Page 1 ABB Robotics Product manual IRB 6700...
Page 2 Trace back information: Workspace R13-2 version a3 Checked in 2013-10-15 Skribenta version 4.0.378...
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
2.4.4 Lifting the robot with roundslings ............... 2.4.5 Manually releasing the brakes ..............2.4.6 Orienting and securing the robot ............... 2.4.7 Loads ....................2.4.8 Fitting equipment to the robot ..............3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 6: Table Of Contents
Lifting the upper arm ................Complete robot ....................4.4.1 Removing the cable harness ..............4.4.2 Refitting the cable harness ............... 4.4.3 Replacing the SMB ................. 4.4.4 Replacing the brake release unit ............... 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 7: Table Of Contents
Weight specifications ..................Standard toolkit ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagrams About circuit diagrams ..................Index 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
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Page 9: Overview Of This Manual
Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 Reference to the circuit diagram for the robot. References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - IRB 6700 3HAC044268-001 Product specification - IRB 6700 3HAC044265-001 Circuit diagram - IRB 6700...
Page 11: Product Documentation, Irc5
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for IRC5 manipulator systems. Product manuals...
Page 12 Operating manual - Introduction to RAPID • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Trouble shooting IRC5, for the controller and manipulator. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 13: How To Read The Product Manual
Likewise certain work methods or general information, that is valid for several robot models, can be illustrated with pictures that show a different robot model that the one described in the current manual. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
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Page 15: Safety
Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section Safety related instructions on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 16: General Safety Information
• stopping functions Safety stops describes different types of • description of emergency stop stops. • description of safety stop • description of safeguarding 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 17: Safety In The Manipulator System
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...
Page 18: Safety Risks
ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the manipulator system.
Page 19 Removed cables to the measurement sys- WARNING If the internal cables for the measurement system have been disconnected during repair or maintenance, then the revolution counters must be updated. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 20 Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balan- cing device is potentially lethal! 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 21: Caution - Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 22: Safety Risks Related To Tools/Work Pieces
Unauthorized modifications of the originally delivered manipulator are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.
Page 23: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems to drop. • Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, etc., from falling due to gravity. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 24: Safety Risks During Operational Disturbances
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 25: Risks Associated With Live Electric Parts
The power supply unit for additional tools, or special power supply units for the machining process. • The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 26 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 27: Safety Actions
(see the section Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 28: Fire Extinguishing
1 Safety 1.2.4.2 Fire extinguishing 1.2.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 29: Emergency Release Of The Manipulator's Arm
Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury! 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 30: Brake Testing
3 Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 31: Risk Of Disabling Function "Reduced Speed 250 Mm/S
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" Note Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 32: Safe Use Of The Flexpendant
The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 33: Work Inside The Manipulator's Working Range
NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is always a risk that the manipulator will move unexpectedly when manipulator axes are moved using the enabling device or during other work inside the manipulator’s working range. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 34: Safety Stops
Emergency stop should not be used for normal program stops as this causes extra, unnecessary wear on the manipulator. For how to perform normal program stops, see section Stopping programs in Operating manual - IRC5 with FlexPendant. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 35 Dual Cabinet Controller). There can also be other types of emergency stops on your manipulator. Consult your plant or cell documentation to see how your manipulator system is configured. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 36: Safety Related Instructions
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 37 1.3.1 Safety signals in the manual Continued Symbol Designation Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 38: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 39 Pressing this button will release the brakes. This means that the manipulator arm can fall down. xx0900000808 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened. xx0900000810 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 40 Risk of crush injuries. xx0900000817 Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 41 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 42 Symbol Description Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 43: Danger - Moving Manipulators Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the manipulator be- fore pressing the start button. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 44: Danger - First Test Run May Cause Injury Or Damage
Pay special attention to the function of the part previously serviced Collision risks CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 45: Warning - The Brake Release Buttons May Be Jammed After Service Work
Make sure none of the buttons are jammed in the tube. If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes! 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 46: Danger - Make Sure That The Main Power Has Been Switched Off
Note/illustration Switch off the main switch on the Drive Module. xx0600002783 K: Main switch, Drive Module Switch off the main switch on the Control A: Main switch, Control Module Module. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 47: Warning - The Unit Is Sensitive To Esd
Location of wrist strap button The location of the wrist strap button is shown in the following illustration. IRC5 The wrist strap button is located in the top right corner. xx1300000856 Wrist strap button 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 48: Warning - Safety Risks During Handling Of Batteries
Risk of fire or explosion. page Use safety glasses when handling the batteries. In the event of leakage, wear gloves and chemical apron. In the event of fire, use self-contained breathing apparatus. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 49: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Do not present in the gearbox, causing overfill the gearbox when filling. lubricant to spray from the xx0100000002 opening. Possible pressure build-up in gearbox Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 51: Installation And Commissioning
If the robot is connected to power, always make sure that the robot is connected to protective earth before starting any installation work! For more information see: • Product manual - IRC5 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 52: Unpacking
It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation Installation craftsmen working with an ABB robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 54 Maximum tilt 0° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Minimum resonance 22 Hz frequency Storage conditions, robot...
Page 55: Working Range
Allowed working area for axis 6 related to axis 5 position is shown in the figure below. -120 -110 -100 -120 -150 -180 -210 -240 -270 Axis 6 xx1300001587 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 56 2 Installation and commissioning 2.2.2 Working range Continued Illustration, working range IRB 6700 - 235/2.65 This illustration shows the unrestricted working range of the robot. 1187 1908 2650 xx1300000281 Robot type Handling capacity (kg) Reach (m) IRB 6700 2.65 Illustration, working range IRB 6700 - 205/2.80 This illustration shows the unrestricted working range of the robot.
Page 57 2 Installation and commissioning 2.2.2 Working range Continued Robot type Handling capacity (kg) Reach (m) IRB 6700 2.80 Illustration, working range IRB 6700 - 175/3.05 1527 1109 2314 3056 xx1300000283 Robot type Handling capacity (kg) Reach (m) IRB 6700 3.05...
Page 58 2 Installation and commissioning 2.2.2 Working range Continued Illustration, working range IRB 6700 - 150/3.20 1604 1067 2445 3200 xx1300000284 Robot type Handling capacity (kg) Reach (m) IRB 6700 3.20 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 59 IRB 6700 - 235/2.65 920 mm 2650 mm IRB 6700 - 205/2.80 958 mm 2794 mm IRB 6700 - 175/3.05 1109 mm 3056 mm IRB 6700 - 150/3.20 1067 mm 3200 mm 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 60: Risk Of Tipping/Stability
This figure shows the robot in its shipping position, which also is a recommended transport position. xx1300000356 WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 61: Main Dimensions
IRB 6700 - 235/2.65 2300 1135 1670 1182.5 IRB 6700 - 205/2.80 2445 1280 1670 1182.5 IRB 6700 - 175/3.05 2300 1135 2080 1592.5 IRB 6700 - 150/3.20 2445 1280 2080 1592.5 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 62: On-Site Transportation
Transportation in any other way than method 1 or 2 can seriously damage the robot. If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim.
Page 63 Always read and follow the instructions in section Pre-installation procedure on page 52 Method 2 Transportation according to method 2 is approved by ABB, if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
Page 64 2 Installation and commissioning 2.3.1 Robot transportation precautions Continued IRB 6700 xx0800000037 Transport Support Hexagon socket head cap screw M16x140 Threaded bar M10x200 Nut M10 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 65 2 Installation and commissioning 2.3.1 Robot transportation precautions Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 6700 xx0800000040 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 66 Always use the recommended transport support when transporting a robot with tool. IRB 6700 ( 10 ) ( 52 ) ( 62 ) IRB6700 2.65 3.05 Lower 1135 1280 1135 1280 arm L 1000 1160 630 xx1300001603 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 67: Securing The Robot
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. Securing the robot xx0800000062 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 68 This can seriously damage the robot. Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see the section Manually releasing the brakes on page 82 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 69: On-Site Installation
Hex socket head cap screw M20x60 quality steel 8.8-A3F (2 pcs per fork lift device) Required equipment Equipment Art. no. Note Fork lift device set 3HAC047054-002 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 70 M20x60, quality 8.8)! xx1300001602 A Fork lift pocket B Attachment screw M20x60 quality 8.8 (2 pcs x 4). Insert fork lift forks into the pock- ets. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 71 2.4.1 Lifting robot with fork lift Continued Action Note CAUTION The IRB 6700 robot weighs 1300 All lifting accessories used must be sized accordingly! CAUTION Lifting the robot with fork lift shall only be done with all four fork lift...
Page 72: Lifting The Base Plate
Fit lifting eyes in specified holes. Shown in figure Hole configur- ation on page Fit lifting slings to the eyes and to the lifting accessory. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 73: Securing The Base Plate
0,25 c (2x R22,5) 3x 90º xx1000001053 E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 74 R50 (12x) 4x Ø18. 325 (2x) 241,1 250,5 225,8 138,4 109,1 xx1000001054 ¤ Four holes for alternative clamping, 4x Ø18 Color: RAL 9005. Thickness: 80-100 µm Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 75 Base plate, grooves and holes The illustration below shows the orienting grooves and guide sleeve holes in the base plate. xx0300000045 Guide sleeve holes (2 pcs) Orienting grooves (3 pcs) Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 76 See references to to the tools required. these procedures in the step-by- step instructions below. Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended bolt quality and dimen- Hilti HDA-P, M20 x 250/50 (maximum thickness of...
Page 78: Lifting The Robot With Roundslings
Do not strain! IRB 6700 - 235/2.65 IRB 6700 - 205/2.80 IRB 6700 - 175/3.05 2.5 m IRB 6700 - 150/3.20 2.5 m Lifting eye, M20 (4 pcs) Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 79 • Axis 5: +70° • Axis 6: no significance. WARNING The robot is likely to be mechanically un- stable if not secured to the foundation! xx1300000356 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 80 Attach a securing roundsling at the rear Roundsling, 2 m according to figure. Note The securing sling must not be strained at lifting. It only secures for tipping. xx1300001573 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 81 2.4.4 Lifting the robot with roundslings Continued Action Note Attach a securing roundsling at the front IRB 6700 - 235/2.65 and IRB 6700 - according to figure. 205/2.80: Roundsling, 2 m IRB 6700 - 175/3.05 and IRB 6700 - Note 150/3.20: Roundsling, 2.5 m...
Page 82: Manually Releasing The Brakes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpec- ted ways! Make sure no personnel is near or beneath the robot arm! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 83 DANGER Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 84: Orienting And Securing The Robot
The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate/foundation. Suitable screws, lightly lubricated: M24 x 100 Quantity: 4 pcs Quality: Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 85 Fit the bolts and washers in the base attachment Specified in Attachment screws on holes. page Note Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 86: Loads
Operating manual - IRC5 with FlexPendant Stop time and braking distances Robot motor brake performance depends on any loads attached. For information about brake performance, read the product specification for the robot. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 87: Fitting Equipment To The Robot
R is the radius (m) from the center of axis 1 • M4 is the total mass (kg) of the equipment including bracket and harness (≤ 250 kg) xx1300000262 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 88 M1 ≤ 50 kg with a distance ≤ 500 mm from the center of gravity in the axis-3 extension. xx1000000417 Mass center xx1300000866 Center of gravity 50 kg Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 89 B - B xx1300000263 Allowed position for attachment holes, M12 through. Be careful not to touch the cables when drilling. Smallest circumscribed radius axis 4, R=216 mm Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 90 2x M8 12 Axis 5 xx1300000264 R= 456 IRB 6700-235/2.65, IRB 6700-175/3.05 = 433 mm IRB 6700-205/2.80, IRB 6700-150/3.20 = 438 mm IRB 6700-235/2.65, IRB 6700-175/3.05 = 418 mm IRB 6700-205/2.80, IRB 6700-150/3.20 = 438 mm IRB 6700-235/2.65, IRB 6700-175/3.05 = 403 mm IRB 6700-205/2.80, IRB 6700-150/3.20 = 438 mm...
Page 91 2 Installation and commissioning 2.4.8 Fitting equipment to the robot Continued Tool flange, standard Below is the standard tool flange. 11x M12 0.05 B - B xx1300000280 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 92 Continued Tool flange, LeanID Below is the tool flange for option 780-4, LeanID. 200 h8 11x M12 0,3 D E 12 H7 0,05 D 100 H7 C - C xx1300000290 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 93: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 94: Mechanically Restricting The Working Range Of Axis 1
Mechanical stop pin axis-1 Required equipment Equipment, etc. Art. no. Note Movable mechanical stop set, axis 1 3HAC044287-001 Includes attachment screws and (15°) an assembly drawing. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 95 If the mechanical stop pin is deformed after a hard collision, it must be replaced! Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 96: Electrical Connections
3HAC026787-001 15 m 3HAC026787-002 22 m 3HAC026787-003 30 m 3HAC026787-004 Robot cable, signals Signal cable length (shielded cable) Article number 3HAC2493-1 15 m 3HAC2530-1 22 m 3HAC2540-1 30 m 3HAC2566-1 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 97: Installation Of Options
2 Installation and commissioning 2.7.1 Installing the signal lamp (option) 2.7 Installation of options 2.7.1 Installing the signal lamp (option) Signal lamp See the assembly instruction delivered with the signal lamp. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
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Page 99: Maintenance
Safety on page 15 before performing any service work! Note If the IRB 6700 is connected to power, always make sure that the IRB 6700 is connected to protective earth before starting any maintenance work! For more information see: •...
Page 100: Maintenance Schedule And Expected Component Life
3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 6700: • Calendar time: specified in months regardless of whether the system is running or not.
Page 101: Maintenance Schedule
Inspecting the robot harness on page 122 Inspection, information labels Inspecting the information labels on page 124 Inspecting, mechanical stop Inspecting the dampers pin, axis 1 on page 128 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 102 The battery is to be replaced at given maintenance interval or at battery low alert. iv Always lubricate the front eye bearing after refitting the shaft of the balancing device. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 103: Expected Component Life
Deviations from this cycle will result in differences in expected life! The SIS for an IRC5 system is described in the Operating manual - Service Information System. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 104: Inspection Activities
Information about the oil is found in Technical reference manual - Lubrica- tion in gearboxes. Required documents Document name Document number Technical reference manual - Lubrication in gearboxes 3HAC042927-001 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 105 Open the oil plug. xx1200000950 Check the oil level. Required oil level is: 58 mm ± 5 mm below the sealing surface of the oil plug.. xx1300000692 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 106 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 107: Inspecting The Oil Level In Axis-2 Gearbox
Information about the oil is found in Technical reference manual - Lubrica- tion in gearboxes. Required documents Document name Document number Technical reference manual - Lubrication in gearboxes 3HAC042927-001 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 108 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 109: Inspecting The Oil Level In Axis-3 Gearbox
Inspecting the oil level in axis-3 gearbox Use this procedure to inspect the oil level in the gearbox. Action Note Run the robot to calibration position. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 110 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 111: Inspecting The Oil Level In Axis-4 Gearbox
Inspecting the oil level in axis-4 gearbox Use this procedure to inspect the oil level in the gearbox. Action Note Run the robot to calibration position. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 112 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 113: Inspecting The Oil Level In Axis-5 Gearbox
Run the robot to calibration position. DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 114 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 115: Inspecting The Oil Level In Axis-6 Gearbox
The procedure includes two alternative positions for axis 5, where one of the positions makes it possible to use the filling plug as a level plug. Action Note Run the robot to calibration position. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 116 Technical reference manual - Lubrication in gearboxes. Further information about how to drain or fill with oil is found in section Changing oil, axis-6 gearbox on page 161. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 117 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 118: Inspecting The Balancing Device
The figure also shows the inspection points, further described in the instructions. xx1300000413 Piston rod (inside balancing device) Link ear Rear attachments of the balancing device (rear bearing) Required tools Visual inspection, no tools are required. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 119 The front ear of the balancing device is lubricated with grease. Leaks at o-rings, sealings etc. are not acceptable and must be attended to immediately to avoid damage to the bearing. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 120 Required material on page 119. Replacement of the complete bearing is also described in section Replacing the balancing device on page 354. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 121 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. xx1300000423 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 122: Inspecting The Cable Harness
3.3.8 Inspecting the cable harness Location of cable harness The cable harness is located as shown in the figure. xx1300001096 Required tools Visual inspection, no tools are needed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 123 Remove any objects that may cause pos- sible cable chafing. Replace damaged cabling, if any. xx1300001094 Replace the cable harness if wear, cracks Detailed in Removing the cable harness on or damage is detected. page 191. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 124: Inspection, Information Labels
These figures show the location of the information labels to be inspected. The symbols are described in section Safety symbols on manipulator labels on page Illustration 1 of 2 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 125 Instruction label Before dismantling see product manual xx0900000816 Instruction label Lifting of robot IRB 6700, m = 1160 - 1600 kg / 2557 - 3527 lbs 570 55 570 55 1x, 2000 kg, 2 m/2,5 m 1x, 2000 kg, 2 m...
Page 126 Heat xx1300001087 Warning label Tip risk when loosening bolts 3HAC 9191-1/02 xx1300001088 Warning label Moving robot Shut off with handle Before dismantling see product manual xx1300001089 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 127 Check the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 565. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 128: Inspecting, Mechanical Stop Pin, Axis 1
Location of mechanical stop pin The mechanical stop axis 1 is located at the base as shown in the figure. xx1200001073 Required equipment Visual inspection, no tools are required. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 129 If the mechanical stop pin is bent or damaged, it must be replaced! Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 130: Inspecting, Additional Mechanical Stops
Attachment screws M12x70 quality 12.9 Gleitmo 603 and washers • Document for mechanical stop Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 131 If any damage is detected, the mechanical stops Art. no. is specified in Required must be replaced! equipment on page 130. Correct attachment screws: • M12x70 quality 12.9 Gleitmo 603 (2 pcs per additional mechanical stop) 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 132: Inspecting The Fork Lift Device Set
Hex socket head cap screw M20x60 quality steel 8.8-A3F (2 pcs per fork lift device) Required equipment Equipment Art. no. Note Fork lift device set 3HAC047054-002 Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 133 Art. no. is specified in Required attachment screws must be replaced! equipment on page 130. Correct attachment screws: • M12x70 quality 12.9 Gleitmo 603 (2 pcs per additional mechanical stop) 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 134: Inspecting The Dampers
• hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 135 B Axis-3 damper, 2 pcs If any damage is detected, the damper must be Spare part number is found in Product replaced with a new one! manual, spare parts - IRB 6700. Attachment screws: M6x60. Locking liquid: Loctite 243. 3HAC044266-001 Revision: -...
Page 136: Inspecting, Signal Lamp (Option)
Checking whether the signal lamp is broken. equipment on page 136. If so, replace it. • Checking cable connections. • Checking the cabling. Replace the cabling if a fault is detected. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 137: Replacement/Changing Activities
In order to always get the latest information of updates about lubrication in gearboxes, always check on ABB Library for the latest revision of the manual. A new revision will be published on ABB Library immediatly after any updates.
Page 138: Changing Oil, Axis-1 Gearbox
One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 137. Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 139 Remove the protective cap from the nipple of the oil hole and connect the oil dis- penser. xx1200000948 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 140 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 141 Type of oil and total amount is detailed in penser. Technical reference manual - Lubrication in gearboxes. Note The amount of oil to be filled depends on the amount previously being drained. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 142 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 143: Changing Oil, Axis-2 Gearbox
One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 137. Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 144 Remove the protective cap from the nipple of the oil hole and connect the oil dis- penser. xx1200000951 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 145 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 146 Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. Note The amount of oil to be filled depends on the amount previously being drained. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 147 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 148: Changing Oil, Axis-3 Gearbox
Content is defined in section Standard toolkit on page 559. Required documents Document name Document number Note Technical reference manu- 3HAC042927-001 al - Lubrication in gearboxes Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 149 Remove the protective cap from the nipple of the oil hole and connect the oil dis- penser. xx1200000954 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 150 Before proceeding, please read the safety information in the section WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 151 109. Remove the oil dispenser and refit the protective cap to the nipple. Refit the level plug. Tightening torque: 24 Nm Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 152 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 153: Changing Oil, Axis-4 Gearbox
Technical reference manu- 3HAC042927-001 al - Lubrication in gearboxes Draining the axis-4 gearbox Use this procedure to drain the gearbox. Action Note Run the robot to calibration position. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 154 WARNING Used oil is hazardous material and must be disposed of in a safe way. See section Decommissioning on page 545 for more in- formation. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 155 Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. Note The amount of oil to be filled depends on the amount previously being drained. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 156 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 157: Changing Oil, Axis-5 Gearbox
Technical reference manu- 3HAC042927-001 al - Lubrication in gearboxes Draining the axis-5 gearbox Use this procedure to drain the gearbox. Action Note Run the robot to calibration position. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 158 Used oil is hazardous material and must be disposed of in a safe way. See section Decommissioning on page 545 for more in- formation. Refit the oil plug. Tightening torque: 24 Nm. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 159 More information is found in Inspecting the oil level in axis-5 gearbox on page 113. Refit the oil plug. Tightening torque: 24 Nm Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 160 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 161: Changing Oil, Axis-6 Gearbox
Technical reference manu- 3HAC042927-001 al - Lubrication in gearboxes Draining the axis-6 gearbox Use this procedure to drain the gearbox. Action Note Jog the robot to calibration position. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 162 The fill hole is opened to speed up the drainage. xx1200000963 Remove the oil plug from the drain hole and let the oil run into the vessel. xx1200000962 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 163 Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. Note The amount of oil to be filled depends on the amount previously being drained. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 164 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 165: Replacing The Smb Battery
Required tools Equipment Article number Note Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 166 Pull out the battery and disconnect the battery cable. Remove the SMB battery. Battery includes protection circuits. Only replace with a specified spare part or with an ABB- ap- proved equivalent. xx1200001069 Continues on next page 3HAC044266-001 Revision: -...
Page 167 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 168: Lubrication Activities
O-ring 85x3 Spherical roller bearing Washer Consumables Equipment, etc. Art. no. Note Grease 3HAC042534-001 Optimol PD0, 50 ml Used for lubrication of the spherical roller bearing. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 169 Unscrew both screws in link ear and fill the Grease: 3HAC042534-001 bearing with grease from the upper hole until the grease appears in the lower hole. xx1300000783 Refit the two screws and wipe clean from residual grease. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 170: Cleaning Activities
Perform according to section Cleaning with water and steam on page 170. Cleaning with water and steam Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus, Wash and Foundry Prime. Equipment, etc. Note Vacuum cleaner...
Page 171 Never point the water jet at connectors, joints, sealings, or gaskets! • Never use compressed air to clean the robot! • Never use solvents that are not approved by ABB to clean the robot! • Never spray from a distance closer than 0.4 meters! •...
Page 172 This page is intentionally left blank...
Page 173: Repair
Make sure to read through the chapter Safety on page 15 before commencing any service work. Note If the IRB 6700 is connected to power, always make sure that the IRB 6700 is connected to earth before starting any repair work. For more information see: •...
Page 174: General Procedures
The test is complete. Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 175: Mounting Instructions For Bearings
• During operation, the bearing should be filled to 70-80% of the available volume. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 176 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. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 177: Mounting Instructions For Seals
Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 178 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 179: Attaching Lifting Accessories
The complete arm system consists of the following parts of the robot: • upper arm • wrist • lower arm • frame. Attachment points of lifting accessory Required tools Equipment, etc. Article number Note Lifting eye 3HAC16131-1 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 180 Attaching the lifting accessories Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 181 All lifting accessories used must be sized accord- ingly! Run a roundsling through the hole in the frame. Roundsling, 1.5 m: Length: 1.5 m. Lifting capacity: 1,000 kg. xx1200001209 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 182 (or similar) and then to the lifting 3HAC15556-1 eye in the arm house and to a roundsling run Roundsling, 1 m: Length: 1 m. Lift- through the wrist. ing capacity: 1,000 kg. xx1200001236 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 183: Lower And Upper Arm Unseparated
Roundsling, 1.5 m Length: 1.5 m. Lifting capacity: 1,000 Roundsling, 1 m Length: 1 m. Lifting capacity: 1,000 kg. Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en- closed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 184 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 185 Use the ball joint housing in the same way. xx1200001251 CAUTION The lower and upper arms together weigh 335 kg. All lifting accessories used must be sized accord- ingly! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 186 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1 washer underneath. Fender washer: Outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. xx1200001134 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 188: Lifting The Upper Arm
Jog the robot to the position: • Axis-1: No significance • Axis-2: -65° • Axis-3: +65° • Axis-4: Calibration position • Axis-5: No significance • Axis-6: No significance xx1200001255 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 189 (or similar) and then to the lifting eye in the arm house and in the wrist. xx1200001308 Raise the lifting accessories to take the weight of the upper arm. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 190 Release the brakes in order to find the most level lifting position of the upper arm as possible, before lifting. In order to release the brakes, connect the 24 VDC power supply 24 VDC power supply. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 191: Complete Robot
The cable harness is located as shown in the figure. xx1300000555 Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 192 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 193 Use this procedure to open the wrist and access the axis-5 and axis-6 motor cables. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 194 • - = pin 5 xx1200001081 Remove the wrist cover. xx1300000486 Cut the cable straps that hold the cable harness to the heat protection plate. xx1300000489 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 195 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and re- move the motor cover. xx1200001080 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 196 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Disconnect the motor cables. xx1200001066 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 197 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 198 Removing the cable harness - wrist and upper arm Action Note If used, remove the DressPack cover with the tube guiding ring fitted, by unscrewing the attachment screws. xx1200000045 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 199 This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 200 Note The screws are reached from outside the upper arm! xx1300000592 Remove the armhouse metal clamp. xx1300000543 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 201 If DressPack is fitted, the cable fixing bracket is replaced by the cable guide. xx1300001973 xx1300000544 Remove the metal clamp on top of the armhouse. xx1300000541 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 203 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the base cover. xx1300000561 Remove connectors in the base: • R1.MP • R1.SMB xx1300000591 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 204 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 205 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 47 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 206 WARNING - The unit is sensitive to ESD! on page 47 Use caution and remove the connectors X8, X9 and X10 from the brake release board. xx1300000670 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 207 If used, remove the metal clamp that hold the DressPack on the frame. Cut the cable tie that hold the cable har- ness on the frame. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 208 SMB unit, and remove the SMB unit. xx1300000730 Put the SMB unit in an ESD bag until it shall be refitted. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 209 Use caution and pull out the cable harness from the SMB recess. xx1300000560 Use caution and pull out the cable harness through the hole in the frame. xx1300000593 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 210 Note The screws are reached from the outside of the lower arm. xx1200001282 Use caution and pull the cable harness out of the lower arm. xx1300000733 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 211: Refitting The Cable Harness
See Product manual, spare parts - IRB 6700. Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 212 This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 213 Check the o-ring located on the SMB/BU O-ring, 21522012-429 cover. Replace if damaged. Wipe clean the contact surfaces of the cover as well as the hole it shall fit in. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 214 Do not tighten the screws fully! It must still be possible to adjust the position of the cable harness by rotating the SMB/BU cover in its hole a little. xx1300000655 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 215 SMB/BU re- cess. xx1300000655 If used, fit the bracket that hold the DressPack to the frame. Fit the cable harness to the frame with a cable tie. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 216 • Make sure that the R1.MP will be on the left side. xx1300000736 Make sure that the markings on the cables are facing upwards when connected. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 217 Make sure that the hoses are running cor- rectly and are not twisted! If used, connect the DressPack cable package on the base plate. xx1200000052 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 218 WARNING - The unit is sensitive to ESD! on page 47 Connect the battery cable to the SMB unit. xx1300000729 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 219 If disconnected, reconnect the connectors X8, X9 and X10 to the brake release board. xx1300000670 Pull out the battery cable through the recess for the battery. xx1300000834 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 220 Reconnecting the axis-1 and axis-2 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 221 The threads will otherwise be damaged. Note Make sure the o-ring is undamaged and properly fitted! xx1200001135 Make sure that the covers are tightly sealed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 222 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. xx1300000558 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 223 (if not already done), to avoid damaging them during the continued pro- cedure. This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 224 Do not run the cable harness into the DressPack tube! xx1300000739 A Tube for DressPack (LeanID) Fit the cable guide. xx1300000657 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 225 Refit the metal clamp axis-4 inside the arm tube. Note The screws are reached from outside the upper arm! xx1300000592 Refit the side cover. xx1300000557 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 226 If used, refit the tube containing the DressPack into the insert. xx1300000658 The figure show IRB 6640. If used, refit the cover with the tube guiding ring fitted. xx1200000045 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 227 Connecting the axis-3 and axis-4 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 228 The threads will otherwise be damaged. Note Make sure the o-ring is undamaged and properly fitted! xx1200001135 Make sure that the covers are tightly sealed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 229 Note Replace the gasket if damaged! xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 230 The threads will otherwise be damaged. Note xx1200001013 Make sure the o-ring is undamaged and properly fitted! Fit the heat protection plate with the re- maing screws. xx1300000490 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 231 If not, connect the 24 VDC power supply, release the brakes and move axis 5 manually to +90°. xx1200001081 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 232 Check that the carrier is level and completely pressed against the bottom. xx1300000485 Secure the cable bracket with its attach- ment screws. xx1300000484 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 233 Place the resolver cable under the motor cable. xx1300000488 Check the gasket. Gasket, 3HAC033489-001 Replace if damaged! xx1200001095 Refit the motor cover. xx1200001080 Disconnect the 24 VDC power supply (if used). Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 234 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 235: Replacing The Smb
- IRB 6700. Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 236 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 47 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 237 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 47 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 238 Use caution, push in the SMB unit into position and fit the bracket that hold the SMB unit. xx1300000730 If disconnected, reconnect the connectors X8, X9 and X10 to the brake release board. xx1300000670 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 239 Get a hold of the battery cable in the recess for the battery and reconnect. Place the battery in the recess. xx1300000829 Refit the battery cover. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 240 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 241: Replacing The Brake Release Unit
- IRB 6700. Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 242 CAUTION If the battery stays connected, put (or hold) the SMB cover in a safe position. The battery cable connectors can otherwise be damaged. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 243 Concluding procedure Action Note Unscrew the attachment screws securing the bracket with the brake release unit. Remove the bracket with the brake release unit fitted. xx1300000744 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 244 Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 245 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 246: Upper And Lower Arms
Lifting eye 3HAC16131-1 Fender washer Outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en- closed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 247 Axis 6: +125° DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 248 24 VDC power supply, release the brakes and move the axis manually into that position. Connect to R2.MP5-connector: • + = pin 2 • - = pin 5 xx1200001081 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 249 Disconnecting the axis-6 motor cables Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 250 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 251 Disconnecting the axis-3 and axis-4 motor cables Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 252 The motor shall be refitted in the same position. xx1200001067 Use caution and pull out the motor cables. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 253 If used, remove the insert that guides the DressPack through the hole in the upper arm, by unscrewing the attachment screws. xx1200000042 The figure show IRB 6640. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 254 Loosen the axis-4 metal clamp that holds the cable harness inside the arm tube by unscrewing the attachment screws. Note The screws are reached from outside the upper arm! xx1300000592 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 255 If DressPack is fitted, the cable fixing bracket is replaced by the cable guide. xx1300001973 xx1300000544 Remove the metal clamp on top of the armhouse. xx1300000541 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 256 DressPack tube, if one is fitted. Removing the DressPack cable package 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 Continues on next page 3HAC044266-001 Revision: - ©...
Page 257 (or similar) and then to the lifting eye in the arm house and in the wrist. xx1200001308 Raise the lifting accessories to take the weight of the upper arm. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 259 Use these procedures to refit the upper arm. Refitting the upper arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 260 M12 screws. xx1300000747 Secure the upper arm to the lower arm with M16, tightening torque: 280 Nm its attachment screws now fitted. M12, tightening torque: 115 Nm Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 262 DressPack tube, if used, through the arm tube. Do not run the cable harness into the DressPack tube! xx1300000739 A Tube for DressPack (LeanID) Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 263 • Together: Use caution and move the Person 2, working at the wrist: cable harness past the axis-5 motor and into the wrist. xx1300000746 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 264 Refit the side cover. xx1300000557 If used, refit the insert that guides the DressPack cable package through the hole in the upper arm. xx1200000042 The figure show IRB 6640. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 265 Refitting the DressPack cable package How to refit the DressPack cable package is described in more detail in the product manual "IRB 6700 DressPack". For article number see References on page Continues on next page 3HAC044266-001 Revision: -...
Page 266 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Connect the motor cables. Connect in accordance with the markings on the connectors. xx1200001066 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 267 The threads will otherwise be damaged. Note Make sure the o-ring is undamaged and properly fitted! xx1200001135 Make sure that the covers are tightly sealed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 268 Note Replace the gasket if damaged! xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 269 The threads will otherwise be damaged. Note xx1200001013 Make sure the o-ring is undamaged and properly fitted! Fit the heat protection plate with the re- maing screws. xx1300000490 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 270 If not, connect the 24 VDC power supply, release the brakes and move axis 5 manually to +90°. xx1200001081 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 271 Check that the carrier is level and completely pressed against the bottom. xx1300000485 Secure the cable bracket with its attach- ment screws. xx1300000484 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 272 Place the resolver cable under the motor cable. xx1300000488 Check the gasket. Gasket, 3HAC033489-001 Replace if damaged! xx1200001095 Refit the motor cover. xx1200001080 Disconnect the 24 VDC power supply (if used). Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 273 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 274: Replacing The Wrist
Standard toolkit Content is defined in section Standard toolkit on page 559. Consumables Equipment, etc. Art. no. Note Cable tie Grease 3HAB3537-1 Used to lubricate o-rings. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 275 If used, open the DressPack axis-6 cable support and remove the DressPack cable package. xx1200000036 Note The figure show the axis-6 cable support fitted on IRB 6640. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 276 Removing the turning disk Action Note Remove the attachment screws securing the turning disk. xx1300000492 Remove the turning disk. xx1300000493 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 277 Use this procedure to open the wrist and access the axis-5 and axis-6 motor cables. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 278 • - = pin 5 xx1200001081 Remove the wrist cover. xx1300000486 Cut the cable straps that hold the cable harness to the heat protection plate. xx1300000489 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 279 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and re- move the motor cover. xx1200001080 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 280 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Disconnect the motor cables. xx1200001066 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 281 Do not attach the roundsling around the axis-5 gearbox! xx1300000673 Note Make sure the roundsling is stretched, so it can carry the weight of the wrist. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 282 CAUTION Make sure that the cabling does not get damaged. xx1300000750 Use caution and pull out the cabling from the wrist unit. xx1300000769 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 283 Placed at a different position, there is a risk of sudden change in the balance, which can cause damage or injury. Do not attach the roundsling around the axis-5 gearbox! xx1300000673 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 284 Use caution and run the cabling into the wrist unit. Be careful not to damage any part of the cable harness. xx1300000769 Slide the wrist on the guide pins into posi- tion. xx1300000771 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 285 Connect to R2.MP5-connector: • + = pin 2 • - = pin 5 Manually move the the axis 5 to +90° (if not already in this position). xx1200001081 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 286 Note Replace the gasket if damaged! xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 287 The threads will otherwise be damaged. Note xx1200001013 Make sure the o-ring is undamaged and properly fitted! Fit the heat protection plate with the re- maing screws. xx1300000490 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 288 If not, connect the 24 VDC power supply, release the brakes and move axis 5 manually to +90°. xx1200001081 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 289 Check that the carrier is level and completely pressed against the bottom. xx1300000485 Secure the cable bracket with its attach- ment screws. xx1300000484 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 290 Replace if damaged! xx1200001095 Refit the motor cover. xx1200001080 Disconnect the 24 VDC power supply (if used). Refitting the turning disk Action Note Wipe clean the contacts surfaces. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 291 Refit the process turning disk. xx1300000600 The figure show IRB 6640. Refit the attachment screws that secure the process turning disk. xx1300000599 The figure show IRB 6640. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 292 Check that the cable harness will be placed in a way that it will not be damaged when the wrist cover is fitted. xx1300000596 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 293 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 294: Replacing The Turning Disk
Use these procedures to remove the turning disk. Preparations Action Note Run the robot to a position most comfort- able for the removal of the turning disk. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 295 Remove the turning disk. xx1300000493 Refitting the turning disk Use this procedure to refit the turning disk. Refitting the turning disk Action Note Wipe clean the contacts surfaces. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 296 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 297: Replacing The Lower Arm
3HAC15556-1 Lifting instruction 3HAC15880-2 en- closed. Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs! Guide pin, M12x200 3HAC13056-3 Always use guide pins in pairs! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 298 Jog the robot to calibration position. DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 299 How to remove the DressPack cable pack- end of the DressPack cable package. age is described in more detail in the product manual "IRB 6700 DressPack". For article number see References on page Remove the cable bracket for the ball joint housing from the wrist cover.
Page 300 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 301 Removing the shaft in the link ear Action Note Remove the small VK cover. Note It is almost impossible to remove the VK cover without damage. New VK covers are needed. xx1200001278 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 302 Use this procedure to open the wrist and access the axis-5 and axis-6 motor cables. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 303 • - = pin 5 xx1200001081 Remove the wrist cover. xx1300000486 Cut the cable straps that hold the cable harness to the heat protection plate. xx1300000489 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 304 Unscrew the screws that hold the bracket and let it hang free. xx1200001184 Open the ball joint housings on the lower arm and remove the DressPack, if one is fitted. xx1200000054 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 305 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 306 Use caution and pull out the motor cables. Disconnecting the axis-5 motor cables Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 307 The motor shall be refitted in the same position. xx1300000656 Use caution and pull out the motor cables. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 308 Removing the cable harness - wrist and upper arm Action Note If used, remove the DressPack cover with the tube guiding ring fitted, by unscrewing the attachment screws. xx1200000045 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 309 This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 310 Note The screws are reached from outside the upper arm! xx1300000592 Remove the armhouse metal clamp. xx1300000543 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 311 If DressPack is fitted, the cable fixing bracket is replaced by the cable guide. xx1300001973 xx1300000544 Remove the metal clamp on top of the armhouse. xx1300000541 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 313 (or similar) and then to the lifting eye in the arm house and in the wrist. xx1200001308 Raise the lifting accessories to take the weight of the upper arm. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 315 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Attach the lifting accessory to the lower arm. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 316 Apply the lifting accessory to the lower arm. CAUTION The lower arm weighs 135 kg. All lifting accessories used must be sized accordingly! Raise the tool to unload the lower arm. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 317 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 319 Remove the lifting accessory from the lower arm. Refitting the upper arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 320 M12 screws. xx1300000747 Secure the upper arm to the lower arm with M16, tightening torque: 280 Nm its attachment screws now fitted. M12, tightening torque: 115 Nm Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 321 This will also make it easier to run the cables through the inside of the robot. xx1300000668 Run the upper end of the cable harness up through the lower arm. xx1300000733 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 322 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. xx1300000558 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 323 (if not already done), to avoid damaging them during the continued pro- cedure. This will also make it easier to run the cables through the inside of the robot. xx1300000668 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 324 Do not run the cable harness into the DressPack tube! xx1300000739 A Tube for DressPack (LeanID) Fit the cable guide. xx1300000657 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 325 Refit the metal clamp axis-4 inside the arm tube. Note The screws are reached from outside the upper arm! xx1300000592 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 326 If used, refit the tube containing the DressPack into the insert. xx1300000658 The figure show IRB 6640. If used, refit the DressPack cover with the tube guiding ring fitted. xx1200000045 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 327 Connecting the axis-3 and axis-4 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 328 The threads will otherwise be damaged. Note Make sure the o-ring is undamaged and properly fitted! xx1200001135 Make sure that the covers are tightly sealed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 329 Note Replace the gasket if damaged! xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 330 The threads will otherwise be damaged. Note xx1200001013 Make sure the o-ring is undamaged and properly fitted! Fit the heat protection plate with the re- maing screws. xx1300000490 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 331 Note Axis 5 must be (as close as possible) in position +90° for a correct installation of the cable harness in the wrist. xx1200001081 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 332 Make sure that the carrier is level and completely pressed against the bottom. xx1300000485 Secure the cable bracket with its attach- ment screws. xx1300000484 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 333 Reconnect the connectors to the axis-6 motor. Note Place the resolver cable under the motor cable. xx1300000488 Check the gasket. Replace if damaged! xx1200001095 Refit the motor cover. xx1200001080 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 334 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. xx1300000772 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 335 How to refit the DressPack cable package cable package: is described in more detail in the product • Refit the distance to the wrist cover. manual "IRB 6700 DressPack". For article number see References on page • Refit the ball joint housing to the distance.
Page 336 Press the shaft in with the hydraulic press tool. Dismantle and mounting tool: 3HAC028920-001 Apply locking liquid (Loctite 2701) on the threads of the screw, first entering the threads in the frame. xx1300000782 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 337 Refit the two screws and wipe clean from residual grease. Concluded refitting of the front shaft Action Note Remove the lifting accessory from the bal- ancing device. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 338 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 339 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 340: Frame And Base
The spherical roller bearing is located in the link ear of the balancing device. xx1300000773 Attachment screws M6x10 quality 8.8-A2F (2 pcs) End cover Radial sealing with dustlip, 50x68x8 (2 pcs) O-ring 85x3 Spherical roller bearing Washer Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 341 If a new balancing device shall replace the removed one, another tool (3HAC020902-001 press tool balancing device) must be used! See Unloading the balancing device on page 379 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 342 Remove the cover plate on the back of the balancing device. DANGER DO NOT remove any other screws then the rear cover attachment screws! xx1300000554 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 344 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1 xx1300000661 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1 raise to unload the weight. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 345 Unscrew the attachment screw and washer. xx1200001279 • M16x70 quality steel 8.8-A3F Use the dismantle and mounting tool and Dismantle and mounting tool: pull out the shaft. 3HAC028920-001 xx1200001280 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 346 If not adjust with the lifting accessory. Unscrew the attachment screws securing the end cover, use caution and remove end cover and radial sealing with a screwdriver. xx1300000774 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 347 Refitting the spherical roller bearing Refitting the spherical roller bearing, link ear Action Note Wipe clean all contact surfaces from resid- ual grease. Refit the washer. xx1300000778 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 348 Apply some grease on the surface for the bearing. Apply the dismantle and mounting tool and Dismantle and mounting tool: press in the spherical roller bearing. 3HAC028920-001 xx1300000776 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 349 Preparations, lifting accessory Action Note Fit a lifting shackle. Fit the lifting accessory to the shackle and raise to unload the weight. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 350 3HAC15556-1 Align the balancing device link ear with the hole in the lower arm. Note Check that the link ear is turned correctly. See figure! xx1300000784 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 351 Secure the shaft with screw and washer. Tightening torque: 200 Nm xx1200001279 Fit the VK-cover. xx1200001278 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 352 Remove the lifting accessory from the bal- ancing device. Refit the cable bracket (if not already refit- ted). xx1200001283 Remove the locking screw (M16x120). xx1200001116 Jog axis-2 to: • -20° or +20°. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 353 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove the distance tool. Refit the cover plate. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 354: Replacing The Balancing Device
VK cover 3HAA2166-28 VK 28x7 Required tools and equipment Equipment, etc. Article number Note Distance tool 3HAC030662-001 Used for unloading a balancing device fitted to the robot. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 355 If a new balancing device shall replace the removed one, another tool (3HAC020902-001 press tool balancing device) must be used! See Unloading the balancing device on page 379 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 356 Remove the cover plate on the back of the balancing device. DANGER DO NOT remove any other screws then the rear cover attachment screws! xx1300000554 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 358 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1 xx1300000661 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1 raise to unload the weight. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 359 Wipe off all residual grease inside the re- cess. Unscrew the attachment screws on each shaft. xx1300000663 M16x70 quality steel 12.9 Gleitmo 603 Remove retaining ring, bore on one side. xx1300000664 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 360 Unscrew the attachment screw and washer. xx1200001279 • M16x70 quality steel 8.8-A3F Use the dismantle and mounting tool and Dismantle and mounting tool: pull out the shaft. 3HAC028920-001 xx1200001280 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 361 Action Note Fit a lifting shackle. Lifting shackle: SA-10-8-NA1 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1 raise to unload the weight. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 363 Unscrew both screws in the cradle and fill Grease: 3HAC042534-001 the bearing with grease from the inner hole (see figure) until grease appears in the outer hole. xx1300000832 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 364 Lubricate the shaft and place it to the front ear. xx1200001280 Press the shaft in with the hydraulic press tool. Dismantle and mounting tool: 3HAC028920-001 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 366 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove the distance tool. Refit the cover plate. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 367: Replacing The Rear Bearing Of The Balancing Device
(2 pcs). Can be ordered separately. Required tools and equipment Equipment, etc. Article number Note Distance tool 3HAC030662-001 Used for unloading a balancing device fitted to the robot. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 369 This is done to compress the spring unit, making it possible to remove the front shaft The balancing device is now unloaded. of the balancing device. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 370 • air pressure supply to the robot, before entering the robot working area. Remove any equipment, if fitted, on or close to the balancing device. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 371 It is almost impossible to remove the VK cover without damage. New VK covers are needed. xx1300000662 Wipe off all residual grease inside the re- cess. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 372 Use these procedures to refit the bearing in the cradle. Refitting the shaft end Action Note Wipe clean all contact surfaces from resid- ual grease and other contamination inside the recess. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 373 Use caution and press the shaft end in po- sition. Remove the press tool and the threaded bar. Apply some locking liquid (Loctite 243) on the attachment screw. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 374 Secure the balancing device. Tightening torque: 280 Nm. xx1300000663 Concluding procedure Action Note Refit the retaining ring bore. xx1300000664 Refit the VK-cover. xx1300000837 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 375 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 376: Replacing The Stop Pin
See Product manual, spare parts - IRB 6700. Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 377 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Unscrew the set screw, cup point. xx1300000476 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 378 Refitting the stop pin Action Note Fit the stop pin. xx1300000477 Secure the stop pin with the set screw, cup point. Locking liquid (Loctite 243) on screw. xx1300000476 M10x20 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 379: Unloading The Balancing Device
DANGER There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 380 To be used with the press tool. Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder. Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 381 Remove the rear cover of the balancing device, by unscrewing the attachment screws. DANGER DO NOT! remove any other screws then the rear cover attachment screws. xx1300000554 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 382 Unload the hydraulic cylinder. The hydraulic cylinder may now be removed from the tool, when necessary. CAUTION Do not remove the press tool! 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 383: Restoring The Balancing Device
The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Press device Bolt, press device Moving pin with marking Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 384 Pin, attached to the fix plate Refit the rear cover to the balancing device with its attachment screws, using locking liquid. Apply Sikaflex on the cover. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 385 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! 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 386: Motors
Used to push out the motor, if neces- sary. Always use removal tools in pairs. Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs! Bits extender 3HAC12342-1 300 mm, bits 1/2" Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 387 Disconnecting the motor cables Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 388 The motor shall be refitted in the same position. xx1200001067 Use caution and pull out the motor cables. Removing the axis-1 motor Action Note Apply the lifting accessory. Lifting accessory, motor: 3HAC14459-1. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 390 Wipe clean the contact surfaces from any remain- ing contamination. Also wipe clean the o-ring groove. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 391 Remove the cover, if the motor is a new spare part. xx1200001135 Securing the axis-1 motor Action Note Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2 Always use guide pins in pairs! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 392 Make sure that the motor pinion does not get damaged. • Make sure that the direction of the cable exit is facing the correct way. See figure! xx1200001072 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 393 174. Disconnect the 24 VDC power supply. Connecting the motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 394 Check the o-ring. O-ring, axis-1: 3HAB3772-111 Replace if damaged! O-ring, axis-2: 3HAB3772-111 O-ring, axis-3: 3HAB3772-111 O-ring, axis-4: 3HAB3772-110 xx1200001070 Wipe clean o-ring and o-ring groove. Refit the o-ring. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 395 Make sure all safety requirements are met when performing the first test run. These are further described in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 396: Replacing The Axis-2 Motor
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs! Bits extender 3HAC12342-1 300 mm, bits 1/2" Rotation tool 3HAC7887-1 Used to rotate the motor pinion. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 397 The lock screw is used to secure the weight of the lower arm, in order to avoid acci- dents or damage. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 398 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 399 To release the brake, connect the 24 VDC power supply. Connect to connector R2.MP2, axis-2 mo- tor: • + = pin 2 • - = pin 5 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 400 Disconnect the 24 VDC power supply. Use caution and remove the motor by slid- ing it out on the guide pins and then put it somewhere safe. xx1200001118 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 401 Replace if damaged! xx1200001019 Make sure the o-ring is seated in the groove. Lubricate the o-ring with some grease for a better fitting in the groove. xx1200001020 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 402 To release the brakes, connect the 24 VDC power supply. Connect to connector R2.MP2, axis-2 mo- tor: • + = pin 2 • - = pin 5 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 403 Use a bits extender in order to reach the Screw dimension: M10x40 quality 12.9 screws. Gleitmo (4 pcs) xx1200001117 Perform a leak-down test. Performing a leak-down test on page 174. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 404 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Connect the motor cables. Connect in accordance with the markings on the connectors. xx1200001066 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 405 Make sure that the covers are tightly sealed. Concluding procedure Action Note Use caution and jog axis-2 a little to fa- ciltate the removel of the M16 lock screw. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 406 Make sure all safety requirements are met when performing the first test run. These are further described in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 407: Replacing The Axis-3 Motor
Used to push out the motor, if neces- sary. Always use removal tools in pairs. Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs! Bits extender 3HAC12342-1 300 mm, bits 1/2" Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 408 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove any equipment hindering access to the motor. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 409 Make a note in which direction the cable exit hole is facing, if the motor also will be removed. The motor shall be refitted in the same position. xx1200001067 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 410 Use caution and lift the motor out on the guide pins, in order to get the pinion away from the gear, and let the motor rest on the guide pins. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 411 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove old paint residues and other contamina- tion from the contact surfaces on both motor and gearbox. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 412 Remove the cover, if the motor is a new spare part. xx1200001135 Securing the axis-3 motor Use this procedure to secure the motor. Action Note Fit guide pins in opposite holes. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 413 • + = pin 2 • - = pin 5 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 414 Screw dimension: M10x30 quality 12.9 Gleitmo (4 pcs) xx1200001126 Remove the rotation tool. Perform a leak-down test. Performing a leak-down test on page 174. Disconnect the 24 VDC power supply. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 415 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Connect the motor cables. Connect in accordance with the markings on the connectors. xx1200001066 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 416 Use this procedure for the concluding refitting. Action Note Remove the equipment used to unload the upper arm. Refill the gearbox with oil. Filling oil into the axis-3 gearbox on page 150. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 417 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 418: Replacing The Axis-4 Motor
Rotation tool 3HAC7887-1 Used to rotate the motor pinion. 24 VDC power supply Used to release the motor brakes. Leak-down tester 3HAC0207-1 Calibration Pendulum toolkit 3HAC15716-1 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 419 Disconnecting the motor cables Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 420 The motor shall be refitted in the same position. xx1200001067 Use caution and pull out the motor cables. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 421 Disconnect the 24 VDC power supply. Remove the motor by carefully lifting it straight out. Make sure the pinion is not damaged in the process. xx1200001138 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 422 Replace if damaged! xx1200001019 Make sure the o-ring is seated in the groove. Lubricate the o-ring with some grease for a better fitting in the groove. xx1200001020 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 423 + = pin 2 • - = pin 5 CAUTION Whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 424 Performing a leak-down test on page 174. Disconnect the 24 VDC power supply. Connecting the motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 425 Check the o-ring. O-ring, axis-1: 3HAB3772-111 Replace if damaged! O-ring, axis-2: 3HAB3772-111 O-ring, axis-3: 3HAB3772-111 O-ring, axis-4: 3HAB3772-110 xx1200001070 Wipe clean o-ring and o-ring groove. Refit the o-ring. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 426 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 427: Replacing The Axis-5 Motor
24 VDC power supply Used to release the motor brakes. Leak-down tester 3HAC0207-1 Calibration Pendulum toolkit 3HAC15716-1 Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 428 With the robot in this position, there is no • Axis 4: +90° need to drain oil from the axis-5 gearbox when the motor is replaced. xx1200001006 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 429 24 VDC power supply, release the brakes and move the axis manually into that position. Connect to R2.MP5-connector: • + = pin 2 • - = pin 5 xx1200001081 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 430 Disconnecting the motor cables Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 431 The motor shall be refitted in the same position. xx1300000656 Use caution and pull out the motor cables. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 432 If needed fit removal tools in opposite Removal tool M10 holes. Use caution and lift out the motor out and put it somewhere safe. xx1200001018 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 433 Clean the contact surfaces from any con- tamination including the recess for the o- ring. xx1200001019 Check the o-ring. O-ring, 3HAB3772-107 Replace if damaged. Lubricate the o-ring with some grease. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 434 To release the brakes, connect the 24 VDC 24 VDC power supply power supply. Connect to connector R2.MP5: • + = pin 2 • - = pin 5 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 435 Screw dimension: M8x30 quality 12.9 Gleitmo(4 pcs) xx1200001017 Perform a leak-down test. Performing a leak-down test on page 174. Disconnect the 24 VDC power supply. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 436 Note Replace the gasket if damaged! xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 437 The threads will otherwise be damaged. Note xx1200001013 Make sure the o-ring is undamaged and properly fitted! Fit the heat protection plate with the re- maing screws. xx1300000490 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 438 Make sure that the cover is tightly sealed. Concluding procedure Action Note Refit the heat protection plate. xx1200001011 Secure the cable harness to the heat pro- tection plate with two cable straps. xx1200001009 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 439 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 440: Replacing The Axis-6 Motor
24 VDC power supply Used to release the motor brakes. Leak-down tester 3HAC0207-1 Calibration Pendulum toolkit 3HAC15716-1 Standard toolkit Content is defined in section Standard toolkit on page 559. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 441 Disconnecting the axis-6 motor cables Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 442 To release the brakes, connect the 24 VDC 24 VDC power supply power supply. Connect to R2.MP6-connector: • + = pin 2 • - = pin 5 Unscrew the motor attachment screws. xx1200001090 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 443 Make sure the motor pinion is not dam- aged! xx1200001091 xx1200001096 Disconnect the 24 VDC power supply. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 444 Replace if damaged! xx1200001019 Make sure the o-ring is seated in the groove. Lubricate the o-ring with some grease for a better fitting in the groove. xx1200001020 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 445 + = pin 2 • - = pin 5 CAUTION Whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 446 Make sure the motor pinion is properly mated with the gear of the axis-6 gearbox. Make sure the motor pinion is not dam- aged! xx1200001091 xx1200001097 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 447 Performing a leak-down test on page 174. Disconnect the 24 V DC power supply. Reconnect the connectors. xx1200001084 Check the gasket. 3HAC033489-001 Replace if damaged! xx1200001095 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 448 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 449: Gearboxes
- IRB 6700. Consumables Equipment, etc Article number Note Grease 3HAB3537-1 Used to lubricate o-rings. O-ring 3HAB3772-93 D=380.59x3.53 Used on gearbox O-ring 3HAB3772-111 D=169.5x3 Used on motor cover. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 450 Guide pin, M16x150 3HAC13120-2 Always use guide pins in pairs! Guide pin, M16x200 3HAC13120-3 Always use guide pins in pairs! Leak-down tester 3HAC0207-1 Calibration Pendulum toolkit 3HAC15716-1 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 451 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 453 • Axis 2: -45° • Axis 3: +50° to 55° (approximately) • Axis 4, 5 and 6: calibration position (0°) xx1200001132 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 454 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1 xx1200001234 CAUTION The complete arm system weigh 1100 kg. All lifting accessories used must be sized accord- ingly! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 455 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1 washer underneath. Fender washer. Outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. xx1200001134 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 456 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Disconnect the motor cables. xx1200001066 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 457 Use a bits extender in order to reach the screws. xx1200001071 Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2 Always use guide pins in pairs! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 458 Preparations before removing the cable harness Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the base cover. xx1300000561 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 459 If used, use caution and pull out the DressPack cables through the protection tube and place it safely over the balancing device. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 461 Apply the lifting accessory to the gearbox. Lifting accessory, gearbox: Article number depends on robot variant. Protect the sealing areas on top of the protec- tion tube. xx1200001187 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 462 Note Use caution and lift the gearbox and put it somewhere safe. xx1200001188 Robot variants IRB 6700 - 235/2.65, - 205/2.80, - 175/3.05, - 150/3.20: 3HAC046112-001. Refitting the axis-1 gearbox These procedures describe how to refit the axis-1 gearbox. Preparations Use this procedure to do the necessary preparations before refitting the gearbox.
Page 463 The o-ring needs to be cleaned also on a new spare part! xx1200001244 Wipe clean the contact surfaces from any contamination. Also wipe clean the o-ring groove. xx1200001245 xx1200001231 Put some grease on the o-ring. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 464 Guide pin, M12x200: 3HAC13056-3 Always use guide pins in pairs! Lubricate the guide pins with some grease to make the gearbox slide better. Robot variants IRB 6700 - 235/2.65, - 205/2.80, - 175/3.05, - 150/3.20: 3HAC046112-001. Securing the gearbox Action Note Attach the guide reduction gear on top of the sealing tube.
Page 465 Wipe clean the contact surfaces from any remaining contamination. Apply flange sealant (Loctite 574) on the contact surface of the gearbox. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 466 Put some grease on the part of the aligning tool that will mate with the hole in the gearbox. Also put some grease in the matching hole in the gearbox. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 467 Tighten the attachment screws. Perform a leak-down test. Performing a leak-down test on page 174. Remove the aligning tool, after the leak- down test is completed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 468 Replace if damaged! xx1200001019 Make sure the o-ring is seated in the groove. Lubricate the o-ring with some grease for a better fitting in the groove. xx1200001020 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 469 + = pin 2 • - = pin 5 CAUTION Whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 470 Gleitmo (4 pcs) xx1200001071 Perform a leak-down test (if not already Performing a leak-down test on done). page 174. Disconnect the 24 VDC power supply. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 471 Make sure that the R1.MP will be on the left side. xx1300000736 Make sure that the markings on the cables are facing upwards when connected. Connect R1.MP and R1.SMB. xx1300000591 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 472 Make sure that the hoses are running cor- rectly and are not twisted! If used, connect the DressPack cable package on the base plate. xx1200000052 Refit the base cover. xx1300000561 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 473 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Connect the motor cables. Connect in accordance with the markings on the connectors. xx1200001066 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 474 Concluding procedure Action Note Turn on the power to the robot and jog to: • axis 1 = -5 degrees • axis 2 = +10 degrees Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 475 Tightening torque: 280 Nm. the frame hole and under the balancing device. xx1200001189 Secure the cable harness inside the frame hole with a cable strap. xx1200001237 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 476 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 477: Replacing The Axis-2 Gearbox
Oil dispenser One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 137. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 478 Calibration Pendulum toolkit 3HAC15716-1 Standard toolkit Content is defined in section Standard toolkit on page 559. Robot variants IRB 6700 - 235/2.65, - 205/2.80, - 175/3.05, - 150/3.20: 3HAC046112-001. Consumables Equipment, etc Article number Note Grease 3HAB3537-1 Used to lubricate o-rings.
Page 479 If a new balancing device shall replace the removed one, another tool (3HAC020902-001 press tool balancing device) must be used! See Unloading the balancing device on page 379 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 480 Remove the cover plate on the back of the balancing device. DANGER DO NOT remove any other screws then the rear cover attachment screws! xx1300000554 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 482 Apply the puller tool and remove the shaft in the front ear. xx1200001280 Put down the balancing device and let it rest on the frame. xx1200001281 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 483 Attaching the lifting accessories Use this procedure to attach the lifting accessories. Action Note Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1 xx1200001133 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 484 This will prevent the roundsling from gliding. Attach the roundsling to the shackle on the wrist. xx1200001253 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 485 Then 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. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 486 Use this procedure to disconnect the motor cables. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 487 Use caution and pull out the motor cables. Removing the axis-2 motor Action Note Before removing the motor, make sure that the axis-2 gearbox is completely drained. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 489 • Open the two ball joint housings age is described in more detail in the from the lower arm and lift away the product manual "IRB 6700 DressPack". For cabling from the housings. article number see References on page xx1200000054...
Page 490 Remove all but one of the remaining attach- ment screws that secure the lower arm to the axis-2 gearbox. xx1300000789 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 491 Guide pin, M12x200: 3HAC13056-3 Always use guide pins in pairs! Lubricate the guide pins with some grease to make the gearbox slide better. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 492 Remove the gearbox and put it somewhere safe. Robot variants IRB 6700 - 235/2.65, - 205/2.80, - 175/3.05, - 150/3.20: 3HAC046112-001. Refitting the axis-2 gearbox Use these procedures to refit the gearbox. Follow the order of the separate procedures according to the order they are presented.
Page 493 Remove the guide pins and fit the remain- ing attachment screws. Secure the gearbox with its attachment Tightening torque: 115 Nm. screws. Robot variants IRB 6700 - 235/2.65, - 205/2.80, - 175/3.05, - 150/3.20: 3HAC046112-001. Preparations prior to refitting motor Action Note DANGER...
Page 494 Remove the cover, if the motor is a new spare part. xx1200001135 Securing the axis-2 motor Action Note Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2 Always use guide pins in pairs! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 495 See figure! Fit two of the attachment screws. Remove the guide pins and replace with the remaining attachment screws. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 496 Before putting the arms on the guide pins, check that the hole pattern is matched and in the correct position for all screws. Slide the lower arm on to the guide pins. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 497 Connecting the axis-2 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 498 The threads will otherwise be damaged. Note Make sure the o-ring is undamaged and properly fitted! xx1200001135 Make sure that the covers are tightly sealed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 499 If robot is equipped with DressPack. How to refit the DressPack is described in • Place the cabling in the two ball joint the product manual "IRB 6700 DressPack". housings on the lower arm and close For article number see References on the housings.
Page 500 Press the shaft in with the hydraulic press tool. Dismantle and mounting tool: 3HAC028920-001 Apply locking liquid (Loctite 2701) on the threads of the screw, first entering the threads in the frame. xx1300000782 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 501 Refit the two screws and wipe clean from residual grease. Concluded refitting of the front shaft Action Note Remove the lifting accessory from the bal- ancing device. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 502 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 503 Calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 537. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 504 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 505: Replacing The Axis-3 Gearbox
Required tools and equipment Equipment, etc. Article number Note Oil collecting vessel The capacity of the vessel must be sufficient to take the complete amount of oil. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 506 Used on motor flange. O-ring 3HAB3772-111 D=169.5x3 Used on motor cover. O-ring 3HAB3772-145 D=266.29x3.53 Used on gearbox. Removing the axis-3 gearbox Use these procedures to remove the axis-3 gearbox. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 507 Connectors are only hidden here to get a better view of which screw to remove. xx1200001331 A Attachment screw to be removed B Attachment screw not to be removed Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 508 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 510 Open the velcro strap on cable fixing bracket. If equipped with DressPack, instead open the velcro straps on the cable guide. xx1300000544 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 511 Attaching the lifting accessories Use this procedure to attach the lifting accessories to the upper arm. Action Note Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1 xx1200001133 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 512 24 VDC power supply 24 VDC power supply. Removing the axis-3 motor Action Note Before removing the motor, check that the axis-3 gearbox is completely drained. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 513 CAUTION The motor weighs 24 kg. All lifting accessories used must be sized accordingly! Apply the lifting accessory to the motor. Lifting accessory, motor: 3HAC15534-1 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 514 Always use guide pins in pairs! (Screws that secure the lower arm to the axis-3 gearbox.) Lubricate the guide pins with some grease to make the upper arm slide better. xx1300000659 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 516 Remove all but one of the remaining attach- ment screws. xx1300001970 Fit three fully threaded screws and use ScrewsM8x75, fully threaded: Used to push them as removal tools. out the gearbox, if necessary. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 517 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The axis-3 gearbox weighs 56 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 518 Screw dimension depends on variant: M12x70. Refitting the upper arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 519 M12 screws. xx1300000747 Secure the upper arm to the lower arm with M16, tightening torque: 280 Nm its attachment screws now fitted. M12, tightening torque: 115 Nm Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 520 Wipe clean the contact surfaces from any remain- ing contamination. Also wipe clean the o-ring groove. Check the o-ring. O-ring, 3HAB3772-107 Replace if damaged! xx1200001019 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 521 Apply the lifting accessory to the motor. Lifting accessory, motor: 3HAC15534-1 Note Make sure the cable exit hole is turned the correct way. See figure! xx1200001129 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 522 Mate the motor pinion properly to the gear of the gearbox. • Do not damage the motor pinion! xx1200001129 Attach two attachment screws. Remove the guide pins. Attach the remaining attachment screws. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 524 Secure the cable harness with the velcro strap on the cable fixing bracket. If equipped with DressPack, instead secure both DressPack and cable harness with velcro straps on the cable guide. xx1300000544 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 525 Use this procedure to connect the motor cables. Action Note Push the motor cables in through the cable gland opening. xx1300000738 Refit the cable gland cover. Note Replace the gasket if damaged! xx1200001067 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 526 The threads will otherwise be damaged. Note Make sure the o-ring is undamaged and properly fitted! xx1200001135 Make sure that the covers are tightly sealed. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 527 Calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 537. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 528 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 529: Replacing The Axis-6 Gearbox
Content is defined in section Standard toolkit on page 559. Consumables Equipment, etc Article number Note Grease 3HAB3537-1 Used to lubricate o-rings. O-ring 3HAB3772-107 D=102x3 Used on motor flange. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 530 Remove all equipment fitted on the turning disk. Drain the gearbox. Draining the axis-6 gearbox on page 161. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 531 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove the synchronization plate axis-6. xx1300000825 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 532 Use the procedure to remove the DressPack process disk, if one is fitted. Action Note Remove the attachment screws that secure the process turning disk. xx1300000599 The figure show IRB 6640. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 533 Screw dimension depends on variant. press out the gearbox. Use caution and remove the gearbox. CAUTION Be careful not to damage motor pinion or gears! xx1300000827 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 534 Use caution and refit the gearbox to the wrist. CAUTION Be careful not to damage motor pinion or gears! xx1300000827 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 535 Secure the turning disk with its attachment Tightening torque: 35 Nm. screws and washers. Attachment screws: M8x25, Steel 12.9 Gleitmo 603 (24 pcs) Washers: steel 8.4x13x1.5 (24 pcs) xx1300000492 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 536 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 537: Calibration Information
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in the section Calibration methods on page 538 , and further detailed in separate calibration manuals.
Page 538: Calibration Methods
To regain 100% absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy! xx0400001197 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 539 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.
Page 540: Calibration Scale And Correct Axis Position
This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales/marks, IRB 6700 Axis 1 Axis 2 xx1300000868 xx1300000869 Axis 3 Axis 4 xx1300000870 xx1300000871 Axis 5 Axis 6 xx1300000873 xx1300000872 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 541: Calibration Movement Directions For All Axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 542: Updating Revolution Counters
Use this procedure to store the revolution counter setting with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. All mechanical units connected to the system are shown with their calibration status. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 543 If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi- tioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See Checking the calibration position on page 544. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 544: Checking The Calibration Position
Check that the calibration marks for the Calibration scale and correct axis pos- axes align correctly. If they do not, update ition on page 540, and Updating revolution the revolution counters! counters on page 542. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 545: Decommissioning
Also note that: • Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 546: Scrapping Of Robot
Always remove all oil in gearboxes. If exposed to heat, for example from a blow torch, the oil will catch fire. • When motors are removed from the robot, the robot will collaps if not properly supported before motor removal. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 547: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 548 The working area must be free of flam- mable materials. Position the balancing device so that the spatter will be directed away from personnel. Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 549 Middle spring: cut at least four coils! • Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs is removed. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 550 This page is intentionally left blank...
Page 551: Reference Information
7 Reference information 7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 552: Applicable Safety Standards
Safety of machinery - General requirements for the design and construction of fixed and movable guards Other standards Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 553 7.2 Applicable safety standards Continued Standard Description ANSI/UL 1740 Safety standard for robots and robotic equipment (option 429-1) CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require- ments (option 429-1) 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 554: Unit Conversion
3.28 ft. 39.37 in Weight 1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 555: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 556 Molycote 1000, Gleitmo 603 or equivalent with allen head screws. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 557 The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 558: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 559: Standard Toolkit
To be shortened to 12 mm Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Plastic mallet 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 560: Special Tools
The required tools are a sum of standard tools, defined in the section Standard toolkit on page 559, and of special tools, listed directly in the instructions and also gathered in this section. Special tools Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 561 7 Reference information 7.7 Special tools Tools and equipment with spare part number: (These tools can be ordered from ABB) Guide pins 3HAC15520-1 Guide pin, M8x100 3HAC15521-2 Guide pin, M10x150 3HAC15521-2 Guide pin, M10x150 3HAC13056-2 Guide pin, M12x150 3HAC13056-3 Guide pin, M12x200...
Page 562 7 Reference information 7.7 Special tools Tools and equipment with spare part number: (These tools can be ordered from ABB) Lifting shackle SA-10-8-NA1 xx1200001243 Fender washer Outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. Roundsling, 1.5 m Length: 1.5 m.
Page 563 Oil dispenser Pallet 3HAC7887-1 Rotation tool Robot variants IRB 6700 - 235/2.65, - 205/2.80, - 175/3.05, - 150/3.20: 3HAC046112-001. Included in Dismantle and mounting tool (3HAC028920-001). Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 564: Lifting Accessories And Lifting Instructions
The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. This implies that the instructions delivered with the lifting accessories should be stored for later reference. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 565: Spare Parts
8 Spare parts 8.1 Spare part lists and illustrations Location Spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation DVD. 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 566 This page is intentionally left blank...
Page 567: Circuit Diagrams
3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Continues on next page 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 568 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 569: Index
544 MoveAbsJ instruction, 544 cable harness updating revolution counters, 542 replacing, 191, 211 fork lift, 69 cable harness attachments, 122 foundation cabling, robot, 96 requirements, 54 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 570 2, 107 with fork lift, 69 gearbox axis 3, 109 Lithium gearbox axis 4, 111 disposal, 545 gearbox axis 5, 113 lower arm gearbox axis 6, 115 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 571 29 updating revolution counters, 542 service, 17 upper arm signals, 36 replacing, 246 signals in manual, 36 symbols, 36 validity and responsibility, 17 symbols on manipulator, 38 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 572 Index working range weight restricting axis 1, 94 axis-1 motor, 389, 392, 457, 469 wrist base plate, 72, 76 replacing, 274 robot, 71, 81, 460, 467, 558 3HAC044266-001 Revision: - © Copyright 2013 ABB. All rights reserved.
Page 574 Telephone +46 (0) 21 344 400 ABB AS, Robotics Discrete Automation and Motion Box 265 N-4349 BRYNE, Norway Telephone: +47 51489000 ABB Engineering (Shanghai) Ltd. 5 Lane 369, ChuangYe Road KangQiao Town, PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 www.abb.com/robotics...

ABB IRB 6700 Product Manual

2 Installation and Commissioning

3 Maintenance

4 Repair

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Summary of Contents for ABB IRB 6700

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