 503: ...ontaining the major actions to be performed 1 Attach the lifting tools 2 Replace the motor 3 Remove the lifting tools Spare parts Note Spare part number Spare part See Product manual spare parts IRB 6700 IRB 6700Inv Axis 1 motor Product manual spare parts IRB 6790 Continues on next page Product manual IRB 6700 503 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 1...

Page 504: ...on motor type see Type A vs type B motors on page 819 3HAC057339 003 3HAC057339 004 Removal tool Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 300 mm bits 1 2 3HAC12342 1 Bits extender Used to rotate the motor pinion 3HAB7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply Leak down tester Required if Calibration Pendulum is the valid calibration method for the ...

Page 505: ...bility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 799 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine...

Page 506: ...f the attachment screws three M10x30 and two of the M5x12 screws 2 xx1400000724 Foundry Plus Remove the two protection plates 3 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 506 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved...

Page 507: ...the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 6700 507 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 508: ... electrical power hydraulic pressure and air pressure are turned off 1 Lifting accessory chain 3HAC15556 1 Attach the lifting accessories 2 Lifting accessory motor 3HAC14459 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to R2 MP1 connector pin 2 pin 5 CAUTION The weight of the motor is 25 kg All lifting accessories used must be sized accordingly 4 Continues ...

Page 509: ...57339 003 If needed use removal tools to help re move the motor 8 Removal tool M14 3HAC057339 004 Depending on motor type A or B see Identifying the motor by article number on page 819 Always use removal tools in pairs Lifting accessory chain 3HAC15556 1 Use caution and lift the motor straight up to get the pinion parted from the gear 9 Lifting accessory motor 3HAC14459 1 xx1200001072 Continues on...

Page 510: ...ther contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 Continues on next page 510 Product manual IRB 6700 ...

Page 511: ...6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 1 motor Note Action Guide pin M12x150 3HAC13056 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 25 kg All lifting accessories used must be sized accordin...

Page 512: ...erly mated to the gear in the gearbox Make sure that the motor pinion does not get damaged Make sure that the direction of the cable gland exit is facing the correct way 7 Lifting accessory motor 3HAC14459 1 xx1200001072 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 8 Tightening torque 50 Nm Use a bits extender to reach the screws Screws M10x30 Steel 12 9 Gle 60...

Page 513: ... the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 6700 513 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued...

Page 514: ...ing axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 514 Product manual IRB 6700 3HAC044266 001 Revision N Copyri...

Page 515: ...g procedure Use this procedure for the concluding refitting Note Action xx1400000723 Foundry Plus Refit the protection plates with three M10x30 and two M5x12 attachment screws Note Make sure that the axis 1 and axis 2 motor cables are run through the hole in the pro tection plates correctly 1 xx1400000722 Foundry Plus Secure the axis 1 and axis 2 motor cables with a cable tie 2 Continues on next p...

Page 516: ... method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 26 4 516 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis...

Page 517: ...ed 1 Drain the axis 2 gearbox 2 Attach the lifting tools 3 Replace the motor 4 Remove the lifting tools 5 Refill the axis 2 gearbox with oil Spare parts Note Spare part number Spare part See Product manual spare parts IRB 6700 IRB 6700Inv Axis 2 motor Product manual spare parts IRB 6790 Continues on next page Product manual IRB 6700 517 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights ...

Page 518: ...use removal tools in pairs Size depending on motor type see Type A vs type B motors on page 819 3HAC057339 003 3HAC057339 004 Removal tool Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 300 mm bits 1 2 3HAC12342 1 Bits extender Used to rotate the motor pinion 3HAB7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply Used to secure lower arm Lock screw M16x120 Leak...

Page 519: ... calibration for Axis Calibration in Reference calibration routine on page 799 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages Dr...

Page 520: ...y hydraulic pressure supply air pressure supply to the robot before entering the robot working area 6 Remove any equipment hindering access to the motor 7 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues...

Page 521: ...e is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 2 motor Note Action Before removing the motor make sure that the axis 2 gearbox is completely drained 1 Continues on next page Product manual IRB 6700 521 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 2 R...

Page 522: ...ke the motor slide better 5 Always use guide pins in pairs CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Removal tool M12 3HAC057339 003 If required press the motor out of its posi tion by using the removal tool in opposite holes of the motor 7 Removal tool M14 3HAC057339 004 Depending on motor type A or B see Identifying the motor by art...

Page 523: ...ng the motor These procedures describes how to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove O r...

Page 524: ... replaced with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass On the axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 2 motor Note Action Guide pi...

Page 525: ...elease the brakes connect the 24 VDC power supply 8 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 9 Use caution and fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool Make sure that the motor pinion is properly mated to t...

Page 526: ...l 12 9 Gle 603 Geo500 4 pcs xx1200001117 See Performing a leak down test on page 198 Perform a leak down test 14 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 526 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB...

Page 527: ...cular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product man...

Page 528: ... ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Concluding procedure Note Action Use caution and jog axis 2 a little to facilit ate the removal of the lock screw 1 Lock screw M16x120 xx1200001115 Remove the lock screw securing the lower arm 2 Continues on next page 528 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reser...

Page 529: ...bot 5 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These are further described in the section First test run may cause injury or damage on page 26 6 Product manual IRB 6700 529 3HAC044266 001 Revi...

Page 530: ...us S2V220 AC 3HAB3537 1 Grease Used to lubricate o rings D 169 5x3 3HAB3772 111 circular pro file 3HAC054692 002 hexagon profile O ring i Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange i The cross section profile is either circular or hexagon If only ordering the o ring order the same profile that is currently installed in the connection box Continues on next page 530 Product...

Page 531: ...he information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be re...

Page 532: ...ese methods Use caution and jog axis 3 to maxim um position Release the brakes and let the upper arm rest against the axis 3 damper Use a fork lift to rest the upper arm onto Use lifting slings and an overhead crane to rest the upper arm onto 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 4 Remove any eq...

Page 533: ...the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 6700 533 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 motor Continued ...

Page 534: ...ned 1 DANGER When releasing the holding brakes of the motor the upper arm will be movable and may fall down if not secured Verify that the upper arm is secured as previously described before continuing 2 To release the brakes connect the 24 VDC power supply 3 Connect to connector R2 MP3 pin 2 pin 5 Bits extender 3HAC12342 1 xx1200001126 Unscrew the attachment screws that hold the motor Use a bits ...

Page 535: ...e guide pins 8 CAUTION The motor weighs 26 kg All lifting accessories used must be sized accordingly 9 Lifting accessory motor 3HAC15534 1 Fasten the lifting accessory to the motor Attach the lifting chain to the accessory and an overhead crane 10 Lifting accessory chain 3HAC15556 1 xx1200001125 When the motor is hanging in the lifting accessory and the pinion no longer is mated to the gear let th...

Page 536: ... power hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 3 Continues on next page 536 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 20...

Page 537: ...nsparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass On the axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 3 motor Use this procedure to secure the motor N...

Page 538: ... pins Do not push the motor pinion into the gear yet This is done in order to fit the motor with the axis 4 motor still fitted 4 Remove the lifting accessory and allow the motor to rest on the guide pins 5 Rotation tool 3HAB7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 6 To release the brakes connect the 24 VDC power supply 7 Connect to connector R2 MP...

Page 539: ...ent screws and wash ers 10 Remove the guide pins 11 Screws M10x30 quality 12 9 Gleitmo Fit the remaining attachment screws and washers 12 Tightening torque 50 Nm Tighten the screws 13 Remove the rotation tool 14 See Performing a leak down test on page 198 Perform a leak down test 15 Disconnect the 24 VDC power supply 16 Connecting the motor cables Note Action xx1300000738 Push the motor cables thr...

Page 540: ...ile Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 3 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Continues on next page 540 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All right...

Page 541: ...sure that the covers are tightly sealed 9 Concluding procedure Use this procedure for the concluding refitting Note Action Remove the equipment used to unload the upper arm 1 See Filling oil into the axis 3 gearbox on page 173 Refill the gearbox with oil 2 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 3 Axis ...

Page 542: ... performing the first test run These are further described in First test run may cause injury or damage on page 26 4 542 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 motor Continued ...

Page 543: ...adus S2V220 AC 3HAB3537 1 Grease Used to lubricate o rings D 119x3 3HAB3772 110 circular pro file 3HAC054692 001 hexagon profile O ring i Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange i The cross section profile is either circular or hexagon If only ordering the o ring order the same profile that is currently installed in the connection box Continues on next page Product man...

Page 544: ...r 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 ence calibration Find pre...

Page 545: ... from the axis 4 gearbox when the motor is replaced 2 If there is no space to position the upper arm pointed straight up drain the axis 4 gearbox 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 4 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic p...

Page 546: ...the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 546 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 motor Continued ...

Page 547: ...nect to connector R2 MP4 pin 2 pin 5 xx1200001137 Unscrew the attachment screws that secure the motor 3 Guide pin M8x150 3HAC15520 2 Apply two guide pins in opposite holes 4 Always use guide pins in pairs CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 5 Removal tool M12 3HAC057339 003 Press the motor out of position by fitting the removal to...

Page 548: ...ns prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 3 Conti...

Page 549: ...placed with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass On the axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 4 motor Note Action Guide pin M...

Page 550: ...the rotation tool and use it to rotate the pinion when mating it into the gear 5 This requires two persons co operating if the motor is installed from above if the upper arm is pointing upwards To release the brakes connect the 24 VDC power supply 6 Connect to connector R2 MP2 pin 2 pin 5 Continues on next page 550 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All right...

Page 551: ... gland is facing the correct way 8 Remove the guide pins 9 Tightening torque 35 Nm Secure the motor with its attachment screws and washers 10 Screws M8x30 quality 12 9 Gleitmo 4 pcs xx1200001137 See Performing a leak down test on page 198 Perform a leak down test 11 Disconnect the 24 VDC power supply 12 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gl...

Page 552: ...ile Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 3 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Continues on next page 552 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All right...

Page 553: ...ed 9 Concluding procedure Note Action See Filling oil into the axis 4 gearbox on page 178 Refill the gearbox with oil if gearbox has been drained 1 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration informat...

Page 554: ... Note Article number Equipment etc Shell Gadus S2V220 AC 3HAB3537 1 Grease Used to lubricate o rings D 119x3 3HAB3772 110 circular pro file 3HAC054692 001 hexagon profile O ring i Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange i The cross section profile is either circular or hexagon If only ordering the o ring order the same profile that is currently installed in the connect...

Page 555: ...s DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values T...

Page 556: ...Axis 3 35 2 With the robot in this position there is no need to drain oil from the axis 5 gearbox when the motor is replaced xx1400000719 Jog axis 4 to this position Axis 4 90 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 4 Continues on next page 556 Product manual IRB 6700 3HAC044266 001 Revision N Cop...

Page 557: ...led Remove the bracket with the com plete ball joint housing still fitted as shown in the figure This is done to be able to reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 xx1300002247 Remove the wrist cover 4 Continues on next page Product manual IRB 6700 557 3HAC044266 001 Revision...

Page 558: ...late 5 Choose figure depending on which plate is installed on the robot xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate xx1300000490 Continues on next page 558 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 559: ...te only for replacing the motor the cabling does not need to be loosened from the plate 6 xx1300000489 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700 559 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing...

Page 560: ...the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 560 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 561: ...all be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 5 motor Note Action Bits extender 3HAC12342 1 xx1200001017 Unscrew the attachment screws that secure the motor using a bits extender 1 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 2 Removal tool M12 3HAC057339 003 If needed fit removal tool...

Page 562: ... procedures describe how to refit the motor Preparations before refitting the axis 5 motor Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 562 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis ...

Page 563: ...ke sure the o ring is seated in the groove 5 Guide pin M8x100 3HAC15520 1 Apply two guide pins in opposite holes 6 Securing the axis 5 motor Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 1 Continues on next page Product manual IRB 6700 563 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 5 Repla...

Page 564: ...ool 3HAB7887 1 xx1200001018 Use caution and lower the motor into posi tion on the guide pins while at the same time rotating the motor pinion slightly Make sure that the motor pinion is properly mated to the gear of the gearbox the motor pinion does not get dam aged the direction of the cable exit is fa cing the same way as before remov al 5 Remove the guide pins 6 Continues on next page 564 Produ...

Page 565: ...leak down test on page 198 Perform a leak down test 8 Disconnect the 24 VDC power supply 9 Connecting the motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 6700 565 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 566: ...connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 566 Product manual IRB 6700 3HAC044266 001 Revision...

Page 567: ...are two versions of the heat protec tion plates Secure the cable harness with cable straps to the heat protection plate Note If replacing a type A motor with a type B motor the heat protection plate must be replaced with plates suited for the type B motor See Type A vs type B motors on page 819 7 Choose figure depending on which plate is installed on the robot xx1500001029 xx1300000489 Continues o...

Page 568: ...the robot Fit the heat protection plate with the screws 8 Screws M5x12 xx1500001030 xx1300000490 Continues on next page 568 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 569: ... B xx1400000383 A Protection plugs 2 on wrist cover and 2 on cover axis 5 gearbox B Washers 10 pcs in gasket holes Inspect the gasket Replace if damaged Foundry Plus and Foundry Prime Make sure that the gasket is undam aged on the cover Replace if dam aged Put washers in the holes of the gas ket Use attachment screws made of stainless steel to fit the wrist cover 2 Continues on next page Product m...

Page 570: ...ckage on the wrist 5 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 6 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first t...

Page 571: ...rticle number Equipment etc Shell Gadus S2V220 AC 3HAB3537 1 Grease Used to lubricate o rings Used on motor cover 3HAC033489 001 3HAC044252 001 Gasket i D 102x3 3HAB3772 107 O ring Used on motor flange i Information about which of the two types of gasket to choose is found in Product manual spare parts IRB 6700 IRB 6700Inv Continues on next page Product manual IRB 6700 571 3HAC044266 001 Revision ...

Page 572: ...al cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new re...

Page 573: ... pointing straight up at an acceptable working posi tion With axis 5 in this position it is possible to replace the motor without draining the oil from the axis 6 gearbox 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1300002247 Remove the wrist cover 4 Continues on next page Product manual IRB 6700 ...

Page 574: ...xx1200001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page 574 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 575: ...tor cables by holding the cables with one hand at the motor and the other at the carrier 7 Removing the axis 6 motor Note Action 24 VDC power supply To release the brakes connect the 24 VDC power supply 1 Connect to R2 MP6 connector pin 2 pin 5 Continues on next page Product manual IRB 6700 575 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis ...

Page 576: ...equired press the motor out of position by fitting the removal tool motor to the at tachment holes of the motor 4 Always use removal tools in pairs CAUTION The motor weighs 9 kg All lifting accessories used must be sized accordingly 5 Continues on next page 576 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Co...

Page 577: ...he 24 VDC power supply 7 Refitting the axis 6 motor Use this procedure to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700 577 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the a...

Page 578: ...1019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page 578 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis ...

Page 579: ...s that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 6 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 To release the brakes connect the 24 VDC power supply 2 Connect to connector R2 MP6 pin 2 pin 5 CAUTION When...

Page 580: ... 4 CAUTION The motor weighs 9 kg All lifting accessories used must be sized accordingly 5 Continues on next page 580 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 581: ...box Make sure the motor pinion is not dam aged 6 xx1200001097 Screws M8x25 Steel 8 8 A2F 4 pcs Check that the gasket is fitted correctly 7 Tightening torque 24 Nm xx1200001090 Secure the motor with its attachment screws Continues on next page Product manual IRB 6700 581 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 582: ... The screw is located at the bottom of the carrier 9 xx1300000484 Refit the cable bracket 10 See Performing a leak down test on page 198 Perform a leak down test 11 Disconnect the 24 V DC power supply 12 Continues on next page 582 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 583: ...tion about which of the two types of gasket to choose is found in Product manual spare parts IRB 6700 IRB 6700Inv xx1200001095 xx1200001082 Refit the motor cover 15 Continues on next page Product manual IRB 6700 583 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 584: ... B xx1400000383 A Protection plugs 2 on wrist cover and 2 on cover axis 5 gearbox B Washers 10 pcs in gasket holes Inspect the gasket Replace if damaged Foundry Plus and Foundry Prime Make sure that the gasket is undam aged on the cover Replace if dam aged Put washers in the holes of the gas ket Use attachment screws made of stainless steel to fit the wrist cover 2 Continues on next page 584 Produ...

Page 585: ...ble package on the wrist 5 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 6 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the f...

Page 586: ...RB 6700 155 2 85 How to replace the gearbox on variants IRB 6700 300 2 70 IRB 6700 245 3 00 see Replacing the axis 1 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 on page 626 Location of the axis 1 gearbox The axis 1 gearbox is located as shown in the figure xx1200001183 Continues on next page 586 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair ...

Page 587: ...nt see Product manual spare parts IRB 6700 O ring nitrile rubber 169 5x3 169 5x4 8x2 65 3HAB3772 111 circular profile 3HAC054692 002 hexagon profile O ring i 102x3 3HAB3772 107 O ring nitrile rubber Cable straps Sealing ring i The cross section profile is either circular or hexagon If only ordering the o ring order the same profile that is currently installed in the connection box Required tools a...

Page 588: ...r supply Used to guide axis 1 gear and frame during refitting Valid for IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 3HAC043870 009 Guide for reduction gear Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Always use guide pins in pairs 3HAC13120 2 Guide pin M16x1...

Page 589: ...bration routine on page 799 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the axis ...

Page 590: ...ical stop pin in a firm grip and remove it by unscrewing the set screw CAUTION The mechanical stop pin weighs 5 kg and may fall down when the set screw is removed 6 xx1200001184 Unscrew the attachment screws that secure the cable bracket 7 Continues on next page 590 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gea...

Page 591: ...9 Unscrew five of the six attachment screws inside the frame recess that secure the frame to the gearbox Note Leave the outermost screw fitted as a safety precaution xx1200001185 10 Continues on next page Product manual IRB 6700 591 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05...

Page 592: ...obot is secured to the foundation Axis 2 40 Axis 3 65 approximately Axis 4 calibration position 0 Axis 5 90 Axis 6 calibration position 0 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Attaching the lifting accessories Use this procedure to attach the lifting accessories Continues on next page 592 Prod...

Page 593: ...31 1 xx1200001133 Fit a lifting eye to the wrist 3 Lifting shackle SA 10 8 NA1 xx1200001234 Fit a lifting shackle in the wrist lifting eye 4 Roundsling 1 5 m Length 1 5 m Lifting capacity 2 000 kg xx1200001209 Run a roundsling through the hole in the frame Attach the roundsling choked See figure xx1400000730 5 Continues on next page Product manual IRB 6700 593 3HAC044266 001 Revision N Copyright 2...

Page 594: ...asher 8 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Lifting accessory chain 3HAC15556 1 Attach the Lifting accessory chain to an over head crane or similar and then to the lifting eye in the arm house and to a roundsling run through the wrist 9 Roundsling 1 m Length 1 m lift ing capacity 1 000 kg xx1200001236 Continues on next page 594 P...

Page 595: ...screws 2 xx1400000724 Foundry Plus Remove the two protection plates 3 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 Continues on next page Product manual IRB 6700 595 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 67...

Page 596: ...present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 596 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued ...

Page 597: ...re turned off 1 Lifting accessory chain 3HAC15556 1 Attach the lifting accessories 2 Lifting accessory motor 3HAC14459 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to R2 MP1 connector pin 2 pin 5 CAUTION The weight of the motor is 25 kg All lifting accessories used must be sized accordingly 4 Continues on next page Product manual IRB 6700 597 3HAC044266 001...

Page 598: ...he motor 8 Removal tool M14 3HAC057339 004 Depending on motor type A or B see Identifying the motor by article number on page 819 Always use removal tools in pairs Lifting accessory chain 3HAC15556 1 Use caution and lift the motor straight up to get the pinion parted from the gear 9 Lifting accessory motor 3HAC14459 1 xx1200001072 Continues on next page 598 Product manual IRB 6700 3HAC044266 001 R...

Page 599: ...1300000561 Remove the base cover 2 xx1300000591 Disconnect connectors R1 MP R1 SMB 3 xx1400000366 If used disconnect the DressPack hoses in the base 4 Continues on next page Product manual IRB 6700 599 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200...

Page 600: ... Note There is no need to pull out the DressPack cables at this point 7 Removing the cable harness in the base Note Action If equipped with DressPack pull out the DressPack cables through the protection tube and place them carefully over the balancing device 1 Continues on next page 600 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Rep...

Page 601: ... is stretched Guide pin M16x150 3HAC13120 2 xx1700001635 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the frame slide better 2 Guide pin M16x200 3HAC13120 3 xx1700001636 Always use guide pins in pairs Continues on next page Product manual IRB 6700 601 3HAC044266 001 Revision N Copyright 2013 2018 ABB All right...

Page 602: ...completely stable on the floor before removing the lifting accessories Do not change the position of the axes from the position described earlier 7 Removing the gearbox Note Action xx1200001186 Remove the attachment screws and washers that secure the gearbox to the base 1 Continues on next page 602 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repa...

Page 603: ...n the lug and the surface of the gear box The surface of the gearbox is a sealing surface not to be damaged 3 CAUTION The weight of the gearbox is 92 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 140 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 4 Continues on next page Product manual IRB 6700 603 3HAC044266 001 Revision N Copyright 2013 2...

Page 604: ...x1400001983 Lift away the gearbox WARNING When the gearbox is lifted make sure not to damage the Pendulum Calibration bracket 7 Continues on next page 604 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85...

Page 605: ...holes in the base Tip Lubricate the guide pins with some grease to make the gearbox slide better 2 Guide pin M12x200 3HAC13056 4 Always use guide pins in pairs xx1700001642 Wipe clean the contact surfaces on the base and the surfaces of the protection tube from any contamination 3 Put grease on the protection tube 4 Continues on next page Product manual IRB 6700 605 3HAC044266 001 Revision N Copyr...

Page 606: ...maged 1 Lifting accessory chain 3HAC15556 1 xx1700002191 Attach the lifting accessory chain 2 CAUTION The weight of the gearbox is 92 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 140 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 3 Continues on next page 606 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All righ...

Page 607: ...t reuse an old o ring 5 Fit the o ring in the groove of the gearbox 6 xx1700002192 Wipe clean the surfaces of the hole in axis 1 gearbox 7 Continues on next page Product manual IRB 6700 607 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 67...

Page 608: ...Make sure that the o ring is still fitted cor rectly when the gearbox is being fitted 2 Remove the guide pins 3 Remove the lifting accessory and the lifting eyes 4 xx1200001186 Fit the attachment screws and washers Tighten by hand 5 Attachment screws M12x90 16 pcs Continues on next page 608 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1...

Page 609: ... gearbox 1 Wipe clean the contact surfaces from any remaining contamination 2 Flange sealant 12340011 116 Loctite 574 xx1700002198 Apply flange sealant on the contact surface of the gearbox 3 Continues on next page Product manual IRB 6700 609 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 670...

Page 610: ...pposite holes in the gearbox Note Make sure that the guide pins are fitted in the correct holes in the gearbox See fig ures Tip Lubricate the guide pins with some grease to make the frame slide better 6 Guide pin M16x150 3HAC13120 2 xx1300000822 Always use guide pins in pairs Continues on next page 610 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 ...

Page 611: ...ccessories still is fitted correctly on the arm system 2 For a more detailed description see Attach ing the lifting accessories on page 592 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm house and to a roundsling run through the wrist 3 Lifting accessory chain 3HAC15556 1 Roundsling 1 m Length 1 m lifting capa city 1 000 kg xx120...

Page 612: ...ame Note The amount of screw holes differ between the frame and the gearbox See figures for correct entering holes for the guide pins 8 Position of Guide pin M16x150 xx1300000822 Continues on next page 612 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IR...

Page 613: ... used 9 Position of Guide pin M16x150 xx1300000822 Lower the arm system to align the other guide pin into the hole 10 Continues on next page Product manual IRB 6700 613 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued...

Page 614: ...ews 2 pcs C Correct fitting of the aligning tool Tightening torque 50 Nm Fit the aligning tool according to figure 12 Continues on next page 614 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued...

Page 615: ...rm system to the axis 1 gearbox with its attachment screws 16 Tightening torque 300 Nm Remove the two guide pins and replace with attachment screws 17 Tighten the remaining accessible attach ment screws See Performing a leak down test on page 198 Perform a leak down test 18 Remove the aligning tool after the leak down test is completed successfully 19 Remove the lifting accessories 20 Preparations...

Page 616: ...for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page 616 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued ...

Page 617: ...in M12x150 3HAC13056 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 25 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC14459 1 Apply the lifting accessory 3 Rotation tool 3HAB7887 1 Fit the rotation tool 4 Connect the 24 VDC power supply to re lease the brakes 5 To release the brakes connect the 24 VDC power supp...

Page 618: ...tor with its attachment screws and washers 8 Tightening torque 50 Nm Use a bits extender to reach the screws Screws M10x30 Steel 12 9 Gle 603 Geo500 4 pcs xx1200001071 See Performing a leak down test on page 198 Perform a leak down test if not already done 9 Disconnect the 24 VDC power supply 10 Continues on next page 618 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB Al...

Page 619: ...ure that the R1 SMB cable will run on the correct side of the R1 MP1 see the figure 2 Make sure that the markings on the cables are facing the base cover when connected 3 Tightening torque for R1 SMB 10 Nm xx1300000591 Connect connectors R1 MP and R1 SMB 4 Continues on next page Product manual IRB 6700 619 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replaci...

Page 620: ...e running cor rectly and are not twisted xx1400000078 If used fit the bracket that hold the DressPack to the frame 8 xx1200000052 If used connect the DressPack cable package on the base plate 9 Continues on next page 620 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6...

Page 621: ... 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 6700 621 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued ...

Page 622: ...is 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 622 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 20...

Page 623: ...y hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 See Filling oil into the axis 1 gearbox on page 161 Refill oil in the gearbox 3 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1400000378 Foundry Plus Apply Mercasol on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 4 Con...

Page 624: ...ribed in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 8 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 Continues on next page 624 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Re...

Page 625: ... the section First test run may cause injury or damage on page 26 9 Product manual IRB 6700 625 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued ...

Page 626: ...2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 on page 586 Location of the axis 1 gearbox The axis 1 gearbox is located as shown in the figure xx1200001183 Summary of the replacement procedure This is a brief summary of the replacement procedure containing the major actions to be performed 1 Drain the axis 1 gearbox 2 Remove the cabling from the base...

Page 627: ...ender M12 3HAC16131 1 Lifting eye M12 3HAC16131 1 Lifting eye Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer SA 10 8 NA1 Lifting shackle Length 1 5 m Lifting capacity 2 000 kg Roundsling 1 5 m Length 1 m lifting capacity 1 000 kg Roundsling 1 m Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain M16 3HAC14457 4 Lifting eye M16 ...

Page 628: ...x and the frame 3HAB3772 160 O ring Located at the oil inlet under neath of gearbox 3HAB3772 97 O ring D 169 5x3 3HAB3772 111 circular pro file 3HAC054692 002 hexagon profile O ring i Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange Located in the frame on top of the protection tube 3HAC047474 001 Sealing ring Located on the sealing ring 3HAB3772 57 O ring Located in the frame ...

Page 629: ...tion routine on page 799 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the axis 1 g...

Page 630: ...axis 1 gearbox 6 xx1400002169 Loosen 14 of the 18 attachment screws as far as it is possible at this point The four screws that are left in place diagon ally located to each other work as an anvil for the axis 1 rotation when unscrewing the hub later on 7 Note It will not be possible to remove the screws completely at this point xx1400000722 Foundry Plus Cut the cable tie that hold the axis 1 and ...

Page 631: ...10 Robot position Note Action xx1200001132 Jog the robot into position Axis 1 no significance as long as the robot is secured to the foundation Axis 2 45 Axis 3 65 Axis 4 0 Axis 5 80 Axis 6 no significance 1 Continues on next page Product manual IRB 6700 631 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 70 IRB 6700 ...

Page 632: ...mplete arm system weighs 1300 Kg All lifting accessories used must be sized accord ingly 2 Lifting eye 3HAC16131 1 Fit a lifting eye to the wrist 3 Lifting eye 3HAC16131 1 Fit a lifting eye to the arm house with a fender washer underneath 4 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Continues on next page 632 Product manual IRB 6700 3HAC044266 001 R...

Page 633: ...g This will prevent the roundsling from gliding A B C D A Upper arm B Shackle C Roundsling D Hole in frame 1 Lifting shackle SA 10 8 NA1 Connect the roundsling with a shackle 2 Use caution and jog axis 3 slowly to stretch the roundsling Note Make sure the roundsling is stretched so it can carry the weight of the frame 3 Continues on next page Product manual IRB 6700 633 3HAC044266 001 Revision N C...

Page 634: ...DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 Continues on next page 634 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gea...

Page 635: ...for electrical power hydraulic pressure and air pressure are turned off 1 Lifting accessory chain 3HAC15556 1 Attach the lifting accessories 2 Lifting accessory motor 3HAC14459 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to R2 MP1 connector pin 2 pin 5 CAUTION The weight of the motor is 25 kg All lifting accessories used must be sized accordingly 4 Continu...

Page 636: ... use removal tools to help re move the motor 8 Removal tool M14 3HAC057339 004 Depending on motor type A or B see Identifying the motor by article number on page 819 Always use removal tools in pairs Lifting accessory chain 3HAC15556 1 Use caution and lift the motor straight up to get the pinion parted from the gear 9 Lifting accessory motor 3HAC14459 1 xx1200001072 Continues on next page 636 Prod...

Page 637: ...and air pressure are turned off 1 xx1300000561 Remove the base cover 2 xx1300000591 Disconnect connectors R1 MP R1 SMB 3 xx1400000366 If used disconnect the DressPack hoses in the base 4 Continues on next page Product manual IRB 6700 637 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Continued ...

Page 638: ...ough the protection tube in the base Note There is no need to pull out the DressPack cables at this point 7 Removing the cable harness in the base Note Action If equipped with DressPack pull out the DressPack cables through the protection tube and place them carefully over the balancing device 1 Continues on next page 638 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB Al...

Page 639: ...accessories 2 xx1700000320 Remove the two protection plugs or M16 screws on the left and right hand side of the frame and install guide pins in the holes Tip Lubricate the guide pins with some grease to make the frame slide better 3 xx1700000321 Guide pin M16x120 3HAC062397 001 Always use guide pins in pairs Continues on next page Product manual IRB 6700 639 3HAC044266 001 Revision N Copyright 201...

Page 640: ...move Use caution in order to avoid injury or damage 6 Note There will be some oil spill Put down the arm system on the floor 7 DANGER When the complete arm system is removed and 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 Continues on next page 640 Pro...

Page 641: ...mage the surface of the gearbox which is a sealing surface 2 CAUTION The weight of the gearbox and base together is 240 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 305 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 3 Continues on next page Product manual IRB 6700 641 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 ...

Page 642: ...o fit the four support legs 5 xx1000000364 Secure the support legs to the foundation using the same holes as to secure the base 6 Lower the base and gearbox to the support legs and secure 7 A Support legs 3HAC15535 1 Continues on next page 642 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 70 ...

Page 643: ...be from the base by removing the two attachment screws and pulling the tube downwards 9 Guide pin M20x180 3HAC048814 002 Fit two guide pins in opposite holes Tip Lubricate the guide pins with some grease to make the gearbox slide better 10 Always use guide pins in pairs xx1700000337 CAUTION The weight of the gearbox is 92 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 140 kg IRB...

Page 644: ... gearbox A new o ring must be installed to the new gearbox 13 xx1400002175 Make sure that the o ring between base and gearbox is not lost 14 Continues on next page 644 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Continued ...

Page 645: ...gearbox CAUTION Leave a couple of millimeters of space between the lug and the surface of the gear box This is done in order not to damage the surface of the gearbox which is a sealing surface 2 CAUTION The weight of the gearbox is 92 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 140 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 3 Continue...

Page 646: ...clean the o ring groove for the small o ring beneath the gearbox 6 O ring 3HAB3772 97 Replace the small o ring between base and gearbox with a new 7 Clean the new o ring put some grease on it and place it in the groove Continues on next page 646 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 7...

Page 647: ...re not fitted like this at this point it will be almost im possible to fit the screws later when the gearbox is resting on the base xx1400002176 Before the gearbox is being fitted place the attachment screws that will secure the gear box to the frame temporarily in their holes and lock screws with the old o ring This is done to prevent the screws from falling out Note Do not use the new o ring 1 C...

Page 648: ...g underneath the gearbox stays fitted correctly when the gearbox is being fitted Note Be careful not to collide with the calibration bracket at the base xx1400002178 3 O ring 3HAB3772 97 Lower the lifting accessory so that the chain is no longer stretched 4 Continues on next page 648 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replac...

Page 649: ... head holes all the way until they reach the bottom one using the torque wrench tighten ing the screws from beside the base 7 xx1700001374 Check the protection tube for damages Especially inspect the surface for the sealing ring Replace if damaged 8 Wipe the surfaces of the protection tube and the hole in axis 1 gearbox clean from any contamination 9 Put some grease on the protection tube 10 Conti...

Page 650: ...e sized accordingly 1 Stretch the lifting accessories to take the weight of base and gearbox 2 Unscrew the screws that secure the base to the support legs and lift up base and gearbox 3 Remove the support legs 4 Lower the base and gearbox to the founda tion 5 M24 x 100 installation on base plate foundation 8 pcs Secure the base to the foundation 6 550 Nm screws lubricated with Molykote 1000 600 72...

Page 651: ...S2V220 AC 3HAB3537 1 Wipe clean the o ring groove in the gearbox and apply some grease to the groove 4 O ring 3HAB3772 160 Wipe a new o ring clean apply some grease to it and replace the old one between base and frame with a new 5 Grease Shell Gadus S2V220 AC 3HAB3537 1 xx1700000336 Install the new o ring in the groove Note A new o ring also needs to be cleaned Continues on next page Product manua...

Page 652: ...ide pins with some grease to make the frame slide better 8 Always use guide pins in pairs xx1700000329 Refitting the arm system Note Action CAUTION The arm system weighs 1300 Kg All lifting accessories used must be sized accordingly 1 See Attachment points of lifting accessory on page 212 Make sure that all lifting accessories still is fitted correctly on the arm system 2 Continues on next page 65...

Page 653: ...ws are miss ing or in the wrong position 7 Lift the complete arm system and lower it slowly down over the guide pins until it is possible to insert the attachment screws manually CAUTION Do not lower the arm system completely at this stage The attachment screws must be fitted in two steps If not the complete arm system will risk resting on the attachment screws in the wrong position 8 Attachment s...

Page 654: ... is needed to be able to reach the attachment screws 12 Tightening torque 300 Nm Manually rotate axis 1 to a position where the remaining attachment screw can be secured 13 xx1700000320 Remove the guide pins and refit the two plastic protection plugs or the two M16 screws 14 xx1700000321 Continues on next page 654 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights...

Page 655: ...pairs CAUTION The motor weighs 25 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC14459 1 Apply the lifting accessory 3 Rotation tool 3HAB7887 1 Fit the rotation tool 4 Connect the 24 VDC power supply to re lease the brakes 5 To release the brakes connect the 24 VDC power supply as described in the list Connect to R2 MP1 connector pin 2 pin 5 Continues on ne...

Page 656: ... Lifting accessory motor 3HAC14459 1 xx1200001072 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 8 Tightening torque 50 Nm Use a bits extender to reach the screws Screws M10x30 Steel 12 9 Gle 603 Geo500 4 pcs xx1200001071 See Performing a leak down test on page 198 Perform a leak down test if not already done 9 Disconnect the 24 VDC power supply 10 Continues on n...

Page 657: ... cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 6700 657 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Continued ...

Page 658: ... 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 658 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB A...

Page 659: ... 9 Refilling oil in the gearbox Note Action See Changing oil axis 1 gearbox on page 158 Refill oil in the gearbox 1 Refitting the cable harness in the base Note Action xx1300000732 Run the cables through the protection tube in this order R1 MP R1 SMB If necessary lubricate the cables with grease to make them run more smoothly 1 Continues on next page Product manual IRB 6700 659 3HAC044266 001 Revi...

Page 660: ...1 Connect connectors R1 MP and R1 SMB 4 Screw dimension M6x16 Connect the earth cable 5 Washer dimension 6 4x17x3 xx1400000354 If used run the DressPack cables through the protection tube in the base 6 If used run the DressPack hoses through the protection tube in the base 7 Make sure that the hoses are running cor rectly and are not twisted Continues on next page 660 Product manual IRB 6700 3HAC0...

Page 661: ...tting the mechanical stop and remaining cable brackets Note Action xx1400000378 Foundry Plus Apply Mercasol on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 1 Continues on next page Product manual IRB 6700 661 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Co...

Page 662: ...screw 2 xx1200001237 Secure the cable harness inside the frame hole with a cable strap 3 xx1200001246 Refit the cable bracket on the frame 4 Continues on next page 662 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Continued ...

Page 663: ...n page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 26 2 Product manual IRB 6700 663 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbo...

Page 664: ...emove the cable harness and DressPack cable package if installed from the robot The described procedure requires free space on the floor in front of the frame with axis 1 in calibration position There should be enough space to place two pallets as shown in the figures in the procedures below DANGER The base shall be fitted to the foundation when performing this procedure Valid in both examples des...

Page 665: ...DressPack fitted is only a recommendation If it is not possible to put the arm system close enough to the robot and keep the cable harness partly fitted it may by necessary to remove the cable harness and DressPack in base and frame first Continues on next page Product manual IRB 6700 665 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gear...

Page 666: ...2 111 circular pro file 3HAC054692 002 hexagon profile O ring i Used on motor cover Located between the gearbox and the frame 3HAB3772 144 D 309 3x3 1 3HAB3772 48 D 319 3x5 7 O ring Size depends on gearbox model Measure the groove to see dimension of the o ring VK 28x7 3HAA2166 28 VK cover Locking liquid Loctite 2701 Continues on next page 666 Product manual IRB 6700 3HAC044266 001 Revision N Copy...

Page 667: ...7 1 Rotation tool Used to release the motor brakes 24 VDC power supply Used to push out the motor if neces sary Always use removal tools in pairs Size depending on motor type see Type A vs type B motors on page 819 3HAC057339 003 3HAC057339 004 Removal tool Used for putting down removed parts from robot Pallet Always use guide pins in pairs 3HAC13120 2 Guide pin M16x150 Always use guide pins in pa...

Page 668: ...stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be use...

Page 669: ...ompressed position using the Distance tool 3HAC030662 001 Note Action DANGER Do not use the Distance tool 3HAC030662 001 to unload or restore the pressure of the balancing device springs This tool is only used to lock the spring unit in a com pressed position after axis 2 has been jogged to 30 or 30 Fitting and removal of the tool shall only be done with axis 2 in this position To unload or restor...

Page 670: ...is used risking that the Distance tool is not properly fitted 5 Attachment screws M10 quality 12 9 4 pcs A xx0800000480 A Distance tool 3HAC030662 001 Turn the power on temporary 6 This is done to compress the balancing device springs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance ...

Page 671: ...B 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 1 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 2 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle and raise to unload the weight 3 Continues on next page Product manual IRB 6700 671 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserve...

Page 672: ...0001278 Remove the VK cover 1 xx1200001279 M16x70 quality steel 8 8 A3F Unscrew the attachment screw and washer 2 Continues on next page 672 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued ...

Page 673: ... procedure to jog the robot into position Valid for variants IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Note Action Note When jogging the axis 2 into position check that the balancing device ear and the ear on the lower arm is not colliding 1 Continues on next page Product manual IRB 6700 673 3HAC044266 001 Revision N Copyright 2013 ...

Page 674: ...ssories Valid for variants IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Note Action CAUTION The lower and upper arms together weigh accord ing to variants 510 kg All lifting accessories used must be sized accord ingly 1 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist 2 Continues on next page 674 Product manual IRB 6...

Page 675: ...ball joint housing on the outside of the lower arm instead 5 xx1200001253 Adjust the roundsling on the other side of the lower arm so that the roundsling runs on the left side of the most lower of the four bosses This will prevent the roundsling from gliding 6 Attach the roundsling to the shackle on the wrist 7 Stretch the roundsling between the wrist and the lower arm by slowly jogging the axis 3...

Page 676: ...equipped with DressPack unscrew the attachment screws of the bracket that holds the ball joint housings on the wrist The DressPack can stay fitted in the ball joint housing 11 Move the DressPack cable package over to the other side of where the lifting accessory will be attached to the shackle on the arm house 12 Continues on next page 676 Product manual IRB 6700 3HAC044266 001 Revision N Copyrigh...

Page 677: ...tched To release the brake connect the 24 VDC power supply 15 Connect to connector R2 MP2 axis 2 motor pin 2 pin 5 Disconnecting the axis 2 motor cables Use this procedure to disconnect the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700 677 3HAC044266 001 Revision N...

Page 678: ...present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 678 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued ...

Page 679: ...tor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 To release the brake connect the 24 VDC power supply 3 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 Bits extender 3HAC12342 1 xx1200001117 Remove the attachment screws Use a bits extender in order to reach the screws 4 Continues on next page ...

Page 680: ... power supply 8 CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 9 Carefully lift the motor out on the guide pins in order to get the pinion away from the gear and let it rest on the guide pins 10 Lifting accessory motor 3HAC15534 1 Fasten the lifting accessory Attach the lifting chain to the accessory and an over head crane 11 Lifting accessory chain 3HAC15556...

Page 681: ...he cabling from the ball joint housings 1 xx1300000540 Unscrew the attachment screws that secure the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp located on the inside of the lower arm by removing the attachment screws Note The screws are reached from outside the lower arm 2 Continues on next page Product manual IRB 6700 681 3HAC044266 001 Revision N Copyright 2013 2018 ABB Al...

Page 682: ...place them with guide pins Tip Lubricate the guide pins with some grease to make the lower arm slide better 1 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1300000788 xx1300000789 Remove all but one of the remaining attach ment screws that secure the lower arm to the axis 2 gearbox 2 Continues on next page 682 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 A...

Page 683: ...sized accordingly 2 xx1300000790 Use caution and remove the remaining screw and slowly lift away the lower and upper arm together Let the cabling run in the lower arm Make sure not to stretch any cabling CAUTION Use extreme caution when lifting the upper arm The cable harness is still partly con nected 3 Use a piece of wood or similar as a support under the arm house when the arm system is put dow...

Page 684: ...gearbox 4 Use two fully threaded attachment screws M12 as removal tools to press the gear box out of position 5 Lifting accessory gearbox Attach the lifting accessory to the gearbox 6 3HAC046112 001 i 3HAC046128 001 ii Use caution and let the gearbox slide out on the guide pins 7 Remove the gearbox 8 i IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 ii IRB 6700 200 2 60 IRB...

Page 685: ...he o ring and wipe it clean Note This must also be done on a new spare part 4 Wipe clean the contact surfaces from any contamination Note Also wipe clean the o ring groove 5 O ring 3HAB3772 144 D 309 3x3 1 3HAB3772 48 D 319 3x5 7 Check the condition of the o ring Replace if damaged 6 Located between the gearbox and the frame Size depends on gearbox model Measure the groove to see dimension of the ...

Page 686: ...th some grease to make the gearbox slide better 10 Guide pin M12x200 3HAC13056 4 Always use guide pins in pairs xx1700000445 Lift the gearbox and let it rest on the guide pins 11 Slide the gearbox into position 12 Continues on next page 686 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox IRB 6700 235 2 65 IRB...

Page 687: ... 70 IRB 6700 245 3 00 Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove Continues on next page Product manual IRB 67...

Page 688: ...for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page 688 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 Continued ...

Page 689: ...pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC15534 1 Apply the lifting accessory 3 Lifting accessory chain 3HAC15556 1 xx1200001120 Note Make sure the cable gland opening is turned the correct way 4 Lift the motor and put it on the guide p...

Page 690: ...o of the attachment screws and washers 11 Remove the guide pins and replace with the remaining attachment screws 12 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 13 Tightening torque 50 Nm Use a bits extender in order to reach the screws Screw dimension M10x30 Steel 12 9 Gle 603 Geo500 4 pcs xx1200001117 See Performing a leak down test on page 198 Perform a leak...

Page 691: ...se caution and slowly lift the lower and upper arm together 6 Make sure not to stretch any of the cables that the arm package is level when lifted Before putting the arms on the guide pins make sure that the hole pattern is matched and in the correct position for all screws 7 Rotation tool 3HAB7887 1 xx1300000819 If the hole pattern is not matching use the rotation tool and adjust 8 Continues on n...

Page 692: ...ers 12 Tightening torque M16 300 Nm Secure the lower arm to the axis 2 gearbox with its attachment screws 13 Disconnect the 24 VDC power supply 14 Remove the lifting accessories 15 Connecting the axis 2 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page 692 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB Al...

Page 693: ... axis 2 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 3 3HAB3772 111 circular profile 3HAC054692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Continues on next page Product manual IRB 6700 693 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox ...

Page 694: ...Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Refitting the cabling Use this procedure to refit the cabling Note Action Use caution and push the cable harness into the lower arm 1 Continues on next page 694 Product manual IRB 6700 3HAC044266 001 Revision N Copyright ...

Page 695: ...e product manual IRB 6700 DressPack For article number see References on page 10 xx1400000195 If robot is equipped with DressPack Place the cabling in the two ball joint housings on the lower arm and close the housings 4 Continues on next page Product manual IRB 6700 695 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox IRB 6700 235 2...

Page 696: ...sidue of Loctite in the screw hole of the shaft 5 Wipe all contact surfaces inside the recess clean from contamination 6 xx1300000784 Align the balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 7 A B C A xx1400000368 A Front link ear B Shaft C Mercasol red dotted lines Foundry Plus Apply Mercasol on the surfaces on the shaft and front ear 8 ...

Page 697: ...700002238 The item numbers refer to mark ings on the tools xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 11 Tightening torque 180 Nm xx1200001279 Secure the shaft with screw and washer 12 Continues on next page Product manual IRB 6700 697 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replaci...

Page 698: ...ease 15 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 xx1200001283 Refit the cable bracket if not already refit ted 2 Continues on next page 698 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 ...

Page 699: ...ismantle and mounting tool 3HAC028920 001 3 This is done in order to compress the spring unit inside the balancing device be fore refitting or removal of the distance tool Jog axis 2 to 30 or 30 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 A xx0800000480 A Distance tool 3HAC030662 001 Remove the dist...

Page 700: ... calibrate the robot 3 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 4 700 Product manual IRB 6700 3HA...

Page 701: ...res free space on the floor in front of the lower arm so that the upper and lower arm can be laid down with the cabling still attached to the robot There should be enough space to place two pallets on the floor If needed run axis 1 into a position that gives the required space DANGER The base shall be fitted to the foundation when performing this procedure Valid in both examples described below No...

Page 702: ...parts IRB 6700 IRB 6700Inv Axis 2 gearbox Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 156 Oil dispenser M12 3HAC16131 1 Lifting eye M16 3HAC14457 4 Lifting eye Continues on next page 7...

Page 703: ...rame so that the play in the motor does not need to be adjusted 3HAC046645 003 Aligning tool Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 3HAC046112 001 i 3HAC046128 001 ii Lifting accessory gearbox To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa Leak down tester Required if Calibration Pendulum ...

Page 704: ...le packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration...

Page 705: ...lock the balancing device springs in a compressed position using the Distance tool 3HAC030662 001 Note Action DANGER Do not use the Distance tool 3HAC030662 001 to unload or restore the pressure of the balancing device springs This tool is only used to lock the spring unit in a com pressed position after axis 2 has been jogged to 30 or 30 Fitting and removal of the tool shall only be done with axi...

Page 706: ...f more tightening torque than 45 Nm is used risking that the Distance tool is not properly fitted 5 Attachment screws M10 quality 12 9 4 pcs A xx0800000480 A Distance tool 3HAC030662 001 Turn the power on temporary 6 This is done to compress the balancing device springs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device...

Page 707: ...150 3 20 200 2 60 155 2 85 185 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 1 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 2 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle and raise to unload the weight 3 Continues on next page Product manual IRB 6700 707 3HAC044266 001 Revision N Copyri...

Page 708: ...f the VK cover and pull it out xx1200001278 Remove the VK cover 1 xx1200001279 M16x70 quality steel 8 8 A3F Unscrew the attachment screw and washer 2 Continues on next page 708 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 2 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Continued ...

Page 709: ...r 3HAC11731 1 xx1200001280 xx1200001281 Put down the balancing device and let it rest on the frame 4 Robot position Note Action Note When jogging the axis 2 into position check that the balancing device ear and the ear on the lower arm is not colliding 1 Continues on next page Product manual IRB 6700 709 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing...

Page 710: ...ering the robot working area 3 Attaching lifting accessories to the lower and upper arm Use this procedure to attach the lifting accessories Note Action CAUTION The lower and upper arms together weigh accord ing to variants 650 kg All lifting accessories used must be sized accord ingly 1 Lifting eye 3HAC16131 1 xx1400002106 Fit a lifting eye to the wrist 2 Continues on next page 710 Product manual...

Page 711: ... Place the roundsling beneath the securing screw With DressPack cable package installed Place the roundsling beneath the ball joint housing on the outside of the lower arm 4 Run the roundsling up and over the upper arm 5 xx1400000729 Connect both ends of the roundsling with a shackle 6 Stretch the roundsling between the upper and the lower arm by slowly jogging the axis 3 Note Make sure the rounds...

Page 712: ...04 Attach the Lifting accessory chain to an over head crane or similar then to the lifting eye in the arm house and to the lifting eye in the wrist 10 Raise the overhead crane to stretch the chains and roundslings 11 Verify that the roundsling between the wrist and the lower arm is stretched To release the brake connect the 24 VDC power supply 12 Connect to connector R2 MP2 axis 2 motor pin 2 pin ...

Page 713: ... the lower arm and lift away the cabling from the ball joint housings 1 xx1300000540 Unscrew the attachment screws that secure the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp located on the inside of the lower arm by removing the attachment screws Note The screws are reached from outside the lower arm 2 Continues on next page Product manual IRB 6700 713 3HAC044266 001 Revisio...

Page 714: ...e them with guide pins Tip Lubricate the guide pins with some grease to make the lower arm slide better 1 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1400002181 xx1400002182 Remove all but one of the remaining attach ment screws that secure the lower arm to the axis 2 gearbox 2 Continues on next page 714 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB A...

Page 715: ...ove the remaining screw and lift away the lower and upper arm together Let the cabling run in the lower arm Make sure not to stretch any cabling Note Two persons required One person to oper ate the overhead crane and one person to handle the arm system 3 Use a piece of wood or similar as a support under the arm house when the arm system is put down on the pallets 4 This is done in order not to dam...

Page 716: ...x1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 716 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 2 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Continued ...

Page 717: ...leasing the holding brakes of the motor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 To release the brake connect the 24 VDC power supply 3 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 Bits extender 3HAC12342 1 xx1200001117 Remove the attachment screws Use a bits extender in order to reach ...

Page 718: ...tools in pairs Disconnect the 24 VDC power supply 8 CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 9 Carefully lift the motor out on the guide pins in order to get the pinion away from the gear and let it rest on the guide pins 10 Lifting accessory motor 3HAC15534 1 Fasten the lifting accessory Attach the lifting chain to the accessory and an over head crane ...

Page 719: ...6 4 Always use guide pins in pairs xx1700000443 xx1700000444 Leave one of the upper attachment screws and remove the rest The remaining screw is used to prevent the gearbox from falling down 2 CAUTION The gearbox weighs 110 kg All lifting accessories used must be sized accordingly 3 Continues on next page Product manual IRB 6700 719 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights rese...

Page 720: ...150 3 20 ii IRB 6700 200 2 60 IRB 6700 155 2 85 IRB 6700 300 2 70 IRB 6700 245 3 00 Refitting the axis 2 gearbox Use these procedures to refit the gearbox Follow the order of the separate procedures according to the order they are presented CAUTION When performing these procedures the cable harness will still be fitted or partly fitted to the robot Use the utmost caution not to cause any damage to...

Page 721: ...ote This must also be done on a new spare part 4 Wipe clean the contact surfaces from any contamination Note Also wipe clean the o ring groove 5 Check the condition of the o ring 6 Replace if damaged Lubricate the o ring with some grease for a better fitting in the groove 7 Fit the o ring in the groove 8 xx1400000374 Foundry Plus Apply Mercasol on the surfaces shown in the figure 9 Continues on ne...

Page 722: ...de pin M12x200 3HAC13056 4 Always use guide pins in pairs xx1700000445 Lift the gearbox and let it rest on the guide pins 11 Slide the gearbox into position 12 Continues on next page 722 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 2 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Continued ...

Page 723: ...ration pin and bushing screws with dimension M12x80 should be used Screw quality 12 9 Gleitmo totally 32 pcs xx1500002118 Remove the lifting accessory 14 Remove the guide pins and fit the remain ing attachment screws 15 Tightening torque 120 Nm Secure the gearbox with its attachment screws 16 i IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 ii IRB 6700 200 2 60 IRB 6700 15...

Page 724: ...ts 2 Wipe clean the contact surfaces and the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 Continues on next page 724 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8...

Page 725: ... are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 2 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 2 Lifting...

Page 726: ...r box the gears may be damaged if excess ive force is used 9 Use caution and fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool Make sure that the motor pinion is properly mated to the gear of the gearbox Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit is facing the correct way 10...

Page 727: ...or to release the brakes of the motor 1 Rotation tool 3HAB7887 1 Fit the rotation tool if not already fitted 2 Guide pin M16x150 3HAC13120 2 Fit two guide pins in opposite holes in the axis 2 gearbox Tip Lubricate the guide pins with some grease to make the lower arm slide better 3 Always use guide pins in pairs xx1400002189 CAUTION The lower and upper arms together weigh 650 kg All lifting access...

Page 728: ...holes in the gear are unused 8 Slide the lower arm onto the guide pins when the hole pattern is matched and in the correct position for all screws 9 Slide the lower arm on to the guide pins 10 Use caution and move the arms into posi tion at the axis 2 gearbox on the guide pins 11 Rotate the axis 2 gearbox until the hole pattern is matching the holes in the lower arm Fit one attachment screw in one...

Page 729: ... VDC power supply 16 Remove the lifting accessories 17 Connecting the axis 2 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 6700 729 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the a...

Page 730: ...54692 002 hexagon pro file O ring axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 730 Product manual IRB 6700 3H...

Page 731: ...Use this procedure to refit the cabling Note Action Use caution and push the cable harness into the lower arm 1 xx1200001282 Refit the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp located on the inside of the lower arm Note The screws are reached from the outside of the lower arm 2 xx1200001283 Refit the cable bracket on the frame 3 Continues on next page Product manual IRB 67...

Page 732: ...tion if not already done 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 4 Lifting accessory chain 3HAC15556 1 Remove all residue of Loctite in the screw hole of the shaft 5 Wipe all contact surfaces insi...

Page 733: ...Foundry Plus Apply Mercasol on the surfaces on the shaft and front ear 8 xx1200001280 Lubricate the shaft and place it to the front ear Note Foundry Plus Do not lubricate surfaces where Mercasol is ap plied 9 Continues on next page Product manual IRB 6700 733 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 2 gearbox IRB 6700 300 2 70 IRB 6700...

Page 734: ... the tools xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 11 Tightening torque 180 Nm xx1200001279 Secure the shaft with screw and washer 12 xx1200001278 Fit the VK cover 13 Continues on next page 734 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 2 g...

Page 735: ... used to lock the spring unit in a compressed position after axis 2 has been jogged to 20 or 20 Fitting and removal of the tool shall only be done with axis 2 in this position To unload or restore a new balancing device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the hydraulic press tool Dismantle and mounting tool 3HAC028920 001 3 This is done ...

Page 736: ... 6 Attachment screws M10 quality 12 9 4 pcs xx1300000554 Refit the cover plate 7 Concluding procedure Note Action If the robot is equipped with DressPack refit the brackets of the ball joint housings on the wrist 1 Continues on next page 736 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 2 gearbox IRB 6700 300 2 70 IR...

Page 737: ...th Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 4 Product manual IRB 6700 737 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 R...

Page 738: ...e enough space to place two pallets in a row If needed run axis 1 into a position that gives the required space at the right hand side of the balancing device DANGER Do not unscrew the attachment screws that secure the robot to the foundation If unscrewed the robot will be unstable Location of the axis 3 gearbox The axis 3 gearbox is located as shown in the figure xx1300000515 Continues on next pa...

Page 739: ...is 3 gearbox Product manual spare parts IRB 6790 Consumables Note Article number Equipment etc Used to lubricate o rings 3HAB3537 1 Grease Mercasol 3110 Waxcoat Re commended drying time is 24h 3HAC034903 001 Rust preventive D 102x3 3HAB3772 107 O ring Used on motor flange D 169 5x3 3HAB3772 111 circular pro file 3HAC054692 002 hexagon profile O ring i Used on motor cover D 266 3x3 5 3HAB3772 145 O...

Page 740: ...obot Pallet Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Always use guide pins in pairs 3HAC13120 3 Guide pin M16x200 Used for rotating the axis 3 gearbox when refitting upper arm 3HAC067546 001 iv 3HAC067547 001 v 3HAC067545 001 vi Pinion Used to release the motor brakes 24 VDC power supply Leak down tester Required if Calibration Pendulum is the valid calibration method for the r...

Page 741: ...eted 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 799 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating ma...

Page 742: ...ER When releasing the holding brakes of the motor the upper arm will be movable and may fall down if not secured Verify that the upper arm is secured as previously de scribed before continuing 3 Release the holding brakes for the axis 3 motor to make the upper arm rest tightly against the mechanical stop 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to t...

Page 743: ...f the DressPack cable package if one is fitted and let it hang down together with the rest of the DressPack cable package 7 See Draining the axis 3 gearbox on page 171 Begin draining the gearbox 8 Put two pallets on the floor at the right hand side of the robot Note This position is only a recommendation If it is not possible to put the upper arm close enough to the robot and keep the cable harnes...

Page 744: ...hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 744 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 3 gearbox Continue...

Page 745: ...ed 1 DANGER When releasing the holding brakes of the motor the upper arm will be movable and may fall down if not secured Verify that the upper arm is secured as previously described before continuing 2 To release the brakes connect the 24 VDC power supply 3 Connect to connector R2 MP3 pin 2 pin 5 Bits extender 3HAC12342 1 xx1200001126 Unscrew the attachment screws that hold the motor Use a bits e...

Page 746: ... guide pins 8 CAUTION The motor weighs 26 kg All lifting accessories used must be sized accordingly 9 Lifting accessory motor 3HAC15534 1 Fasten the lifting accessory to the motor Attach the lifting chain to the accessory and an overhead crane 10 Lifting accessory chain 3HAC15556 1 xx1200001125 When the motor is hanging in the lifting accessory and the pinion no longer is mated to the gear let the...

Page 747: ... the cable harness upper arm and wrist on page 233 Use this procedure to loosen required cable brackets of the robot cable harness in order to get the longest possible length of the cable harness between the lower and upper arm Note Action xx1800000042 Unscrew the attachment screws that hold the axis 3 lower arm metal clamp the one closest to the axis 3 gearbox located on the inside of the lower a...

Page 748: ...cable bracket under the arm house 3 xx1300000544 Cut the cable tie at the cable fixing bracket Note If DressPack is fitted the cable fixing bracket is replaced by the cable guide xx1300001973 4 Continues on next page 748 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 3 gearbox Continued ...

Page 749: ...d with DressPack Open the two ball joint housings on the lower arm and lift away the cable harness from the ball joint housings 6 If the robot is equipped with DressPack 7 Lift the DressPack cable package at the arm house up and put the cable bracket on the cable guide where the velcro strap normally is fitted Secure the temporary position with a velcro strap or similar to ensure it will not fall ...

Page 750: ... a lifting eye to the wrist 2 Lifting eye 3HAC16131 1 Fit a lifting eye in the arm house with a fender washer underneath xx1400002196 3 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Lifting accessory chain 3HAC15556 1 xx1200001308 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in th...

Page 751: ...ent screws M12 in opposite holes and replace them with guide pins Note Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M12x200 3HAC13056 4 Always use guide pins in pairs xx1300000659 Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1300000747 Leave one of the remaining attachment screws fitted remove the o...

Page 752: ...maining attachment screws fitted remove the other screws 2 Preparations before removing the upper arm IRB 6700 300 2 70 IRB 6700 245 3 00 Note Action Guide pin M16x150 3HAC13120 2 Remove two attachment screws in opposite holes and replace them with guide pins Note Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M16x200 3HAC13120 3 Always u...

Page 753: ...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 Product manual IRB 6700 753 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 3 gearbox Continued ...

Page 754: ...059 Lift the upper arm and place it on the pre pared area CAUTION Only valid when the upper arm is removed due to replacement of the axis 3 gearbox If the cable harness is still fitted or partly fitted use caution when lifting the upper arm over to the other side of the robot in order not to cause any damage to the cable harness 3 Continues on next page 754 Product manual IRB 6700 3HAC044266 001 R...

Page 755: ... Use this procedure to remove the gearbox Note Action Guide pin M12x150 3HAC13056 2 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the gearbox slide better 1 Always use guide pins in pairs IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 xx1300001969 IRB 6700 200 2 60 IRB 6700 155 2 85 TBD...

Page 756: ...ly threaded screws and use them as removal tools 3 Remove the remaining attachment screw 4 Loosen the gearbox from its fitting position with the help of the removal tools but only pull it out on the guide pins a little DANGER There is a risk that the gearbox may glide out and fall down before the lifting access ory is applied if pulled out to far 5 Continues on next page 756 Product manual IRB 670...

Page 757: ...ting it slide out on the guide pins 9 Remove the gearbox 10 i IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 ii IRB 6700 200 2 60 IRB 6700 155 2 85 iii IRB 6700 300 2 70 IRB 6700 245 3 00 Refitting the axis 3 gearbox Use these procedures to refit the axis 3 gearbox Follow the order of the separate procedures according to the order they are presented Preparations before ref...

Page 758: ...e contact surfaces both on the gearbox and in the upper arm 7 Also wipe clean the o ring groove Lubricate the o ring with some grease 8 Fit the o ring in the groove 9 Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite holes Tip Lubricate the guide pins with some grease to make the gearbox slide better 10 Always use guide pins in pairs Lift the gearbox to the upper arm and let it rest on ...

Page 759: ...orque 120 Nm xx1300001970 Screws M12x70 xx1300001969 Remove the guide pins and replace with the remaining attachment screws and washers 2 Tightening torque 120 Nm Secure the remaining attachment screws 3 Remove the lifting accessory 4 Continues on next page Product manual IRB 6700 759 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 3 gearbox ...

Page 760: ...ws 2 Tightening torque 120 Nm Secure the remaining attachment screws 3 M12x70 Remove the lifting accessory 4 Securing the axis 3 gearbox IRB 6700 300 2 70 IRB 6700 245 3 00 Note Action Tightening torque 120 Nm Secure the gearbox with 28 of the 30 attach ment screws 1 M12x70 xx1400002193 Continues on next page 760 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights ...

Page 761: ...Action Wipe clean all contact surfaces 1 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1700001880 Foundry Plus Apply Mercasol on the surface on the lower arm as shown in the figure CAUTION Keep the sealing surfaces clean from Mer casol 2 Continues on next page Product manual IRB 6700 761 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved ...

Page 762: ... guide pins in opposite M12 holes in the axis 3 gearbox Tip Lubricate the guide pins with some grease to make the upper arm slide better Always use guide pins in pairs xx1400000361 Guide pin M16x150 3HAC13120 2 IRB 6700 300 2 70 IRB 6700 245 3 00 5 Guide pin M16x200 3HAC13120 3 Fit two guide pins in opposite M16 holes in the axis 3 gearbox Tip Lubricate the guide pins with some grease to make the ...

Page 763: ...d to the upper arm 4 Rotation tool In order to release the brakes connect the 24 VDC power supply Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm Pinion If the axis 3 motor is not installed to the upper arm 5 3HAC067546 001 i Use the pinion to rotate the axis 3 gearbox to find the correct pos...

Page 764: ...ed accordingly 1 See Attaching lifting accessories to the upper arm on page 228 Attach the lifting accessories if not already fitted 2 Lift the upper arm and put it on the guide pins 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool In order to release the brakes connect the 24 VDC power supply Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and ...

Page 765: ... 6700 300 2 70 IRB 6700 245 3 00 Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 360 kg IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 200 2 60 155 2 85 465 kg IRB 6700 300 2 70 245 3 00 All lifting accessories used must be sized accordingly 1 See Attaching lifting accessories to the upper arm on page 228 Attach the lifting accessories if not already fitted 2 Lift th...

Page 766: ...the guide pins and fit the two re maining screws 7 M16 tightening torque 300 Nm Secure the upper arm by tightening the at tachment screws 8 i IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 ii IRB 6700 200 2 60 IRB 6700 155 2 85 iii IRB 6700 300 2 70 IRB 6700 245 3 00 Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power h...

Page 767: ... the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page Product manual IRB 6700 767 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 3 gearbox Continued ...

Page 768: ...ent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 3 motor Use this procedure to secure the motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs CAUTION The motor weighs 26 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC155...

Page 769: ...damaged if excessive force is used 8 Use caution and push the motor in position while at the same time the motor pinion is slightly rotated 9 Pay attention to following points Mate the motor pinion properly to the gear of the gearbox Do not damage the motor pinion Screws M10x30 quality 12 9 Gleitmo Fit two of the attachment screws and wash ers 10 Remove the guide pins 11 Screws M10x30 quality 12 9...

Page 770: ...ries 1 Move the cable harness and DressPack back to the correct side of the robot 2 xx1800000042 Refit the axis 3 lower arm metal clamp the one closest to the axis 3 gearbox located on the inside of the lower arm Note The screw is reached from the outside of the lower arm 3 xx1300000541 Fasten the cable bracket on top of the arm house 4 xx1300000543 Fasten the cable bracket under the arm house 5 C...

Page 771: ...g bracket is replaced by the cable guide xx1300001973 6 xx1400000195 Refit the DressPack cable package into the ball joint housings on the lower arm and close them 7 Continues on next page Product manual IRB 6700 771 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 3 gearbox Continued ...

Page 772: ...nd opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page 772 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 3 gearbox Continued ...

Page 773: ...ng axis 4 3HAB3772 110 circular profile 3HAC054692 001 hexagon pro file xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 6700 773 3HAC044266 001 Revision N Copyrig...

Page 774: ... ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Refitting DressPack cable packages Note Action Remove the lifting accessory 1 xx1200001332 Fit the bracket of the DressPack cable package if one is fitted under the arm house with its screws 2 Continues on next page 774 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserve...

Page 775: ...arbox 1 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These...

Page 776: ... Product manual spare parts IRB 6790 Consumables Note Article number Equipment etc Used to lubricate o rings 3HAB3537 1 Grease D 102x3 3HAB3772 107 O ring Used on motor flange Used on motor cover 3HAC033489 001 3HAC044252 001 Gasket D 151 99x3 53 3HAB3772 58 O ring Used on gearbox Continues on next page 776 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserv...

Page 777: ...ructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read m...

Page 778: ...quipment fitted on the turning disc 4 xx1400000208 If installed remove the DressPack axis 6 support 5 xx1400000223 Jog the robot to Axis 1 No significance as long as the robot is secured to the founda tion Axis 2 25 Axis 3 20 Axis 4 0 Axis 5 55 Axis 6 10 6 Continues on next page 778 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 6 Replaci...

Page 779: ... Action xx1300000492 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 Remove the screws and washers that se cure the turning disc 1 xx1300002302 IRB 6700 200 2 60 IRB 6700 155 2 85 Remove the screws and washers that se cure the turning disc 2 Continues on next page Product manual IRB 6700 779 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 ...

Page 780: ...mo 16 pcs IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 M6x30 quality 12 9 Gleitmo 24 pcs IRB 6700 200 2 60 155 2 85 M8x50 quality 12 9 Gleitmo 16 pcs IRB 6700 300 2 70 245 3 00 xx1700001600 Unscrew the attachment screws that secure the axis 6 gearbox 1 Continues on next page 780 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 6 Replacing t...

Page 781: ... Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1300000828 Remove the o ring and wipe it clean Note The o ring needs to be cleaned also on a new spare part 2 Check the o ring 3 Replace if damaged Wipe clean the contact surfaces from any contamination 4 Also wipe clean the o ring groove Continues on next page Product manual...

Page 782: ...rbox Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 1 xx1700001601 Fit the gearbox to the wrist CAUTION Be careful not to damage motor pinion or gears 2 Continues on next page 782 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 4 Repair 4 8 6 Replacing the axis 6 gearbox Continued ...

Page 783: ...og axis 5 to horizontal position 5 See Filling oil into the axis 6 gearbox on page 186 Refill oil in the gearbox 6 Refitting the turning disc Note Action See Replacing the synchronization mark plate on page 368 If new turning disc spare part is installed verify that the correct synchronization mark plate for axis 6 is installed on the wrist 1 Wipe clean the contact surfaces 2 A B xx1400000385 Foun...

Page 784: ...achment screws M10x25 Steel 12 9 Gleitmo 603 9 pcs Secure the turning disc with its attachment screws and washers Washers 3 pcs xx1300002302 Tightening torque 70 Nm IRB 6700 300 2 70 IRB 6700 245 3 00 6 Attachment screws M10x25 Steel 12 9 Gleitmo 603 21 pcs Secure the turning disc with its attachment screws and washers Washers Steel 11x17x25 21 pcs xx1400002195 Continues on next page 784 Product m...

Page 785: ...in Calibrating with Axis Calibration method on page 798 General calibration information is included in section Calibration on page 787 DANGER Make sure all safety requirements are met when performing the first test run These are further described in First test run may cause injury or damage on page 26 3 Product manual IRB 6700 785 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserv...

Page 786: ...This page is intentionally left blank ...

Page 787: ...at is used for calibration of the robot Calibration position A 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 ca...

Page 788: ...rdinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions as well as absolute a...

Page 789: ...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 CalibWare Absolute Accuracy calibration To achieve a good positioning in the Cartesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculat...

Page 790: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 794 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and co...

Page 791: ...chronization marks and the synchronization position for each axis Synchronization marks IRB 6700 Axis 2 xx1300000869 Axis 1 xx1300000868 Axis 4 xx1300000871 Axis 3 xx1300000870 Continues on next page Product manual IRB 6700 791 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 792: ...rk plates xx1300000873 Axis 5 xx1300000872 xx1500000845 792 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 793: ...nes will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 Product manual IRB 6700 793 3HAC044266 001 Rev...

Page 794: ...tion Make sure the axes are positioned according to the correct calibration values not only according to the synchronization marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution counters are updated If on...

Page 795: ...ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page Product manual IRB 6700 795 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 796: ... calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 A screen is displayed tap Rev Counters en0400000771 4 Continues on next page 796 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 797: ...e updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury Ch...

Page 798: ...vable 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 inse...

Page 799: ... the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Note When calibrating the robot with the reference calibration routine the robot must be dressed with the same tools process cabling and any other equipment as when the reference values were created Update revolution counters Choose this routine to m...

Page 800: ...gs may cause severe 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 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection ...

Page 801: ...solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavi...

Page 802: ...ollows xx1500000890 Spare parts When calibration is not being performed a protective cover and an o ring should always be installed on the fixed calibration pin as well as a protective plug included a sealing in the bushing Replace damaged parts with new if needed Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protecti...

Page 803: ...re 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 brief overview of the calibration procedure sequence ...

Page 804: ...ant while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robots working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use...

Page 805: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 803 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and...

Page 806: ...alibration SafeMove needs to be unsynchronized The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine Safety controller not synchronized SafeMove message Note Action SafeMove generates the message Safety control ler not sync...

Page 807: ... Unsynchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page Product manual IRB 6700 807 3HAC044266 001 Revision N Copyright 2013 2018 ABB Al...

Page 808: ...ection cover and plug set 3HAC056806 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC056806 001 808 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 20...

Page 809: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools Product manual IRB 6700 809 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 810: ...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 791 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 Remove any calibration equipment fr...

Page 811: ... page 791 and Updating revolution counters on page 794 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 812: ...This page is intentionally left blank ...

Page 813: ...s Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance ...

Page 814: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 814 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 815: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 6700 815 3HAC044266 001 Revision N Copyright 2013 2018 ABB All r...

Page 816: ... procedures in the step by step in structions below DANGER Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Action on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissione...

Page 817: ... spring coils are cut from a safe distance and somewhat from above 2 DANGER The hole must be cut as specified in the figure Pieces of the spring can be thrown out from the cylinder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft 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 xx0700000...

Page 818: ...the springs is removed 6 Double check the number of coils cut and make sure all the tension in the springs is removed 818 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 6 Decommissioning 6 3 Decommissioning of balancing device Continued ...

Page 819: ...The article numbers specified are found in WebConfig Contact ABB Service for further assistance regarding which motor type is installed on the robot if needed Note The article numbers in the table can not be used for ordering spare parts The numbers are only used for identification of installed motors See Product manual spare parts IRB 6700 IRB 6700Inv for spare part numbers 245 3 00 300 2 70 155 ...

Page 820: ...xis Requirements notes for replacing type A motor with type B motor Motor replacement from type A to type B Robot axis Fully interchangeable 1 Fully interchangeable 2 Fully interchangeable 3 Fully interchangeable 4 Replacement to type B requires replacement of the heat protection plates that are fitted to the motor Partly interchangeable 5 A type B motor does not fit a wrist that is manu factured ...

Page 821: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 6700 821 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 822: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 823: ...R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 6700 823 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 8 Reference information 8 2 Applicable standards Continued ...

Page 824: ...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 824 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 825: ...ld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions ...

Page 826: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 827: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 6700 827 3HAC044266 001 Rev...

Page 828: ...sory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 1300 kg All lifting accessories used must be sized accord ingly 828 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB...

Page 829: ...it Comment Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hexagon headed screw M16x90 1 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm...

Page 830: ... sum of standard tools defined in the section Standard toolkit on page 829 and of special tools listed directly in the instructions and also gathered in this section Special tools Continues on next page 830 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 8 Reference information 8 7 Special tools ...

Page 831: ...13056 2 x x x x x Guide pin M12x200 3HAC13056 4 Guide pin M12x250 3HAC13056 4 x x x Guide pin M16x150 3HAC13120 2 x x x Guide pin M16x200 3HAC13120 3 Lifting accessories x x x x x x xx1200001241 Lifting accessory chain 3HAC15556 1 x x Lifting accessory motor 3HAC14459 1 x x x Lifting accessory motor 3HAC15534 1 x Lifting accessory gearbox 3HAC046112 001 ii 3HAC046128 001 iii x Lifting accessory ge...

Page 832: ... diameter 13 mm thickness 3 mm x x x Roundsling 1 5 m Length 1 5 m Lifting capacity 2 000 kg x x x x x x x x x x Roundsling 1 m Length 1 m lifting capacity 1 000 kg x x x x x Fork lift accessory set 3HAC047054 003 Press puller and unloading tools x x x AdapterM20 M16 3HAC12475 6 x x x x x Dismantle and mounting tool 3HAC028920 001 x x x x xx1400000726 Distance tool 3HAC030662 001 x x x x Hydraulic...

Page 833: ...ower supply x xx1700001659 Aligning tool 3HAC046645 003 x x x Long AllenKeySocketIN19L 6 140 x x x x x Bits extender 3HAC12342 1 x x x x x x x x x x x x x x Calibration Pendulum toolkit ix 3HAC15716 1 x x x x x x x x x x x x x x Calibration tool box Axis Calibration ix 3HAC055412 001 x xx1700002195 Guide for reduction gear 3HAC043870 009 x x x x x x x x x x Leak down tester x x x x Lock screw M16x...

Page 834: ...5 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRB 6700 200 2 60 IRB 6700 155 2 85 v IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 vi IRB 6700 200 2 60 IRB 6700 155 2 85 vii IRB 6700 300 2 70 IRB 6700 245 3 00 Included in Dismantle and mounting tool 3HAC028920 001 ix The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory Always use the same cali...

Page 835: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 6700 835 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 8 Reference information 8 8 Lifting accessories and lifting ...

Page 836: ...This page is intentionally left blank ...

Page 837: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 6700 837 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 9 Spare parts 9 1 Spare part lists and illustrations ...

Page 838: ...This page is intentionally left blank ...

Page 839: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 840: ...6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 840 Product manual IRB 6700 3HAC044266 001 Revision N Copyright 2013 2018 ABB All rights reserved 10 Circuit diagrams 10 1 Circuit diagrams ...

Page 841: ...ttery shutdown service routine 189 bearing balancing device front eye 192 brake release 85 brake release unit replacing 291 brakes testing function 34 BRU replacing 291 buttons for brake release 85 C cabinet lock 23 29 cable harness replacing 231 255 cable harness attachments 140 cabling robot 99 cabling between robot and controller 99 calibrating robot 798 roughly 794 calibrating robot 798 calibr...

Page 842: ...ipment 88 HRA 18 humidity operation 51 storage 51 I information labels location 142 inspecting additional mechanical stop 148 cable harness 140 dampers 152 information labels 142 mechanical stop 146 motor seal 116 inspecting balancing device 136 inspecting oil levels axis 1 118 axis 2 123 axis 3 126 axis 4 129 axis 5 131 axis 6 133 installation mechanical stop axis 1 97 installation on track motio...

Page 843: ...86 701 axis 1 motor 503 balancing device 461 battery 189 brake release unit 291 cable harness 231 255 gearbox axis 1 626 lower arm 377 mechanical stop pin 499 SMB unit 285 turning disc 365 upper arm 296 wrist 340 xx 67 479 requirements on foundation 50 responsibility and validity 17 restoring balancing device 496 restricting working range axis 1 97 revolution counters storing on FlexPendant 795 up...

Page 844: ... position enabling device 28 torques on foundation 49 track motion securing robot 83 transporting the robot 65 transport support 65 troubleshooting oil spills 194 turning disc replacing 365 type A motors 819 type B motors 819 U unloading balancing device 492 updating revolution counters 794 upper arm replacing 296 V validity and responsibility 17 velocity adjusting 109 verifying calibration 810 W ...

Page 845: ......

Page 846: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC044266 001 Rev N en Copyright 2013 2018 ABB All rights reserved Specifications subject to change without notice ...

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