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ABB IRB 6700 Product Manual

Summary of IRB 6700

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    Abb robotics product manual irb 6700

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    Trace back information: workspace r13-2 version a3 checked in 2013-10-15 skribenta version 4.0.378.

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    Product manual irb 6700 - 235/2.65 irb 6700 - 205/2.80 irb 6700 - 175/3.05 irb 6700 - 150/3.20 irc5 document id: 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved..

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    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...

  • Page 5: Table Of Contents

    Table of contents 9 overview of this manual ................................................................................................................... 11 product documentation, irc5 .......................................................................................................... 13...

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    93 2.5 restricting the working range .............................................................................. 93 2.5.1 introduction ............................................................................................ 94 2.5.2 mechanically restricting the working range of axis 1 ..........

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    246 4.5 upper and lower arms ........................................................................................ 246 4.5.1 replacing the upper arm .......................................................................... 274 4.5.2 replacing the wrist ..............................................

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  • Page 9: Overview Of This Manual

    Overview of this manual about this manual this manual contains instructions for: • mechanical and electrical installation of the robot • maintenance of the robot • mechanical and electrical repair of the robot. Usage this manual should be used during: • installation, from lifting the robot to its wo...

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    Contents chapter reference to the spare part list for the robot. Spare parts and exploded views reference to the circuit diagram for the robot. Circuit diagram references documentation referred to in the manual, is listed in the table below. Document id document name 3hac044268-001 product manual, s...

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    Product documentation, irc5 categories for manipulator documentation the manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be order...

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    An application manual generally contains information about: • the purpose of the application (what it does and when it is useful). • what is included (for example cables, i/o boards, rapid instructions, system parameters, dvd with pc software). • how to install included or required hardware. • how t...

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    How to read the product manual reading the procedures the procedures contain references to figures, tools, material, and so on. The references are read as described below. References to figures the procedures often include references to components or attachment points located on the manipulator/cont...

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  • Page 15: 1 Safety

    1 safety 1.1 introduction to safety information overview the safety information in this manual is divided into two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in general safety i...

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    1.2 general safety information 1.2.1 introduction to general safety information definitions this section details general safety information for personnel performing installation, repair and maintenance work. Sections the general safety information is divided into the following sections. Containing c...

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    1.2.2 safety in the manipulator system validity and responsibility the information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system. To protect personnel, the complete system must be des...

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    1.2.3 safety risks 1.2.3.1 safety risks during installation and service work on manipulators overview this section includes information on general safety risks to be considered when performing installation and service work on the manipulator. These safety instructions have to be read and followed by...

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    • turntables or the like should be used to keep the operator out of the manipulator's working space. • the axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving manipulator parts, there is a risk of being crushed by the parallel arm (i...

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    Cabling description safety risk caution the cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Cable packs are sensitive to mechanical damage! Gearboxes and motors description safety risk caution whenever partin...

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    1.2.3.2 caution - hot parts may cause burns! Description during normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity. Because of a higher environment temperat...

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    1.2.3.3 safety risks related to tools/work pieces safe handling it must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves). Safe design grippers/e...

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    1.2.3.4 safety risks related to pneumatic/hydraulic systems general special safety regulations apply to pneumatic and hydraulic systems. Note all components that remain pressurized after separating the machine from the power supply must be provided with clearly visible drain facilities and a warning...

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    1.2.3.5 safety risks during operational disturbances general • the industrial manipulator is a flexible tool that can be used in many different industrial applications. • all work must be carried out professionally and in accordance with the applicable safety regulations. • care must be taken at all...

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    1.2.3.6 risks associated with live electric parts voltage related risks, general work on the electrical equipment of the manipulator must be performed by a qualified electrician in accordance with electrical regulations. • although troubleshooting may, on occasion, need to be carried out while the p...

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    Voltage related risks, manipulator a danger of high voltage is associated with the manipulator in: • the power supply for the motors (up to 800 vdc). • the user connections for tools or other parts of the installation (max. 230 vac). See chapter installation and commissioning on page 51 . Voltage re...

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    1.2.4 safety actions 1.2.4.1 safety fence dimensions general install a safety cell around the manipulator to ensure safe manipulator installation and operation. Dimensioning dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the manipulator is d...

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    1.2.4.2 fire extinguishing note use a carbon dioxide (co 2 ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 28 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 1 safety 1.2.4.2 fire extinguishing.

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    1.2.4.3 emergency release of the manipulator’s arm description in an emergency situation, any of the manipulator's axes may be released manually by pushing the brake release buttons on the manipulator. How to release the brakes is detailed in the section: • manually releasing the brakes on page 82 ....

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    1.2.4.4 brake testing when to test during operation, the holding brake of each axis normally wears down. A test can be performed to determine whether the brake can still perform its function. How to test the function of the holding brake of each axis motor may be checked as described below: 1 run ea...

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    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: - 31 © copyright 2013 abb. All rights reserved. ...

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    1.2.4.6 safe use of the flexpendant enabling device the enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are sto...

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    1.2.4.7 work inside the manipulator's working range warning if work must be carried out within the manipulator’s work area, the following points must be observed: • the operating mode selector on the controller must be in the manual mode position to render the enabling device operational and to bloc...

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    1.2.5 safety stops 1.2.5.1 what is an emergency stop? Definition of emergency stop an emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts, and disconnects power from any potentially dangerous functions co...

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    Classification of stops the safety standards that regulate automation and manipulator equipment define categories in which each type of stop applies: ... Then it is classified as... If the stop is... Category 0 (zero) uncontrolled category 1 controlled emergency stop devices in a manipulator system ...

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    1.3 safety related instructions 1.3.1 safety signals in the manual introduction to safety signals this section specifies all dangers that can arise when doing the work described in this manual. Each danger consists of: • a caption specifying the danger level (danger, warning, or caution) and the typ...

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    Significance designation symbol describes important facts and conditions. Note xx0100000004 describes where to find additional information or how to do an operation in an easier way. Tip xx0100000098 3hac044266-001 revision: - 37 © copyright 2013 abb. All rights reserved. 1 safety 1.3.1 safety signa...

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    1.3.2 safety symbols on manipulator labels introduction to labels this section describes safety symbols used on labels (stickers) on the manipulator. Symbols are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain...

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    Description symbol see user documentation xx0900000813 read user documentation for details. Which manual to read is defined by the symbol: • no text: product manual . • eps: application manual - electronic position switches . Before dismantling see product manual xx0900000816 do not dismantle xx0900...

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    Description symbol crush xx0900000817 risk of crush injuries. Heat xx0900000818 risk of heat that can cause burns. Moving robot xx0900000819 the robot can move unexpectedly. Xx1000001141 brake release buttons xx0900000820 xx1000001140 continues on next page 40 3hac044266-001 revision: - © copyright ...

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    Description symbol lifting bolt xx0900000821 chain sling with shortener xx1000001242 lifting of robot xx0900000822 oil xx0900000823 can be used in combination with prohibition if oil is not allowed. Mechanical stop xx0900000824 no mechanical stop xx1000001144 stored energy xx0900000825 warns that th...

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    Description symbol pressure xx0900000826 warns that this part is pressurized. Usually contains additional text with the pressure level. Shut off with handle xx0900000827 use the power switch on the controller. 42 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 1 safety 1.3.2 sa...

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    1.3.3 danger - moving manipulators are potentially lethal! Description any moving manipulator is a potentially lethal machine. When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any ...

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    1.3.4 danger - first test run may cause injury or damage! Description since performing a service activity often requires disassembly of the robot, there are several safety risks to take into consideration before the first test run. Elimination follow the procedure below when performing the first tes...

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    1.3.5 warning - the brake release buttons may be jammed after service work description the brake release unit has push-buttons for the brake release of each axis motor. When service work is performed inside the smb recess that includes removal and refitting of the brake release unit, the brake relea...

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    1.3.6 danger - make sure that the main power has been switched off! Description working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these dangers, do not proceed working before eliminating the...

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    1.3.7 warning - the unit is sensitive to esd! Description esd (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not...

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    1.3.8 warning - safety risks during handling of batteries description under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact. There is a risk of exposure only...

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    1.3.9 warning - safety risks during work with gearbox lubricants (oil or grease) description when handling gearbox lubricants, there is a risk of both personal injury and product damage occurring. The following safety information must be regarded before performing any work with lubricants in the gea...

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    Elimination/action description warning make sure not to overfill the gearbox when filling it with oil or grease! Overfilling of gearbox lubricant can lead to internal over-pres- sure inside the gearbox which in turn may: • damage seals and gas- kets • completely press out seals and gaskets • prevent...

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    2 installation and commissioning 2.1 introduction general this chapter contains information for installing the robot at the working site. See the product specification for the robot for more detailed technical data, such as: • load diagram • permitted extra loads (equipment) • location of extra load...

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    2.2 unpacking 2.2.1 pre-installation procedure introduction this section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation installation craftsmen ...

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    Loads on foundation, robot the illustration shows the directions of the robots stress forces. The directions are valid for all floor mounted and suspended robots. Xy xy z z t f f t xx1100000521 force in any direction in the xy plane f xy force in the z plane f z bending torque in any direction in th...

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    Requirements, foundation the table shows the requirements for the foundation where the weight of the installed robot is included: note value requirement flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from abb. 0.2 mm maximum deviation...

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    2.2.2 working range working range note working range type of motion axis ±170° rotation motion axis 1 -65°/+85° arm motion axis 2 -180°/+70° arm motion axis 3 default value. ±300° wrist motion axis 4 ±130° i bend motion axis 5 default value. ±360° ii turn motion axis 6 maximum value. ± 93.7 revoluti...

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    Illustration, working range irb 6700 - 235/2.65 this illustration shows the unrestricted working range of the robot. 1187 920 1908 2650 3114 320 xx1300000281 reach (m) handling capacity (kg) robot type 2.65 235 irb 6700 illustration, working range irb 6700 - 205/2.80 this illustration shows the unre...

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    Reach (m) handling capacity (kg) robot type 2.80 205 irb 6700 illustration, working range irb 6700 - 175/3.05 1527 2314 1109 3056 726 3520 xx1300000283 reach (m) handling capacity (kg) robot type 3.05 175 irb 6700 continues on next page 3hac044266-001 revision: - 57 © copyright 2013 abb. All rights ...

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    Illustration, working range irb 6700 - 150/3.20 1604 2445 1067 3200 713 3665 xx1300000284 reach (m) handling capacity (kg) robot type 3.20 150 irb 6700 continues on next page 58 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.2.2 working range...

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    Turning radius r2 r1 170° 170° xx1300001082 r2 r1 robot variant 2650 mm 920 mm irb 6700 - 235/2.65 2794 mm 958 mm irb 6700 - 205/2.80 3056 mm 1109 mm irb 6700 - 175/3.05 3200 mm 1067 mm irb 6700 - 150/3.20 3hac044266-001 revision: - 59 © copyright 2013 abb. All rights reserved. 2 installation and co...

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    2.2.3 risk of tipping/stability risk of tipping if the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over. The shipping position is the most stable p...

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    2.2.4 main dimensions illustration (c) (b) 1029 360 360 745 186 209 320 377 1004 780 200 200 (a) (d) (e) (f) (g) 456 xx1300000241 description pos 350 mm for leanid (option 780-4) a radius = 532 mm (axis 1 front side) b radius = 634 mm (axis 1 back side) c dimensions for different robot variants g f ...

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    2.3 on-site transportation 2.3.1 robot transportation precautions general this section describes abb approved transportation precautions for abb robots. Caution all transportation in or outside the plant, must be carried out according to description in method 1. If transportation according to method...

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    Always follow these instructions when transporting an abb robot according to method 1: • always remove the tool before transportation of the robot. • always place the robot in the abb recommended transport position, described in section risk of tipping/stability on page 60 . • always read and follow...

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    Irb 6700 xx0800000037 transport support a hexagon socket head cap screw m16x140 b threaded bar m10x200 c nut m10 d continues on next page 64 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.3.1 robot transportation precautions continued.

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    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: - 65 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.3.1 robot transportation prec...

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    Recommended transport support always use the recommended transport support when transporting a robot with tool. Irb 6700 220 250 r 90 r 110 200 30 65 130 (10) r3 m10 (52) (62) b 50 50 40 18 60 12 r 20 30° a 5 irb6700 2.65 2.8 3.05 3.2 lower arm l 1135 1280 1135 1280 a 1000 1160 630 860 b 21 21 21 21...

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    2.3.2 securing the robot general this section describes how to secure the robot using the transport support. Danger releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary. Securing the robot xx080000006...

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    Note action do not tighten the screw. Fit the transport support’s lower end to the robot using the recommended screw joint, (a) in figure. 1 see attachment point for the specific ro- bot in the section transport position with a transport support on page 65 . Caution do not try to jog the robot to th...

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    2.4 on-site installation 2.4.1 lifting robot with fork lift general the robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Fork lift device set the fork lift device set is fitted to the robot...

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    Note art. No. Equipment content is defined in section standard toolkit on page 559 . - standard toolkit lifting the robot with fork lift this procedure details how to secure the fork lift set in order to lift the robot and move it using fork lift only! Note action release the brakes if required as d...

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    Note action caution the irb 6700 robot weighs 1300 kg. All lifting accessories used must be sized accordingly! 5 caution lifting the robot with fork lift shall only be done with all four fork lift pockets fitted! If lifting with fewer than four fork lift pockets fitted, there is a risk of accidents ...

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    2.4.2 lifting the base plate required equipment note art. No. Equipment 3 pcs 3hac14457-4 lifting eye, m16 3 pcs lifting slings length: approx. 2 m hole configuration xx0200000096 attachment holes for lifting eyes (x3) a lifting, base plate note action caution the base plate weighs 353 kg! All lifti...

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    2.4.3 securing the base plate base plate, dimensions a a b b c d g h e f 2x r525 598,31 560,85 487,01 243,5 0 73,84 111,30 1020 857,3 73,84 132,64 317,3 502,04 560,85 634,68 0 2x 50x45º 231,5 2x 450 950 (Ø 800) 12x m24 Ø1 a 455 c a 4x48 13 (2) 1,6 3x45º 0.2 Ø 45p7 a-a Ø1.5 (4x) 6,3 (48) (2) 1,6 3x45...

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    840,9 699,5 625 (2x) 325 (2x) 250,5 109,1 0 874,6 (2x) 790 (2x) 706 (2x) 290 (2x) 0 0 119 138,4 241,1 225,8 r50 (12x) 4x Ø18. 2x206,9 2x219,8 2x31 1,1 2x365,3 0 831 811,6 724,2 708,9 50 0 27 (4x) 68 150 202 385 565 748 800 882 923 (4x) Ø16 (5x) Ø22 (16x) 861 (2x) 358 (2x) 18 0 905 813 475 137 45 0 0...

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    Guide sleeve xx1000001055 guide sleeve protected from corrosion a 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) a orienting grooves (3 pcs) b continues on next page 3hac044266-001 rev...

  • Page 76

    Levelling bolts, attachment holes (4 pcs) c required equipment note art. No. Equipment includes • guide sleeves, 3hac12937-3 • levelling screws, 9ada120-79 • attachment screws and washers for securing the robot to the base plate. A drawing of the base plate itself may be ordered from abb robotics! 3...

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    Note action if possible, observe the recommenda- tions specified in section recommenda- tions, quality on page 76 . Abb does not assume any responsibility for other foundation qualities, due to great vari- ations in the foundation properties. Use the base plate as a template and drill 16 attachment ...

  • Page 78

    2.4.4 lifting the robot with roundslings attaching the roundslings c a b d roundsling, 2.5 m (4 pcs) a roundsling, 2 m (1 pc) do not strain! B length roundsling (1 pc) do not strain! C 2 m irb 6700 - 235/2.65 2 m irb 6700 - 205/2.80 2.5 m irb 6700 - 175/3.05 2.5 m irb 6700 - 150/3.20 lifting eye, m2...

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    Required equipment see quantity of roundslings in figure attaching the roundslings on page 78 . Note article number equipment, etc. - overhead crane working load limit: 2,000 kg. Quantity: 4 pcs required. - lifting eye, m20 length: 2 m. Lifting capacity: 2,000 kg. - roundsling, 2 m length: 2.5 m. Li...

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    Note action xx1200001301 fit lifting eyes to the outer holes on each corner of the base. 2 xx1200001302 make sure the roundslings do not rub against any sharp edges. Run roundslings through the lifting eyes and fasten them in an overhead crane. Caution if the lifting eyes have sharp edges that might...

  • Page 81

    Note action irb 6700 - 235/2.65 and irb 6700 - 205/2.80: roundsling, 2 m attach a securing roundsling at the front according to figure. Note the securing sling must not be strained at lifting. It only secures for tipping. 5 irb 6700 - 175/3.05 and irb 6700 - 150/3.20: roundsling, 2.5 m xx1300001574 ...

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    2.4.5 manually releasing the brakes introduction to manually releasing the brakes this section describes how to release the holding brakes for the motors of each axis. Location of brake release unit the internal brake release unit is located as shown in the figure. Xx1200000964 releasing the brakes ...

  • Page 83

    Note action release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release unit. 3 the brake will function again as soon as the button is released. Supplying power to connector r1.Mp if the robot is not connected to the controller, power must ...

  • Page 84

    2.4.6 orienting and securing the robot general this section details how to orient and secure the robot to the base plate in order to run the robot safely. Hole configuration, base this illustration shows the hole configuration used when securing the robot. D - d 8x 30 8x 53 4x 45 h7 4x 3x45 16 8x 49...

  • Page 85

    4 mm flat washer suitable washer: 625 nm tightening torque: securing the robot use this procedure to secure robot to base plate after fitting plate to the foundation. Note action see section lifting the robot with roundslings on page 78 . Lift the robot. 1 move robot close to its installation locati...

  • Page 86

    2.4.7 loads general any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and mass moments of inertia) in order to avoid jolting movements and overloading motors, gears and structure. Caution incorrectly defined loads may result in o...

  • Page 87

    2.4.8 fitting equipment to the robot general extra loads can be fitted on the upper arm housing, the lower arm, and on the frame. Definitions of distances and masses are shown in the following figures. The robot is supplied with holes for fitting extra equipment (see figure in holes for fitting extr...

  • Page 88

    Upper arm allowed extra load on the upper arm housing, in addition to the maximum handling weight, is m1 ≤ 50 kg with a distance ≤ 500 mm from the center of gravity in the axis-3 extension. (a) m1 m1 a xx1000000417 mass center a 200 400 (a) xx1300000866 center of gravity 50 kg a continues on next pa...

  • Page 89

    Holes for fitting extra equipment allowed positions for attachment holes 652,5 3 6 5 0,3 80 1 2 0 3x m10 a a 349 428 12 (2x m12) 147 (2x m12) cl axis 5 2x m8 16 8 0 4 0 100 cl axis 3 4x m12 22 220 190 110 90 3 2 8 3 3 1 0 2 19 2x m12 197 m12 19 22) 106 (4x m12 53 52 ,5° 117 r 1 3 4 x m 8 m12 20 52 ,...

  • Page 90

    Upper arm, lower arm and frame 190 90 3 2 8 cl axis 5 8 0 4 0 100 2x m8 12 cl axis 1 2 6 5 465 30 33 6 0 50 50 4 9 9 .9 304 2x m12 25 20 m12 320 4x m10 2x m12 255 80 349 428 (b) (2x m12) (c) (m12) (d) (2x m12) 20) (4x m120 456 b d (1 3,8) b (a) d c c c - c 186 (2x m8) 208.5 (2x m8) xx1300000264 r= 4...

  • Page 91

    Tool flange, standard below is the standard tool flange. 160 1 2 x 3 0 ° c b 0.05 b b 0.3 c 1 0 11x m12 2 2 h8 100 200 h7 h7 15 18 12 1 x 4 5 b b b - b xx1300000280 continues on next page 3hac044266-001 revision: - 91 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.4.8 ...

  • Page 92

    Tool flange, leanid below is the tool flange for option 780-4, leanid. C - c 200 h8 12 h7 15 100 h7 11x m12 18 8 15 0,05 d 0,3 d e d e 160 12x 30° c c xx1300000290 92 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.4.8 fitting equipment to the...

  • Page 93

    2.5 restricting the working range 2.5.1 introduction general when installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axes may be re...

  • Page 94

    2.5.2 mechanically restricting the working range of axis 1 general the working range of axis 1 is limited by fixed mechanical stops and adjustment of the system parameter configuration. The working range can be reduced by adding additional mechanical stops giving 15° graduation, between ±5° and ±125...

  • Page 95

    Note art. No. Equipment, etc. Content is defined in section standard toolkit on page 559 . - standard toolkit art. No. Is specified in section references on page 10 . - technical reference manual - system parameters installation, mechanical stops axis 1 use this procedure to fit the additional mecha...

  • Page 96

    2.6 electrical connections 2.6.1 robot cabling and connection points introduction connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories all cables between the robot and ...

  • Page 97

    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: - 97 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.7.1 installing the signal lamp (option).

  • Page 98

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  • Page 99: 3 Maintenance

    3 maintenance 3.1 introduction structure of this chapter this chapter describes all the maintenance activities recommended for the irb 6700. It is based on the maintenance schedule found at the beginning of the chapter. The schedule contains information about required maintenance activities includin...

  • Page 100

    3.2 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 month...

  • Page 101

    3.2.2 maintenance schedule scheduled and non-predictable maintenance the robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be...

  • Page 102

    Reference every 40,000 hours i every 20,000 hours i every 12,000 hours i every 36 months every 12 months regularly maintenance activities inspecting the dampers on page 134 x inspecting the mechanical stop replacement/changing activities changing oil, axis-1 gearbox on page 138 x changing the oil in...

  • Page 103

    3.2.3 expected component life general the expected life of a specific component of the robot can vary greatly depending on how hard it is run. Expected component life - protection type standard note expected life component not including: • possible spotpack harnesses • optional upper arm harnesses 4...

  • Page 104

    3.3 inspection activities 3.3.1 inspecting the oil level in axis-1 gearbox location of oil plug the oil plug through which the oil level is inspected is located as shown in the figure. Xx1200000950 tightening torque: 24 nm required tools note article number equipment content is defined in section st...

  • Page 105

    Inspecting the oil level in axis-1 gearbox use this procedure to inspect the oil level in the gearbox. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 warning handling gearbox oil invol...

  • Page 106

    Note action type of oil and total amount is detailed in technical reference manual - lubrication in gearboxes . Add or drain oil, if required. 5 further information about how to drain or fill with oil is found in section changing oil, axis-1 gearbox on page 138 . Tightening torque: 24 nm. Refit the ...

  • Page 107

    3.3.2 inspecting the oil level in axis-2 gearbox location of oil plug the gearbox has a level plug that is located as shown in the figure. Xx1200000952 tightening torque: 24 nm required tools note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard ...

  • Page 108

    Inspecting the oil level in axis-2 gearbox use this procedure to inspect the oil level in the gearbox. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 warning handling gearbox oil invol...

  • Page 109

    3.3.3 inspecting the oil level in axis-3 gearbox location of oil plug the gearbox has a level plug that is located as shown in the figure. Xx1200000955 tightening torque: 24 nm required tools note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard ...

  • Page 110

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning ...

  • Page 111

    3.3.4 inspecting the oil level in axis-4 gearbox location of oil plug the gearbox has a level plug that is located as shown in the figure. Xx1200000957 tightening torque: 24 nm required tools note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard ...

  • Page 112

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning ...

  • Page 113

    3.3.5 inspecting the oil level in axis-5 gearbox location of oil plug the gearbox has a level plug that is located as shown in the figure. Xx1200000959 tightening torque: 24 nm required tools note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard ...

  • Page 114

    Note action warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning - safety risks during work with gearbox lubricants (oil or grease) on page 49 . 3 xx1200000959 open the oil plug. 4 check the oil level. 5 required oil...

  • Page 115

    3.3.6 inspecting the oil level in axis-6 gearbox location of oil plug the oil plug through which the oil level is inspected is located as shown in the figure. Xx1200000963 tightening torque: 24 nm required tools note article number equipment, etc. Content is defined in section standard toolkit on pa...

  • Page 116

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning ...

  • Page 117

    Note action tightening torque:24 nm. Refit the oil plug. 8 danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 44 . 9 3hac044266-001 revision: - 117 © copyright 2013...

  • Page 118

    3.3.7 inspecting the balancing device general several points are to be checked on the balancing device during the inspection. This section describes how to perform the inspection regarding: • dissonance • damage • leakage • contamination / lack of free space. Inspection points, balancing device the ...

  • Page 119

    Required material note art. No. Equipment includes: • bearing and seals • vk cover. 3hac045815-001 maintenance kit, link ear includes: • bearings and seals • vk cover. 3hac045822-001 maintenance kit, rear attachment check for dissonance the check points are shown in the figure inspection points, bal...

  • Page 120

    Check the o-rings and sealings in the front ear of the balancing device for leaks. Xx1000000207 shaft a sealing ring (radial (2 pcs) b o-ring c sealing spacer d note action clean the area at the front ear from contamina- tion. 1 run the robot for some minutes, in order to move the balancing device p...

  • Page 121

    Check for contamination / lack of free space note action danger turn off all: • electric power supply to the robot • hydraulic pressure supply to the robot • air pressure supply to the robot before entering the robot working area. 1 xx1300000423 check that there are no obstacles inside the frame, th...

  • Page 122

    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 122 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 3 maintenance 3.3.8 i...

  • Page 123

    Inspecting the cable harness use this procedure to inspect cable harness of axes 1-6. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 xx1300001095 make an overall inspection of the cabl...

  • Page 124

    3.3.9 inspection, information labels location of 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 38 . Illustration 1 of 2 h j n n e f f f e e e e b k m continues on next page 124 3hac0...

  • Page 125

    Illustration 2 of 2 a p s r c j l j j n n n t d e g illustration description calibration label a xx0900000816 instruction label before dismantling see product manual b 45° 20° 70° 890 50 570 55 65° ! ! ! 4x irb 6700, m = 1160 - 1600 kg / 2557 - 3527 lbs 3hac 046732-001 / 00 4x, 2000kg, 2,5 m 1x, 200...

  • Page 126

    3 h a c 8 2 2 5 -1 /0 4 ! Xx1300001083 instruction label brake release moving robot brake release buttons d oil specification label e grease specification label f complete oil specification g 3hac 9526-1/04 ! Xx1300001086 warning label do not dismantle stored energy h 3 h a c 4 4 3 1 -1 /0 6 ! Xx130...

  • Page 127

    3hac 020611-001/ 03 ! Xx1300001090 warning label keep areas around the balancing device free from objects m xx1300001091 warning label flash n rating label p absolute accuracy label r ul label s ± 220° 3hac 021761-001/02 eps ! Xx1300001092 label extended rotation no mechanical stop see user document...

  • Page 128

    3.3.10 inspecting, mechanical stop pin, axis 1 warning mechanical stop pin can not be mounted on robot if option 810-1 electronic position switch is used. Location of mechanical stop pin the mechanical stop axis 1 is located at the base as shown in the figure. Xx1200001073 required equipment visual ...

  • Page 129

    Inspecting, mechanical stop pin use this procedure to inspect the mechanical stop pin axis 1. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 shown in figure location of mechan- ical st...

  • Page 130

    3.3.11 inspecting, additional mechanical stops location of mechanical stops the figure shows the location of additional mechanical stops. A b c b xx1300001971 attachment screws m12x70 quality 12.9 gleitmo 603 (2 pcs per additional mechanical stop) a movable mechanical stop b mechanical stop pin axis...

  • Page 131

    Inspecting, mechanical stops use this procedure to inspect the additional mechanical stops. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 shown in figure location of mechanical stops ...

  • Page 132

    3.3.12 inspecting the fork lift device set location of fork lift device set the fork lift device set is fitted to the robot as shown in the figure. A b xx1300001602 fork lift device (4 pcs) a hex socket head cap screw m20x60 quality steel 8.8-a3f (2 pcs per fork lift device) b required equipment not...

  • Page 133

    Inspecting, fork lift device set use this procedure to inspect the fork lift device set. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 check the fork lift devices for damage. 2 check ...

  • Page 134

    3.3.13 inspecting the dampers location of dampers the figure below shows the location of all the dampers to be inspected. Xx1300000414 axis-2 damper, 2 pcs a axis-3 damper, 2 pcs b required equipment visual inspection, no tools are required. A damper must be replaced if damaged! Inspecting, dampers ...

  • Page 135

    Note action xx1300000414 a axis-2 damper, 2 pcs b axis-3 damper, 2 pcs check all dampers for damage, and for cracks or existing impressions larger than 1 mm. 2 check attachment screws for deformation. 3 spare part number is found in product manual, spare parts - irb 6700 . If any damage is detected,...

  • Page 136

    3.3.14 inspecting, signal lamp (option) location of signal lamp the signal lamp is located as shown in this figure. Required equipment note art. No. Equipment, etc. To be replaced if damage is detected. See spare parts on page 565 . Signal lamp kit content is defined in section stand- ard toolkit on...

  • Page 137

    3.4 replacement/changing activities 3.4.1 type of lubrication in gearboxes introduction this section describes where to find information about the type of lubrication , article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubr...

  • Page 138

    3.4.2 changing oil, axis-1 gearbox usage of oil dispenser the oil change procedure in this section describes usage of an oil dispenser. Location of oil plugs the oil plugs of the gearbox are located as shown in the figure. Xx1200000950 xx1200000948 vent hole plug oil hole with nipple used for both v...

  • Page 139

    Required documents note document number document name 3hac042927-001 technical reference manu- al - lubrication in gearboxes draining the axis-1 gearbox use this procedure to drain the gearbox. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply...

  • Page 140

    Note action xx1200000950 remove the plug from the vent hole. Warning if the vent hole is not open when the oil dispenser is working, there is a risk of damaging vital parts in the gear! 5 suck out the oil with the oil dispenser. Note there will be some oil left in the gear after draining. 6 warning ...

  • Page 141

    Note action warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning - safety risks during work with gearbox lubricants (oil or grease) on page 49 . 2 xx1200000948 remove the protective cap from the nipple of the oil hol...

  • Page 142

    Note action xx1200000950 inspect the oil level. 6 required oil level: 58 mm ± 5 mm below the sealing surface of the oil plug. Xx1300000692 remove the oil dispenser and refit the protective cap to the nipple. 7 tightening torque: 24 nm refit the vent hole plug. 8 danger make sure all safety requireme...

  • Page 143

    3.4.3 changing oil, axis-2 gearbox usage of oil dispenser the oil change procedure in this section describes usage of an oil dispenser. Location of oil plugs the oil plugs of the gearbox are located as shown in the figure. Xx1200000952 xx1200000951 vent hole plug / level plug oil hole with nipple us...

  • Page 144

    Required documents note document number document name 3hac042927-001 technical reference manu- al - lubrication in gearboxes draining the axis-2 gearbox use this procedure to drain the gearbox. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply...

  • Page 145

    Note action xx1200000952 remove the plug from the vent hole. Warning if the vent hole is not open when the oil dispenser is working, there is a risk of damaging vital parts in the gear! 5 suck out the oil with the oil dispenser. Note there will be some oil left in the gear after draining. 6 warning ...

  • Page 146

    Note action warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning - safety risks during work with gearbox lubricants (oil or grease) on page 49 . 2 xx1200000951 remove the protective cap from the nipple of the oil hol...

  • Page 147

    Note action xx1200000952 inspect the oil level at the vent hole (level plug). 6 required oil level is: 0 - 10 mm below the oil plug hole. More information is found in inspecting the oil level in axis-2 gearbox on page 108 . Remove the oil dispenser and refit the protective cap to the nipple. 7 tight...

  • Page 148

    3.4.4 changing oil, axis-3 gearbox usage of oil dispenser the oil change procedure in this section describes usage of an oil dispenser. Location of oil plugs the oil plugs of the gearbox are located as shown in the figure. Xx1200000955 xx1200000954 vent hole plug / level plug oil hole with nipple us...

  • Page 149

    Draining the axis-3 gearbox use this procedure to drain the gearbox. Note action run the robot to calibration position. 1 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning handling gearbox oi...

  • Page 150

    Note action xx1200000955 remove the plug from the vent hole. Warning if the vent hole is not open when the oil dispenser is working, there is a risk of damaging vital parts in the gear! 6 suck out the oil with the oil dispenser. Note there will be some oil left in the gear after draining. 7 warning ...

  • Page 151

    Note action xx1200000954 remove the protective cap from the nipple of the oil hole and connect the oil dis- penser. 4 xx1200000955 remove the plug from the vent hole. Note the vent hole is opened to let out air during the filling process. 5 type of oil and total amount is detailed in technical refer...

  • Page 152

    Note action danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 44 . 10 152 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 3 maintenance 3.4.4...

  • Page 153

    3.4.5 changing oil, axis-4 gearbox location of oil plugs the oil plugs of the gearbox are located as shown in the figure. Xx1200000957 xx1200000956 oil fill plug / level plug oil drain plug tightening torque: 24 nm. Tightening torque: 24 nm. Required material note material information about the oil ...

  • Page 154

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning ...

  • Page 155

    Note action tightening torque: 24 nm. Refit the oil plugs. 9 filling oil into the axis-4 gearbox use this procedure to refill the gearbox with oil. Note action run the robot to calibration position. 1 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to t...

  • Page 156

    Note action the level is measured at the fill hole. Xx1200000957 inspect the oil level. 6 required oil level is: 0 - 10 mm below the oil plug hole. See inspecting the oil level in axis-4 gear- box on page 111 . Tightening torque: 24 nm refit the oil plug. 7 danger make sure all safety requirements a...

  • Page 157

    3.4.6 changing oil, axis-5 gearbox location of oil plugs the oil plugs of the gearbox are located as shown in the figure. Xx1200000959 xx1200000958 oil fill plug / level plug oil drain plug tightening torque: 24 nm. Tightening torque: 24 nm. Required material note material information about the oil ...

  • Page 158

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning ...

  • Page 159

    Filling oil into the axis-5 gearbox use this procedure to refill the gearbox with oil. Note action run the robot to calibration position. 1 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning h...

  • Page 160

    Note action danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 44 . 8 160 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 3 maintenance 3.4.6 ...

  • Page 161

    3.4.7 changing oil, axis-6 gearbox location of oil plugs the oil plugs of the gearbox are located as shown in the figure. Xx1200000963 xx1200000962 oil fill plug oil drain plug tightening torque: 24 nm. Tightening torque: 24 nm. Required material note material information about the oil is found in t...

  • Page 162

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning ...

  • Page 163

    Note action 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. 8 tightening torque: 24 nm. Refit the oil plugs. 9 filling oil into the axis-6 gearbox use this procedure to refill the gearbox with oil. Note act...

  • Page 164

    Note action the level is measured at the fill hole. Xx1200000963 inspect the oil level. 6 required oil level is: 50 mm ± 5 mm below the sealing surface of the oil plug. Xx1300000693 more information is found in inspecting the oil level in axis-6 gearbox on page 115 . Tightening torque: 24 nm refit t...

  • Page 165

    3.4.8 replacing the smb battery note the battery low alert (38213 battery charge low ) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced. Warning see instruction...

  • Page 166

    Required spare parts note art. No. Spare part battery includes protection circuits. Only replace with a specified spare part or an abb-approved equivalent. For spare part no. See: • spare parts on page565 battery pack removing, battery use this procedure to remove the smb battery. Note action this i...

  • Page 167

    Refitting, battery use this procedure to refit the smb battery. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 electrostatic discharge (esd) the unit is sensitive to esd. Before handli...

  • Page 168

    3.5 lubrication activities 3.5.1 lubricating the spherical roller bearing, balancing device location of spherical roller bearing the spherical roller bearing is located in the link ear of the balancing device. Xx1300000773 attachment screws m6x10 quality 8.8-a2f (2 pcs) a end cover b radial sealing ...

  • Page 169

    Lubricating the spherical roller bearing use this procedure to lubricate the spherical roller bearing. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 grease: 3hac042534-001 xx130000078...

  • Page 170

    3.6 cleaning activities 3.6.1 cleaning, robot warning turn off all electrical power supplies to the manipulator before entering its work space. General to secure high uptime it is important that the robot is cleaned regularly. The frequency of cleaning depends on the environment in which the robot w...

  • Page 171

    Note equipment, etc. • max. Water pressure at the nozzle: 700 kn/m 2 (7 bar) i • fan jet nozzle should be used, min. 45° spread • distance from nozzle to encapsulation: min. 0.4 m • flow: max. 20 liters/min i . Water cleaner • water pressure at nozzle: max. 2,500 kn/m 2 (25 bar) • type of nozzle: fa...

  • Page 172

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  • Page 173: 4 Repair

    4 repair 4.1 introduction structure of this chapter this chapter describes all repair activities recommended for the irb 6700 and any external unit. It is made up of separate procedures, each describing a specific repair activity. Each procedure contains all the information required to perform the a...

  • Page 174

    4.2 general procedures 4.2.1 performing a leak-down test when to perform a leak-down test after refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment note article number equipment, etc. 3hac0207-1 le...

  • Page 175

    4.2.2 mounting instructions for bearings general this section describes how to mount and grease different types of bearings on the robot. Equipment note art. No. Equipment, etc. Used to grease the bearings, if not specified otherwise. 3hab3537-1 grease assembly of all bearings follow the following i...

  • Page 176

    • ensure that grease is handled and stored properly to avoid contamination. Grease the different types of bearings as following description: • grooved ball bearings must be filled with grease from both sides. • tapered roller bearings and axial needle bearings must be greased in the split condition....

  • Page 177

    4.2.3 mounting instructions for seals general this section describes how to mount different types of seals onto the robot. Equipment note art. No. Equipment, etc. Used to lubricate the seals. 3hab3537-1 grease rotating seals the procedure below describes how to fit rotating seals. Caution please obs...

  • Page 178

    Flange seals and static seals the following procedure describes how to fit flange seals and static seals. Action check the flange surfaces. They must be even and free from pores. 1 it is easy to check flatness using a gauge on the fastened joint (without sealing com- pound). If the flange surfaces a...

  • Page 179

    4.3 attaching lifting accessories 4.3.1 arm system (including the frame) definition of the complete arm system 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 note article number equi...

  • Page 180

    Note article number equipment, etc. M12 3hac16131-1 lifting eye outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. - fender washer sa-10-8-na1 - lifting shackle length: 1.5 m. Lifting capacity: 1,000 kg. - roundsling, 1.5 m length: 1 m. Lifting capacity: 1,000 kg. - roundsling, 1 ...

  • Page 181

    Note action lifting eye: 3hac16131-1 xx1200001133 fit a lifting eye to the wrist. 2 lifting shackle: sa-10-8-na1 xx1200001234 fit a lifting shackle in the wrist lifting eye. 3 caution the complete arm system weigh 1100 kg. All lifting accessories used must be sized accord- ingly! 4 roundsling, 1.5 m...

  • Page 182

    Note action xx1200001235 attach the roundsling to the shackle on the wrist and jog axis-3 slowly to stretch the roundsling. Note make sure the roundsling is stretched, so it can carry the weight of the frame. 6 lifting eye: 3hac16131-1 fit a lifting eye in the arm house, with a fender washer underne...

  • Page 183

    4.3.2 lower and upper arm unseparated attachment points of lifting accessory xx1200001254 required tools note article number equipment, etc. M12 3hac16131-1 lifting eye m12 3hac16131-1 lifting eye outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. - fender washer sa-10-8-na1 - lif...

  • Page 184

    Note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard toolkit attaching the lifting accessories robot position note action note when jogging the axis-2 into position check that the balancing device ear and the ear on the lower arm is not collidin...

  • Page 185

    Attaching the lifting accessories use this procedure to attach the lifting accessories. Note action lifting eye: 3hac16131-1 xx1200001133 fit a lifting eye to the wrist. 1 lifting shackle: sa-10-8-na1 xx1200001234 fit a lifting shackle in the wrist lifting eye. 2 xx1200001251 in order to secure the ...

  • Page 186

    Note action roundsling, 1.5 m: length: 1.5 m. Lifting capacity: 1,000 kg. Xx1200001252 run a roundsling around the lower arm, place it accordingly: • no dresspack cable package installed: place the roundsling beneath the securing screw. • with dresspack cable package installed: place the roundsling ...

  • Page 187

    Note action if the robot is equipped with dresspack, unscrew the attachment screws of the brackets that holds the ball joint housings on the wrist. 11 then move the dresspack cable package over to the other side of where the lifting accessory will be attached to the shackle on the arm house. 12 lift...

  • Page 188

    4.3.3 lifting the upper arm attachment points of lifting accessory xx1200001308 required equipment note article number equipment, etc. M12 3hac16131-1 lifting eye m12 3hac16131-1 lifting eye outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. - fender washer lifting instruction 3ha...

  • Page 189

    Lifting the upper arm attaching the lifting accessories use this procedure to attach the lifting accessories to the upper arm. Note action lifting eye: 3hac16131-1 xx1200001133 fit a lifting eye to the wrist. 1 lifting eye: 3hac16131-1 fit a lifting eye in the arm house, with a fender washer underne...

  • Page 190

    Note action in case of necessary adjustments, use the shortening loops on the lifting accessory (chain), making sure to place the chain the right way through the loops! 6 release the brakes in order to find the most level lifting position of the upper arm as possible, before lifting. 7 24 vdc power ...

  • Page 191

    4.4 complete robot 4.4.1 removing the cable harness location of the cable harness the cable harness is located as shown in the figure. Xx1300000555 required tools and equipment note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard toolkit continu...

  • Page 192

    Removing the cable harness - upper arm and wrist these procedures describes how to remove the cable harness in the upper arm and wrist. Preparations before removing the cable harness note action note the specified position shown below is a recommended position. Depending on what tool is used, one or...

  • Page 193

    Note action a b c xx1300000821 attachment screws a ball joint housing b bracket c if dresspack is installed: • remove the complete ball joint housing fitted on the bracket. Leave the dresspack cable package fitted in the ball joint housing. • remove the bracket. 4 see ball joint housing in the back ...

  • Page 194

    Note action 24 vdc power supply xx1200001081 if axis-5 is not already in position +90°, connect the 24 vdc power supply, release the brakes and move the axis manually into that position. Connect to r2.Mp5-connector: • + = pin 2 • - = pin 5 2 xx1300000486 remove the wrist cover. 3 xx1300000489 cut th...

  • Page 195

    Note action xx1300000490 pull the cable harness to the side and re- move the heat protection plate. Note keep the heat protection plate somewhere safe until it shall be refitted. 5 disconnecting the axis-6 motor cables note action danger make sure that all supplies for electrical power, hydraulic pr...

  • Page 196

    Note action xx1300000488 disconnect the motor cables. 3 disconnecting the axis-5 motor cables note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 xx1200001135 unscrew the attachment screws and washers and remove the motor cover....

  • Page 197

    Note action xx1300000656 remove the cable gland cover by perform- ing the following steps: 1 open the inner screw a little (the one the arrow is pointing at). No need to remove this screw. 2 remove the outer screw. 3 slide the cable gland cover away from the inner screw. Make sure the gasket is not ...

  • Page 198

    Note action xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor also will be removed. The motor shall be refitted in the same position. 4 use caution...

  • Page 199

    Note action xx1300000657 remove the cable guide by unscrewing the attachment screws. 2 xx1200000042 if used, remove the insert that guides the dresspack through the hole in the upper arm, by unscrewing the attachment screws. 3 the figure show irb 6640. Xx1300000658 if used, push the tube containing ...

  • Page 200

    Note action xx1300000557 remove the side cover on the arm tube. 6 xx1300000592 loosen the axis-4 metal clamp that holds the cable harness inside the arm tube by unscrewing the attachment screws. Note the screws are reached from outside the upper arm! 7 xx1300000543 remove the armhouse metal clamp. 8...

  • Page 201

    Note action xx1300000544 open the velcro straps at the cable fixing bracket. Note if dresspack is fitted, the cable fixing bracket is replaced by the cable guide. Xx1300001973 9 xx1300000541 remove the metal clamp on top of the armhouse. 10 continues on next page 3hac044266-001 revision: - 201 © cop...

  • Page 202

    Note action person 1, working at the side hole: xx1300000745 tip this step is best performed by two persons working together. Use caution and remove the cable harness from the wrist like this: • person 1: put one hand inside the side hole and take a hold of the cable harness. • person 2: take a hold...

  • Page 203

    Removing the cable harness - base, frame and lower arm these procedures describes how to remove the cable harness from base, frame and lower arm. Preparations before removing the cable harness note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure a...

  • Page 204

    Note action b a xx1300001972 m6x16 and plain washer large 6.4x17x3 a earth b disconnect the earth cable. 4 disconnecting the axis-1 and axis-2 motor cables note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 xx1200001135 unscrew...

  • Page 205

    Note action xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor also will be removed. The motor shall be refitted in the same position. 4 use caution...

  • Page 206

    Note action xx1300000829 open the small cover on the smb cover, disconnect the battery cable and remove the battery. 3 xx1300000669 remove the smb cover. 4 disconnecting the bu unit note action danger make sure that all supplies for electrical power, hy- draulic pressure, and air pressure are turned...

  • Page 207

    Removing the cable harness in the base note action if used, use caution and pull out the dresspack hoses through the protection tube in the base. 1 if used, use caution and pull out the dresspack cables through the protection tube and place it safely over the balancing device. 2 xx1300000732 use cau...

  • Page 208

    Note action xx1200001237 cut the cable tie inside the hole in the frame. 5 xx1300001114 disconnect connectors on the smb unit. 6 xx1300000730 unscrew the screws and washers that holds the bracket with the smb unit, and remove the smb unit. 7 put the smb unit in an esd bag until it shall be refitted....

  • Page 209

    Note action xx1300000655 unscrew the three attachment screws that hold the smb/bu cover from inside the smb recess. 9 xx1300000560 use caution and pull out the cable harness from the smb recess. 10 xx1300000593 use caution and pull out the cable harness through the hole in the frame. 11 continues on...

  • Page 210

    Removing the cable harness in the lower arm note action xx1200001282 loosen the axis-2 lower arm metal clamp and the axis-3 lower arm metal clamp loc- ated on the inside of the lower arm by re- moving the attachment screws. Note the screws are reached from the outside of the lower arm. 1 xx130000073...

  • Page 211

    4.4.2 refitting the cable harness location of the cable harness the cable harness is located as shown in the figure. Xx1300000555 spare part note spare part number spare part see product manual, spare parts - irb 6700 . Cable harness required tools and equipment note article number equipment, etc. C...

  • Page 212

    Consumables note article number consumable used to lubricate o-rings. 3hab3537-1 grease d=84.5x3 21522012-429 o-ring used on the smb/bu cover. D=169.5x3 3hab3772-111 o-ring used on axis-1 motor cover. D=169.5x3 3hab3772-111 used on axis-2 motor cover. D=169.5x3 3hab3772-111 used on axis-3 motor cove...

  • Page 213

    Note action xx1300000733 run the upper end of the cable harness up through the lower arm. 3 xx1300000734 secure the axis-2 lower arm cable bracket. Note do not secure the axis-3 lower arm cable bracket at this point. Note screws are reached from the outside of the lower arm. 4 xx1300000735 run the c...

  • Page 214

    Note action xx1300000737 fit the o-ring. 3 the figure shows the position of the o-ring. Apply sikaflex on the o-ring before as- sembly. 4 xx1300000560 run the smb/bu cables into the smb re- cess. 5 xx1300000655 use caution and fit the smb/bu cover in its hole with three attachment screws from inside...

  • Page 215

    Note action xx1300000593 adjust the cables running through the hole in the frame by carefully moving the smb/bu cover on its screws, while at the same time checking the position of the cable harness through the hole. Note the cables must be placed so that they don't rub against any part of the robot...

  • Page 216

    Note action xx1300000542 refit the frame metal clamp. 11 refitting the cable harness in the base note action xx1300000732 use caution and run the cables down through the protection tube in this order: • r1.Mp • r1.Smb 1 xx1300000736 • make sure that the cables are not twisted. The cables shall be in...

  • Page 217

    Note action xx1300000591 connect r1.Mp and r1.Smb. 4 b a xx1300001972 m6x16 and plain washer large 6.4x17x3 a earth b connect the earth cable. 5 if used, run the dresspack cables down through the protection tube in the base. 6 if used, run the dresspack hoses down through the protection tube in the ...

  • Page 218

    Note action xx1300000561 refit the base cover. 9 refit and reconnect the smb and bu units note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 electrostatic discharge (esd) the unit is sensitive to esd. Before handling the unit p...

  • Page 219

    Note action xx1300000728 connect all connectors to the smb board: r1.Smb1-3, r1.Smb4-6 and r2.Smb 4 xx1300000730 use caution, push in the smb unit into position and fit the bracket that hold the smb unit. 5 xx1300000670 if disconnected, reconnect the connectors x8, x9 and x10 to the brake release bo...

  • Page 220

    Note action xx1300000669 secure the smb cover with its attachment screws. 8 reconnecting the axis-1 and axis-2 motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001067 refit the cable gland cover. Note replace the gasket if damaged! 2 continues o...

  • Page 221

    Note action xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring a...

  • Page 222

    Refitting the cable harness - lower arm note action xx1300000595 before fitting the remaining axis-3 lower arm cable bracket inside the lower arm, make sure that it will stay twisted between the metal clamps, after fitting, as shown in the figure. 1 xx1300000558 refit the axis-3 lower arm metal clam...

  • Page 223

    Refitting the cable harness - upper arm and wrist these procedures describes how to refit the cable harness in upper arm and wrist. Refitting the cable harness - upper arm note action xx1300000541 refit the metal clamp on top of the arm house. 1 xx1300000543 refit the arm house metal clamp. 2 make s...

  • Page 224

    Note action person 1, working at the side hole: xx1300000745 tip this step is best performed by two persons working together: • person 1: put one hand inside the side hole of the arm tube and take a hold of the cable harness. • person 2: take a hold on the cable harness at the back of the robot. • t...

  • Page 225

    Note action use caution and push the cable harness into the upper arm tube. 8 person 1, working at the side hole: xx1300000745 tip this step is best performed by two persons working together. Use caution and push the cable harness into the wrist like this: • person 1: put one hand inside the side co...

  • Page 226

    Note action xx1200000042 if used, refit the insert that guides the dresspack cable package through the hole in the upper arm. 12 the figure show irb 6640. Xx1300000658 if used, refit the tube containing the dresspack into the insert. 13 the figure show irb 6640. Xx1200000045 if used, refit the cover...

  • Page 227

    Note action xx1300000544 secure the cable harness to the cable fixing bracket with the velcro strap. Note if dresspack is fitted, the cable fixing bracket is replaced by the cable guide. Xx1300001973 15 connecting the axis-3 and axis-4 motor cables note action xx1300000738 push the motor cables in t...

  • Page 228

    Note action xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring a...

  • Page 229

    Connecting the axis-5 motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001016 refit the cable gland cover by performing the following steps: • slide the cable gland cover onto the inner screw. • refit and tighten the outer screw. • tighten the i...

  • Page 230

    Note action o-ring, axis-5, 3hab3772-110 xx1200001021 check the o-ring on the motor. Replace if damaged! 4 xx1200001013 refit the motor cover with its attachment screws. Note do not refit the screws that will hold the heat protection plate at this point. Note do not reuse the self-threading attachme...

  • Page 231

    Note action xx1300000489 secure the cable harness with the cable straps to the heat protection plate. 7 make sure that the cover is tightly sealed. 8 connecting the axis-6 motor cables note action xx1300000596 make sure that the cable harness will be placed in a way that it will not be damaged when ...

  • Page 232

    Note action xx1300000667 use caution and push the cable harness into the wrist recess and up into the axis-6 motor. 3 xx1300001113 use caution and push the carrier into posi- tion. 4 xx1300000485 secure the carrier with the m4 screw. Note the screw is located at the bottom of the carrier. Tip the at...

  • Page 233

    Note action xx1300000488 reconnect the connectors to the axis-6 motor. Note place the resolver cable under the motor cable. 7 gasket, 3hac033489-001 xx1200001095 check the gasket. Replace if damaged! 8 xx1200001080 refit the motor cover. 9 disconnect the 24 vdc power supply (if used). 10 continues o...

  • Page 234

    Concluding procedures note action tightening torque: 10 nm. Xx1300000772 use caution and refit the wrist cover. In order not to damage the cable harness when the wrist cover is refitted, by following this method: 1 hold the cover in an angle. See figure! 2 catch any part of the cable harness hanging...

  • Page 235

    4.4.3 replacing the smb location of smb unit the smb unit (smb = serial measurement board) is located inside the smb/bu recess, as shown in the figure. Xx1300000740 spare part note art. No. Equipment, etc. See product manual, spare parts - irb 6700 . Smb unit see product manual, spare parts - irb 67...

  • Page 236

    Removing the smb unit use these procedures to disconnect and remove the smb unit. Preparations before disconnecting the smb unit note action danger make sure that all supplies for electrical power, hy- draulic pressure, and air pressure are turned off. 1 electrostatic discharge (esd) the unit is sen...

  • Page 237

    Note action xx1300000730 remove the screws and washers that holds bracket with the smb unit. 3 xx1300000728 use caution, pull out the smb unit a little and discon- nect the connectors from the smb board: r1.Smb1-3, r1.Smb4-6 and r2.Smb 4 xx1300000731 use caution and pull out the smb unit and put it ...

  • Page 238

    Note action xx1300000729 connect the battery cable to the smb unit. 3 xx1300000728 connect all connectors to the smb board: r1.Smb1-3, r1.Smb4-6 and r2.Smb 4 xx1300000730 use caution, push in the smb unit into position and fit the bracket that hold the smb unit. 5 xx1300000670 if disconnected, recon...

  • Page 239

    Note action xx1300000834 pull out the battery cable through the recess for the battery. 7 xx1300000669 secure the smb cover with its attachment screws. 8 refitting the smb battery note action electrostatic discharge (esd) the unit is sensitive to esd. Before handling the unit please read the safety ...

  • Page 240

    Concluding procedures note action see updating revolution counters on page 542 . Update the revolution counter! 1 danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page...

  • Page 241

    4.4.4 replacing the brake release unit location of bu unit the brake release unit (bu unit) is located inside smb/bu recess, as shown in the figure. Xx1300000741 spare part note art. No. Equipment, etc. See product manual, spare parts - irb 6700 . Brake release unit see product manual, spare parts -...

  • Page 242

    Removing the brake release unit preparations note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 electrostatic discharge (esd) the unit is sensitive to esd. Before handling the unit please ...

  • Page 243

    Disconnecting the bu unit note action danger make sure that all supplies for electrical power, hy- draulic pressure, and air pressure are turned off. 1 electrostatic discharge (esd) the unit is sensitive to esd. Before handling the unit please read the safety information in the section warning - the...

  • Page 244

    Refitting the brake release unit use this procedure to refit the brake release unit. Note action electrostatic discharge (esd) the unit is sensitive to esd. Before handling the unit please read the safety information in the section warning - the unit is sensitive to esd! On page 47 1 xx1300000744 re...

  • Page 245

    Note action xx1300000743 refit the push button guard to the smb cover. 6 see updating revolution counters on page 542 . The revolution counters must be updated if the battery has been disconnected. 7 danger make sure all safety requirements are met when performing the first test run. These are furth...

  • Page 246

    4.5 upper and lower arms 4.5.1 replacing the upper arm location of the upper arm the upper arm is located as shown in the figure. These sections describe how to replace the complete upper arm, which includes the wrist unit. Xx1300000483 spare part note spare part number spare part see product manual...

  • Page 247

    Note article number equipment, etc. Used for putting down removed parts from robot. Pallet always use guide pins in pairs! 3hac13056-2 guide pin, m12x150 always use guide pins in pairs! 3hac13056-3 guide pin, m12x200 used to release the motor brakes. - 24 vdc power supply 3hac15716-1 calibration pen...

  • Page 248

    Note action xx1300000818 if dresspack is installed: 1 remove the complete ball joint housing. 2 remove the bracket fitted between the ball joint housing and the wrist cover. 4 retrieving access to the wrist cabling use this procedure to open the wrist and access the axis-5 and axis-6 motor cables. N...

  • Page 249

    Note action xx1300000486 remove the wrist cover. 3 xx1300000489 cut the cable straps that hold the cable harness to the heat protection plate. 4 xx1300000490 pull the cable harness to the side and re- move the heat protection plate. Note keep the heat protection plate somewhere safe until it shall b...

  • Page 250

    Note action xx1200001080 unscrew the attachment screws and re- move the motor cover. 2 xx1300000488 disconnect the motor cables. 3 disconnecting the axis-5 motor cables note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 xx12000...

  • Page 251

    Note action xx1200001066 disconnect the motor cables. 3 xx1300000656 remove the cable gland cover by perform- ing the following steps: 1 open the inner screw a little (the one the arrow is pointing at). No need to remove this screw. 2 remove the outer screw. 3 slide the cable gland cover away from t...

  • Page 252

    Note action xx1200001135 unscrew the attachment screws and washers and remove the motor cover. 2 xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor ...

  • Page 253

    Removing the cable harness - wrist and upper arm note action xx1200000045 if used, remove the dresspack cover with the tube guiding ring fitted, by unscrewing the attachment screws. 1 xx1300000657 remove the cable guide by unscrewing the attachment screws. 2 xx1200000042 if used, remove the insert t...

  • Page 254

    Note action xx1300000658 if used, push the tube containing the dresspack a little backwards. 4 the figure show irb 6640. Xx1300000668 tie the axis-5 and axis-6 connectors and carrier into a bundle with tape (if not already done). This is done to facilitate the procedure and to avoid damaging the par...

  • Page 255

    Note action xx1300000543 remove the armhouse metal clamp. 8 xx1300000544 open the velcro straps at the cable fixing bracket. Note if dresspack is fitted, the cable fixing bracket is replaced by the cable guide. Xx1300001973 9 xx1300000541 remove the metal clamp on top of the armhouse. 10 continues o...

  • Page 256

    Note action person 1, working at the side hole: xx1300000745 tip this step is best performed by two persons working together. Use caution and remove the cable harness from the wrist like this: • person 1: put one hand inside the side hole and take a hold of the cable harness. • person 2: take a hold...

  • Page 257

    Attaching the lifting accessories use this procedure to attach the lifting accessories to the upper arm. Note action lifting eye: 3hac16131-1 xx1200001133 fit a lifting eye to the wrist. 1 lifting eye: 3hac16131-1 fit a lifting eye in the arm house, with a fender washer underneath. 2 fender washer: ...

  • Page 258

    Note action in case of necessary adjustments, use the shortening loops on the lifting accessory (chain), making sure to place the chain the right way through the loops! 6 release the brakes in order to find the most level lifting position of the upper arm as possible, before lifting. 7 24 vdc power ...

  • Page 259

    Note action note make sure the lift is done completely level! In case of necessary adjustments, use the shortening loops on the lifting accessory (chain), but make sure to place the chain the right way through the loops! 4 xx1300001610 remove the remaining attachment screw and slide the upper arm on...

  • Page 260

    Note action guide pin, m12x150: 3hac13056-2 fit two guide pins in opposite m12 holes. Tip lubricate the guide pins with some grease to make the upper arm slide better. 2 guide pin, m12x200: 3hac13056-3 always use guide pins in pairs! Xx1300000659 caution the complete upper arm (including the wrist) ...

  • Page 261

    Note action xx1300000659 remove the guide pins and fit the two re- maining m12 screws. 10 m12, tightening torque: 115 nm secure the remaining two m12 screws. 11 refitting the cable harness - upper arm note action xx1300000541 refit the metal clamp on top of the arm house. 1 xx1300000543 refit the ar...

  • Page 262

    Note action xx1300000668 tie the axis-5 and axis-6 motor cables into bundles (if not already done), to avoid damaging them during the continued pro- cedure. This will also make it easier to run the cable harness through the inside of the robot. 4 person 1, working at the side hole: xx1300000745 tip ...

  • Page 263

    Note action xx1300000657 fit the cable guide. 7 use caution and push the cable harness into the upper arm tube. 8 person 1, working at the side hole: xx1300000745 tip this step is best performed by two persons working together. Use caution and push the cable harness into the wrist like this: • perso...

  • Page 264

    Note action xx1300000592 refit the metal clamp axis-4 inside the arm tube. Note the screws are reached from outside the upper arm! 10 xx1300000557 refit the side cover. 11 xx1200000042 if used, refit the insert that guides the dresspack cable package through the hole in the upper arm. 12 the figure ...

  • Page 265

    Note action xx1300000658 if used, refit the tube containing the dresspack into the insert. 13 the figure show irb 6640. Xx1200000045 if used, refit the cover with the tube guiding ring fitted. 14 xx1300000544 secure the cable harness to the cable fixing bracket with the velcro strap. Note if dresspa...

  • Page 266

    Connecting the axis-3 and axis-4 motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001067 refit the cable gland cover. Note replace the gasket if damaged! 2 xx1200001066 connect the motor cables. Connect in accordance with the markings on the con...

  • Page 267

    Note action o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring and o-ring groove. 5 refit the o-ring. 6 xx1200001135 refit the motor cover with its attachment screw...

  • Page 268

    Connecting the axis-5 motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001016 refit the cable gland cover by performing the following steps: • slide the cable gland cover onto the inner screw. • refit and tighten the outer screw. • tighten the i...

  • Page 269

    Note action o-ring, axis-5, 3hab3772-110 xx1200001021 check the o-ring on the motor. Replace if damaged! 4 xx1200001013 refit the motor cover with its attachment screws. Note do not refit the screws that will hold the heat protection plate at this point. Note do not reuse the self-threading attachme...

  • Page 270

    Note action xx1300000489 secure the cable harness with the cable straps to the heat protection plate. 7 make sure that the cover is tightly sealed. 8 connecting the axis-6 motor cables note action xx1300000596 make sure that the cable harness will be placed in a way that it will not be damaged when ...

  • Page 271

    Note action xx1300000667 use caution and push the cable harness into the wrist recess and up into the axis-6 motor. 3 xx1300001113 use caution and push the carrier into posi- tion. 4 xx1300000485 secure the carrier with the m4 screw. Note the screw is located at the bottom of the carrier. Tip the at...

  • Page 272

    Note action xx1300000488 reconnect the connectors to the axis-6 motor. Note place the resolver cable under the motor cable. 7 gasket, 3hac033489-001 xx1200001095 check the gasket. Replace if damaged! 8 xx1200001080 refit the motor cover. 9 disconnect the 24 vdc power supply (if used). 10 continues o...

  • Page 273

    Concluding procedure note action tightening torque: 10 nm xx1300000772 use caution refit the wrist cover. In order not to damage the cable harness when the wrist cover is refitted, by following this method: 1 hold the cover in an angle. See fig- ure! 2 catch any part of the cable harness hanging dow...

  • Page 274

    4.5.2 replacing the wrist location of the wrist the wrist is located as shown in the figure. Xx1300000597 spare part note spare part number spare part see product manual, spare parts - irb 6700 . Wrist required tools and equipment note article number equipment, etc. Length: 1 m. Lifting capacity: 1,...

  • Page 275

    Note art. No. Equipment, etc. D=119x3 3hab3772-110 o-ring used on axis-5 motor cover. Used on axis-6 motor cover. 3hac033489-001 gasket removing the wrist these procedures describes how to remove the wrist. Preparations note action remove all equipment fitted to the wrist. 1 how to remove the dressp...

  • Page 276

    Note action jog the robot into position: • axis 1: no significance (as long as the robot is secured to the founda- tion) • axis 2: -60° • axis 3: +60° • axis 4: +90° • axis 5: +90° • axis 6: no significance 6 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure sup...

  • Page 277

    Removing the process turning disk use the procedure to remove the dresspack process disk, if one is fitted. Note action xx1300000599 remove the attachment screws that secure the process turning disk. 1 the figure show irb 6640. Xx1300000600 remove the process turning disk. 2 the figure show irb 6640...

  • Page 278

    Note action 24 vdc power supply xx1200001081 if axis-5 is not already in position +90°, connect the 24 vdc power supply, release the brakes and move the axis manually into that position. Connect to r2.Mp5-connector: • + = pin 2 • - = pin 5 2 xx1300000486 remove the wrist cover. 3 xx1300000489 cut th...

  • Page 279

    Note action xx1300000490 pull the cable harness to the side and re- move the heat protection plate. Note keep the heat protection plate somewhere safe until it shall be refitted. 5 disconnecting the axis-6 motor cables note action danger make sure that all supplies for electrical power, hydraulic pr...

  • Page 280

    Note action xx1300000488 disconnect the motor cables. 3 disconnecting the axis-5 motor cables note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 xx1200001135 unscrew the attachment screws and washers and remove the motor cover....

  • Page 281

    Note action xx1300000656 remove the cable gland cover by perform- ing the following steps: 1 open the inner screw a little (the one the arrow is pointing at). No need to remove this screw. 2 remove the outer screw. 3 slide the cable gland cover away from the inner screw. Make sure the gasket is not ...

  • Page 282

    Removing the wrist note action guide pin, m12x150: 3hac13056-2 remove two attachment screws in opposite holes and replace them with guide pins. Tip lubricate the guide pins with some grease to make the wrist slide better. 1 always use guide pins in pairs! Xx1300000748 xx1300000749 remove the remaini...

  • Page 283

    Note action xx1300000770 slide the wrist off the guide pins and put it somewhere safe on a pallet or similar. 5 refitting the wrist these procedures describes how to refit the wrist. Preparations note action wipe clean all contact surfaces. 1 guide pin, m12x150: 3hac13056-2 fit two guide pins in opp...

  • Page 284

    Note action note make sure the roundsling is stretched, so it can carry the weight of the wrist. 3 refitting the wrist note action xx1300000770 lift the wrist unit on to the guide pins. If leaving a small opening between wrist and arm tube it will be easier to run the cable harness back into the wri...

  • Page 285

    Note action xx1300000749 fit and secure the attachment screws. 4 xx1300000748 remove the guide pins and replace them with the remaining attachment screws. 5 m12x50, tightening torque: 115 nm. Tighten all attachment screws. 6 24 vdc power supply in order to release the brakes, connect the 24 vdc powe...

  • Page 286

    Connecting the axis-5 motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001016 refit the cable gland cover by performing the following steps: • slide the cable gland cover onto the inner screw. • refit and tighten the outer screw. • tighten the i...

  • Page 287

    Note action o-ring, axis-5, 3hab3772-110 xx1200001021 check the o-ring on the motor. Replace if damaged! 4 xx1200001013 refit the motor cover with its attachment screws. Note do not refit the screws that will hold the heat protection plate at this point. Note do not reuse the self-threading attachme...

  • Page 288

    Note action xx1300000489 secure the cable harness with the cable straps to the heat protection plate. 7 make sure that the cover is tightly sealed. 8 connecting the axis-6 motor cables note action xx1300000596 make sure that the cable harness will be placed in a way that it will not be damaged when ...

  • Page 289

    Note action xx1300000667 use caution and push the cable harness into the wrist recess and up into the axis-6 motor. 3 xx1300001113 use caution and push the carrier into posi- tion. 4 xx1300000485 secure the carrier with the m4 screw. Note the screw is located at the bottom of the carrier. Tip the at...

  • Page 290

    Note action xx1300000488 reconnect the connectors to the axis-6 motor. Note place the resolver cable under the motor cable. 7 gasket, 3hac033489-001 xx1200001095 check the gasket. Replace if damaged! 8 xx1200001080 refit the motor cover. 9 disconnect the 24 vdc power supply (if used). 10 refitting t...

  • Page 291

    Note action tightening torque: 35 nm. Secure the turning disk with its attachment screws and washers. 2 attachment screws: m8x25, steel 12.9 gleitmo 603 (24 pcs) washers: steel 8.4x13x1.5 (24 pcs) xx1300000492 refitting the process turning disk if used, use this procedure to refit the process turnin...

  • Page 292

    Concluding procedure note action xx1300000490 refit the heat protection plate to the axis- 5 motor. 1 xx1300000489 secure the motor cables to the heat protec- tion plate with a cable tie. 2 xx1300000596 check that the cable harness will be placed in a way that it will not be damaged when the wrist c...

  • Page 293

    Note action tightening torque: 10 nm xx1300000772 use caution refit the wrist cover. In order not to damage the cable harness when the wrist cover is refitted, by following this method: 1 hold the cover in an angle. See fig- ure! 2 catch any part of the cable harness hanging down. 3 lift the cover, ...

  • Page 294

    4.5.3 replacing the turning disk location of the turning disk the turning disk is located in the front of the wrist housing as shown in the figure. Xx1300000491 spare part note spare part number spare part see product manual, spare parts - irb 6700 . Turning disk required tools and equipment note ar...

  • Page 295

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 remove any equipment fitted to the turning disk. 3 removing the turning disk note action xx1300000492 remove the attachment screws securi...

  • Page 296

    Note action tightening torque: 35 nm. Secure the turning disk with its attachment screws and washers. 2 attachment screws: m8x25, steel 12.9 gleitmo 603 (24 pcs) washers: steel 8.4x13x1.5 (24 pcs) xx1300000492 concluding procedure note action danger make sure all safety requirements are met when per...

  • Page 297

    4.5.4 replacing the lower arm location of the lower arm the lower arm is located as shown in the figure. Xx1300000786 spare part note spare part number spare part see product manual, spare parts - irb 6700 . Lower arm required tools and equipment note article number equipment, etc. Used for unloadin...

  • Page 298

    Note article number equipment, etc. Used for putting down removed parts from robot. Pallet always use guide pins in pairs! 3hac13120-2 guide pin, m16x150 used to rotate the motor pinion. 3hac7887-1 rotation tool used to release the motor brakes. - 24 vdc power supply included in the tool kit dismant...

  • Page 299

    Note action how to remove the dresspack cable pack- age is described in more detail in the product manual "irb 6700 dresspack". For article number see references on page 10 . If dresspack is fitted, remove the upper end of the dresspack cable package. 4 remove the cable bracket for the ball joint ho...

  • Page 300

    Note action xx1300000554 remove the cover plate on the back of the balancing device. Danger do not remove any other screws then the rear cover attachment screws! 4 tightening torque: 45 nm fit the distance tool on the back of the balancing device using the four screws. Danger use caution when tighte...

  • Page 301

    Preparations to remove the shaft note action jog axis-2 to the calibration position (if not already in this position). 1 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 remove any equipment, if fit...

  • Page 302

    Note action xx1200001279 • m16x70 quality steel 8.8-a3f unscrew the attachment screw and washer. 2 dismantle and mounting tool: 3hac028920-001 xx1200001280 use the dismantle and mounting tool and pull out the shaft. 3 xx1200001281 put down the balancing device and let it rest on the frame. 4 retriev...

  • Page 303

    Note action 24 vdc power supply xx1200001081 if axis-5 is not already in position +90°, connect the 24 vdc power supply, release the brakes and move the axis manually into that position. Connect to r2.Mp5-connector: • + = pin 2 • - = pin 5 2 xx1300000486 remove the wrist cover. 3 xx1300000489 cut th...

  • Page 304

    Note action xx1300000490 pull the cable harness to the side and re- move the heat protection plate. Note keep the heat protection plate somewhere safe until it shall be refitted. 5 removing brackets note action xx1200001184 unscrew the screws that hold the bracket and let it hang free. 1 xx120000005...

  • Page 305

    Note action xx1200001332 unscrew the screw that hold the connection plate and let the dresspack hang free, if one is fitted. 3 disconnecting the axis-3 and axis-4 motor cables note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 ...

  • Page 306

    Note action xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor also will be removed. The motor shall be refitted in the same position. 4 use caution...

  • Page 307

    Note action xx1200001135 unscrew the attachment screws and washers and remove the motor cover. 2 xx1200001066 disconnect the motor cables. 3 xx1300000656 remove the cable gland cover by perform- ing the following steps: 1 open the inner screw a little (the one the arrow is pointing at). No need to r...

  • Page 308

    Disconnecting the axis-6 motor cables note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 xx1200001080 unscrew the attachment screws and re- move the motor cover. 2 xx1300000488 disconnect the motor cables. 3 removing the cable ...

  • Page 309

    Note action xx1300000657 remove the cable guide by unscrewing the attachment screws. 2 xx1200000042 if used, remove the insert that guides the dresspack through the hole in the upper arm, by unscrewing the attachment screws. 3 the figure show irb 6640. Xx1300000658 if used, push the tube containing ...

  • Page 310

    Note action xx1300000557 remove the side cover on the arm tube. 6 xx1300000592 loosen the axis-4 metal clamp that holds the cable harness inside the arm tube by unscrewing the attachment screws. Note the screws are reached from outside the upper arm! 7 xx1300000543 remove the armhouse metal clamp. 8...

  • Page 311

    Note action xx1300000544 open the velcro straps at the cable fixing bracket. Note if dresspack is fitted, the cable fixing bracket is replaced by the cable guide. Xx1300001973 9 xx1300000541 remove the metal clamp on top of the armhouse. 10 continues on next page 3hac044266-001 revision: - 311 © cop...

  • Page 312

    Note action person 1, working at the side hole: xx1300000745 tip this step is best performed by two persons working together. Use caution and remove the cable harness from the wrist like this: • person 1: put one hand inside the side hole and take a hold of the cable harness. • person 2: take a hold...

  • Page 313

    Attaching the lifting accessories use this procedure to attach the lifting accessories to the upper arm. Note action lifting eye: 3hac16131-1 xx1200001133 fit a lifting eye to the wrist. 1 lifting eye: 3hac16131-1 fit a lifting eye in the arm house, with a fender washer underneath. 2 fender washer: ...

  • Page 314

    Note action in case of necessary adjustments, use the shortening loops on the lifting accessory (chain), making sure to place the chain the right way through the loops! 6 release the brakes in order to find the most level lifting position of the upper arm as possible, before lifting. 7 24 vdc power ...

  • Page 315

    Note action note make sure the lift is done completely level! In case of necessary adjustments, use the shortening loops on the lifting accessory (chain), but make sure to place the chain the right way through the loops! 4 xx1300001610 remove the remaining attachment screw and slide the upper arm on...

  • Page 316

    Note action open the ball joint housings on the lower arm and remove the dresspack. 3 xx1300000540 loosen the axis-2 lower arm metal clamp and the axis-3 lower arm metal clamp loc- ated on the inside of the lower arm by re- moving the attachment screws. Note the screws are reached from outside the l...

  • Page 317

    Note action xx1300000788 remove two attachment screws and washers parallel to each other and replace with guide pins. 9 xx1300000789 remove the remaining attachment screws and washers securing the lower arm to the axis 2 gearbox. 10 slide the lower arm out on the guide pins and remove the lower arm....

  • Page 318

    Note action guide pin, m16x150: 3hac13120-2 xx1300000788 fit two guide pins in opposite holes. 2 caution the lower arm weighs 135 kg. All lifting accessories used must be sized accordingly! 3 attach the lifting accessory to the lower arm. 4 wipe clean all contact surfaces. 5 lift the lower arm onto ...

  • Page 319

    Note action xx1300000790 fit an attachment screw in one of the upper holes and use it for security when the lifting accessory is removed. 8 tightening torque: 280 nm secure the lower arm with its attachment screws and washers. 9 attachment screws: m16x50 quality steel 12.9 gleitmo (21 pcs) washers: ...

  • Page 320

    Note action guide pin, m12x150: 3hac13056-2 fit two guide pins in opposite m12 holes. Tip lubricate the guide pins with some grease to make the upper arm slide better. 2 guide pin, m12x200: 3hac13056-3 always use guide pins in pairs! Xx1300000659 caution the complete upper arm (including the wrist) ...

  • Page 321

    Note action xx1300000659 remove the guide pins and fit the two re- maining m12 screws. 10 m12, tightening torque: 115 nm secure the remaining two m12 screws. 11 refitting the cable harness - lower arm note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure...

  • Page 322

    Note action xx1300000734 refit the axis-2 lower arm metal clamp located on the inside of the lower arm. Note the screws are reached from the outside of the lower arm. 4 xx1300000595 before fitting the remaining axis-3 lower arm cable bracket inside the lower arm, check that it will stay twisted a li...

  • Page 323

    Refitting the cable harness - upper arm note action xx1300000541 refit the metal clamp on top of the arm house. 1 xx1300000543 refit the arm house metal clamp. 2 xx1300000668 tie the axis-5 and axis-6 motor cables into bundles (if not already done), to avoid damaging them during the continued pro- c...

  • Page 324

    Note action person 1, working at the side hole: xx1300000745 tip the next step is best performed by two persons working together: • person 1: put one hand inside the side hole of the arm tube and take a hold of the cable harness. • person 2: take a hold on the cable harness at the back of the robot....

  • Page 325

    Note action xx1300000820 use caution and push the cable harness into the upper arm tube. Note do not run the cable harness into the dresspack tube! 7 person 1, working at the side hole: xx1300000745 tip this step is best performed by two persons working together. Use caution and push the cable harne...

  • Page 326

    Note action xx1300000557 refit the side cover. 10 xx1200000042 if used, refit the insert that guides the dresspack cable package through the hole in the upper arm. 11 the figure show irb 6640. Xx1300000658 if used, refit the tube containing the dresspack into the insert. 12 the figure show irb 6640....

  • Page 327

    Note action xx1300000544 secure the cable harness to the cable fixing bracket with the velcro strap. If dresspack is fitted, the cable fixing bracket is replaced by the cable guide. 14 connecting the axis-3 and axis-4 motor cables note action xx1300000738 push the motor cables in through the cable g...

  • Page 328

    Note action xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring a...

  • Page 329

    Connecting the axis-5 motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001016 refit the cable gland cover by performing the following steps: • slide the cable gland cover onto the inner screw. • refit and tighten the outer screw. • tighten the i...

  • Page 330

    Note action o-ring, axis-5, 3hab3772-110 xx1200001021 check the o-ring on the motor. Replace if damaged! 4 xx1200001013 refit the motor cover with its attachment screws. Note do not refit the screws that will hold the heat protection plate at this point. Note do not reuse the self-threading attachme...

  • Page 331

    Note action xx1300000489 secure the cable harness with the cable straps to the heat protection plate. 7 make sure that the cover is tightly sealed. 8 connecting the axis-6 motor cables note action xx1300000596 make sure that the cable loop and the rest of the cable harness will be placed in a way th...

  • Page 332

    Note action xx1300000667 use caution and push the cable harness into the wrist recess and up into the axis-6 motor. 3 xx1300001113 use caution and push the carrier into posi- tion. 4 xx1300000485 secure the carrier with the m4 screw. Note the screw is located at the bottom of the carrier. Tip the at...

  • Page 333

    Note action xx1300000488 reconnect the connectors to the axis-6 motor. Note place the resolver cable under the motor cable. 7 xx1200001095 check the gasket. Replace if damaged! 8 xx1200001080 refit the motor cover. 9 continues on next page 3hac044266-001 revision: - 333 © copyright 2013 abb. All rig...

  • Page 334

    Concluded refitting of the cable harness note action xx1300000490 refit the heat protection plate. 1 xx1300000489 secure the cable harness to the heat pro- tection plate with two cable straps. 2 xx1300000596 make sure that the cable harness will be placed in a way that it will not be damaged when th...

  • Page 335

    Note action how to refit the dresspack cable package is described in more detail in the product manual "irb 6700 dresspack". For article number see references on page 10 . If the robot is equipped with dresspack cable package: • refit the distance to the wrist cover. • refit the ball joint housing t...

  • Page 336

    Refitting the front shaft of the balancing device note action turn on the power to the robot. 1 use caution and jog the robot to the calibration position (if not already done). 2 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before enter...

  • Page 337

    Note action tightening torque: 200 nm xx1200001279 secure the shaft with screw and washer. 9 xx1200001278 fit the vk-cover. 10 grease: 3hac042534-001 xx1300000783 unscrew both screws in link ear and fill the bear- ing with grease from the upper hole until the grease appears in the lower hole. 11 ref...

  • Page 338

    Note action xx1200001283 refit the cable bracket (if not already refit- ted). 2 danger do not use the distance tool: 3hac030662- 001 to unload or restore the pressure of the balancing device spring unit! This tool is only used to lock the spring unit in a compressed position, after axis-2 has been j...

  • Page 339

    Note action a xx0800000480 a distance tool: 3hac030662-001 remove the distance tool. 6 xx1300000554 refit the cover plate. 7 concluding procedure note action remove the lifting accessory. 1 calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. Recalibrate th...

  • Page 340

    4.6 frame and base 4.6.1 replacing spherical roller bearing, link ear location of spherical roller bearing the spherical roller bearing is located in the link ear of the balancing device. Xx1300000773 attachment screws m6x10 quality 8.8-a2f (2 pcs) a end cover b radial sealing with dustlip, 50x68x8 ...

  • Page 341

    Spare part note art. No. Equipment, etc. The maintenance kit contains: • end cover • radial sealing with dustlip, 50x68x8 (2 pcs) • o-ring 85x3 • spherical roller bearing • washer see product manual, spare parts - irb 6700 . Maintenance kit link ear required tools and equipment note article number e...

  • Page 342

    Note action danger do not use the distance tool: 3hac030662- 001 to unload or restore the pressure of the balancing device spring unit! This tool is only used to lock the spring unit in a compressed position, after axis-2 has been jogged to -20° or +20°. Fitting and removal of the tool shall only be...

  • Page 343

    Note action tightening torque: 45 nm fit the distance tool on the back of the balancing device using the four screws. Danger use caution when tightening the screws. The threads in the cover can be damaged if more tightening torque than 45 nm is used, risking that the unloading tool is not properly f...

  • Page 344

    Note action lock screw, m16x120 xx1200001116 fit a locking screw through the hole for the lock screw in the frame and into the lower arm (or using a lifting accessory or similar). The lock screw is used to secure the weight of the lower arm, in order to avoid acci- dents or damage. 2 danger turn off...

  • Page 345

    Removing the shaft in the front note action xx1200001278 remove the small vk cover. Note it is almost impossible to remove the vk cover without damage. New vk covers are needed. 1 xx1200001279 • m16x70 quality steel 8.8-a3f unscrew the attachment screw and washer. 2 dismantle and mounting tool: 3hac...

  • Page 346

    Note action xx1200001281 put down the balancing device and let it rest on the frame. 4 removing the spherical roller bearing, link ear note action xx1200001184 unscrew the attachment screws of the bracket, use caution and move it a little to the side, to give room for the dismantle and mounting tool...

  • Page 347

    Note action xx1300000775 remove the o-ring. 4 dismantle and mounting tool: 3hac028920-001 xx1300000840 a spherical roller bearing b radial sealing c washer apply the dismantle and mounting tool and pull out the spherical roller bearing together with the radial sealing and washer. 5 refitting the sph...

  • Page 348

    Note action xx1300000839 put the radial sealing on the press tool. Note make sure that the seailng is turned the right way! 3 xx1300000777 use a plastic mallet or similar on the press tool (3hac034037-001) and refit the radial sealing. 4 apply some grease on the surface for the bearing. 5 dismantle ...

  • Page 349

    Note action xx1300000775 refit the o-ring. 7 xx1300000774 apply loctite 243 on the screws and secure the end cover with the radial sealing ring. 8 preparations, lifting accessory note action fit a lifting shackle. 1 fit the lifting accessory to the shackle and raise to unload the weight. 2 continues...

  • Page 350

    Unloading a new spare part, balancing device note action danger do not use the distance tool: 3hac030662- 001 to unload or restore the pressure of the balancing device spring unit! This tool is only used to lock the spring unit in a compressed position, after axis-2 has been jogged to -20° or +20°. ...

  • Page 351

    Note action xx1200001280 lubricate the shaft and place it to the front ear. 6 dismantle and mounting tool: 3hac028920-001 press the shaft in with the hydraulic press tool. 7 xx1300000782 apply locking liquid (loctite 2701) on the threads of the screw, first entering the threads in the frame. 8 tight...

  • Page 352

    Note action grease: 3hac042534-001 xx1300000783 unscrew both screws in link ear and fill the bear- ing with grease from the upper hole until the grease appears in the lower hole. 11 refit the two screws and wipe clean from residual grease. 12 concluded refitting of the front shaft note action remove...

  • Page 353

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 5 remove the distance tool. 6 refit the cover plate. 7 3hac044266-001 revision: - 353 © copyright 2013 abb. All rights reserved. 4 repair 4...

  • Page 354

    4.6.2 replacing the balancing device location of the balancing device the balancing device is located as shown in the figure. Xx1300000660 spare part note spare part number equipment, etc. See product manual, spare parts - irb 6700 . Balancing device vk 90x12 3haa2166-28 vk cover, (2 pcs) vk 28x7 3h...

  • Page 355

    Note article number equipment, etc. Used to secure lower arm. - lock screw, m16x120 3hac9909-15 threaded bar, m16x340 included in the tool kit dismantle and mounting tool (3hac028920-001). 3hac047273-001 anvil 3hac020902-001 press tool, balancing device used for removing and fitting shaft and bearin...

  • Page 356

    Note action danger do not use the distance tool: 3hac030662- 001 to unload or restore the pressure of the balancing device spring unit! This tool is only used to lock the spring unit in a compressed position, after axis-2 has been jogged to -20° or +20°. Fitting and removal of the tool shall only be...

  • Page 357

    Note action tightening torque: 45 nm fit the distance tool on the back of the balancing device using the four screws. Danger use caution when tightening the screws. The threads in the cover can be damaged if more tightening torque than 45 nm is used, risking that the unloading tool is not properly f...

  • Page 358

    Note action xx1200001116 fit a locking screw m16x120 through the hole for the lock screw in the frame and into the lower arm (or using a lifting access- ory or similar). The lock screw is used to secure the weight of the lower arm, in order to avoid acci- dents or damage. 2 danger turn off all: • el...

  • Page 359

    Removing the axes in the rear perform this procedure on both sides. Note action xx1300000662 remove both vk covers by driving a screwdriver (or similar) through the vk cover, as close as possible to the center of the vk cover. If not making a hole in the center of the vk cover, there is a risk of da...

  • Page 360

    Note action use the removal tool and pull the shaft out a few millimeters, just long enough for the balancing device to go free. 5 removing the axis in the front note action xx1200001278 remove the small vk cover. Note it is almost impossible to remove the vk cover without damage. New vk covers are ...

  • Page 361

    Note action xx1200001281 put down the balancing device and let it rest on the frame. 4 concluding procedure note action remove the balancing device and put it somewhere safe. 1 if the same balancing device shall be refit- ted, the distance tool 3hac030662-001 must stay fitted during the time the bal...

  • Page 362

    Unloading a new spare part, balancing device note action danger do not use the distance tool: 3hac030662- 001 to unload or restore the pressure of the balancing device spring unit! This tool is only used to lock the spring unit in a compressed position, after axis-2 has been jogged to -20° or +20°. ...

  • Page 363

    Note action xx1300000664 fit the retaining ring bore. 5 xx1300000663 apply loctite 243 on the screws and secure the shafts on both sides. 6 xx1300000837 refit new vk covers. 7 grease: 3hac042534-001 xx1300000832 unscrew both screws in the cradle and fill the bearing with grease from the inner hole (...

  • Page 364

    Note action refit the screws. 9 wipe clean from residual grease. 10 danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 44 . 11 refitting the front shaft of the bala...

  • Page 365

    Note action xx1300000782 apply locking liquid (loctite 2701) on the threads of the screw, first entering the threads in the frame. 8 tightening torque: 200 nm xx1200001279 secure the shaft with screw and washer. 9 xx1200001278 fit the vk-cover. 10 grease: 3hac042534-001 xx1300000783 unscrew both scr...

  • Page 366

    Concluded refitting of the front shaft note action remove the lifting accessory from the bal- ancing device. 1 xx1200001283 refit the cable bracket (if not already refit- ted). 2 xx1200001116 remove the locking screw (m16x120). 3 jog axis-2 to: • -20° or +20°. 4 danger turn off all: • electric power...

  • Page 367

    4.6.3 replacing the rear bearing of the balancing device location of rear bearings, balancing device the rear bearings of the balancing device are located in the cradle, one on each side. Xx1300000785 spare part note art. No. Equipment, etc. The maintenance kit contains: • 2216264-001 spacer (2 pcs)...

  • Page 368

    Note article number equipment, etc. Used to secure lower arm. - lock screw, m16x120 sa-10-8-na1 - lifting shackle lifting instruction 3hac15880-2 en- closed. 3hac15556-1 lifting accessory (chain) 3hac9909-15 threaded bar, m16x340 content is defined in section standard toolkit on page 559 . - standar...

  • Page 369

    Note action this is done in order to compress the spring unit inside the balancing device be- fore fitting the unloading tool. Jog axis-2 to: • -20° or +20° 2 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot workin...

  • Page 370

    Note action let the distance tool stay fitted during the continued procedure. 7 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 8 preparations note action jog axis-2 to the calibration position (if n...

  • Page 371

    Note action lifting shackle: sa-10-8-na1 xx1300000661 fit a lifting shackle to the balancing device. 5 lifting accessory (chain): 3hac15556-1 fit the lifting accessory to the shackle and raise to unload the weight. 6 removing the shaft end, cradle the procedure of removing the shaft end in the cradl...

  • Page 372

    Note action xx1300000663 unscrew the attachment screw securing the shaft. 3 xx1300000664 remove the retaining ring bore. 4 xx1300000838 before pulling out the shaft end, put a big screw driver between the cradle and balan- cing device and use it as a distance tool. 5 apply the press tool and pull ou...

  • Page 373

    Note action apply some grease in the hole for the bearing in the cradle. 2 threaded bar, m16x340: 3hac9909-15 xx1300000831 apply a threaded bar into the hole in the balancing device. 3 xx1300000830 put sealing ring, radial sealing, spacer and groove ball bearing onto the shaft end manually. 4 put th...

  • Page 374

    Note action while using the screw driver between the cradle and balancing device as a distance tool, tighten the attachment screw com- pletely. 12 tightening torque: 280 nm. Xx1300000663 secure the balancing device. 13 concluding procedure note action xx1300000664 refit the retaining ring bore. 1 xx...

  • Page 375

    Note action grease: 3hac042534-001 xx1300000832 unscrew both screws and refill grease from the inner hole (see figure). 3 xx1300000833 refit the screws. 4 wipe clean from residual grease. 5 danger make sure all safety requirements are met when performing the first test run. These are further detaile...

  • Page 376

    4.6.4 replacing the stop pin location of the stop pin the stop pin is located as shown in the figure. Xx1300000475 spare part note art. No. Equipment, etc. See product manual, spare parts - irb 6700 . Stop pin required tools and equipment note article number equipment, etc. Content is defined in sec...

  • Page 377

    Removing the stop pin note action xx1300000479 jog the robot to this position: • axis 1 = -5° 1 xx1300000478 note if the axis-1 is not in this position the stop pin will not be able to go free from the axis- 1 oil plug draining, when removed. See figure! 2 danger turn off all: • electric power suppl...

  • Page 378

    Note action xx1300000477 remove the stop pin. 5 refitting the stop pin note action xx1300000477 fit the stop pin. 1 xx1300000476 secure the stop pin with the set screw, cup point. Locking liquid (loctite 243) on screw. 2 m10x20 378 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved...

  • Page 379

    4.6.5 unloading the balancing device prerequisite this section describes how to unload the balancing device using the hydraulic tool dismantle and mounting tool: 3hac028920-001. Danger if the balancing device is fitted on the robot during the procedure, remember to: • jog axis-2 to calibration posit...

  • Page 380

    Press tool and hydraulic cylinder the figure below shows the hydraulic cylinder mounted on the press tool. The press tool includes two press devices that are used to different models of the balancing device. Xx0200000174 press block a hydraulic cylinder b press device c bolt, press device d moving p...

  • Page 381

    Unloading the balancing device the procedure below details how to use the press tool in order to unload the balancing device. How to remove the press tool, is detailed in section restoring the balancing device on page 383 . Note action press device: 3hac12800-1 fit the moving pin to the correct pres...

  • Page 382

    Note action press tool, balancing device: 3hac020902-001. Xx0200000174 press block a hydraulic cylinder b press device c bolt, press device d moving pin with marking e bolt (4 pcs) f pin, attached to the fix plate g fit the press tool to the rear of the balancing device with enclosed bolts. Tighten ...

  • Page 383

    4.6.6 restoring the balancing device overview this section details how to restore the balancing device and how to remove the press tool from the device. Danger there is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property. Press tool and hydr...

  • Page 384

    Bolt (4 pcs) f pin, attached to the fix plate g required equipment note article number equipment, etc. To be used with the press tool. 3hac11731-1 hydraulic cylinder to be used with the hydraulic cylinder. 3hac13086-1 hydraulic pump 80 mpa content is defined in section standard toolkit on page 559 ....

  • Page 385

    Note action danger the rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the ro- bot! 7 3hac044266-001 revision: - 385 © copyright 2013 abb. All rights reserved. 4 repair 4.6.6 restoring the bala...

  • Page 386

    4.7 motors 4.7.1 replacing the axis-1 motor location of the axis-1 motor the motor is located as shown in the figure. Xx1200001064 spare parts note spare part number spare part see product manual, spare parts - irb 6700 . Axis-1 motor required tools and equipment note article number equipment, etc. ...

  • Page 387

    Note article number equipment, etc. Used to rotate the motor pinion. 3hac7887-1 rotation tool used to release the motor brakes. - 24 vdc power supply 3hac0207-1 leak-down tester 3hac15716-1 calibration pendulum toolkit content is defined in section standard toolkit on page 559 . - standard toolkit c...

  • Page 388

    Note action xx1200001135 unscrew the attachment screws and washers and remove the motor cover. 2 xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor ...

  • Page 389

    Note action 24 vdc power supply to release the brakes, connect the 24 vdc power supply . 2 connect to r2.Mp1-connector: • + = pin 2 • - = pin 5 caution the motor weighs 21 kg. All lifting accessories used must be sized accordingly! 3 bits extender: 3hac12342-1 xx1200001071 unscrew the attachment scr...

  • Page 390

    Note action xx1200001072 use caution and lift the motor straight up to get the pinion away from the gear. 8 disconnect the 24 vdc power supply. 9 put the motor somewhere safe. 10 refitting the axis-1 motor these procedures describes how to refit the motor. Preparations prior to refitting motor note ...

  • Page 391

    Note action o-ring, 3hab3772-107 xx1200001019 check the o-ring. Replace if damaged! 4 xx1200001020 make sure the o-ring is seated in the groove. Tip lubricate the o-ring with some grease for a better fitting in the groove. 5 xx1200001135 remove the cover, if the motor is a new spare part. 6 securing...

  • Page 392

    Note action caution the motor weighs 21 kg. All lifting accessories used must be sized accordingly! 2 lifting accessory, motor: 3hac14459-1. Apply the lifting accessory. 3 rotation tool: 3hac7887-1 fit the rotation tool. 4 in order to release the brakes, connect the 24 vdc power supply. 5 connect to...

  • Page 393

    Note action bits extender: 3hac12342-1 secure the motor with its attachment screws and washers. 8 tightening torque: 47 nm. Use a bits extender in order to reach the screws. Screw dimension : m10x40 quality 12.9 gleitmo (4 pcs) xx1200001071 see performing a leak-down test on page 174 . Perform a lea...

  • Page 394

    Note action xx1200001067 refit the cable gland cover. Note replace the gasket if damaged! 2 xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, ax...

  • Page 395

    Note action xx1200001135 refit the motor cover with its attachment screws. Note do not reuse the self-threading attachment screws! Replace with standard attachment screws. The threads will otherwise be damaged. Note make sure the o-ring is undamaged and properly fitted! 7 make sure that the covers a...

  • Page 396

    4.7.2 replacing the axis-2 motor location of the motor the motor is located as shown in the figure. Xx1200001112 spare parts note spare part number spare part see product manual, spare parts - irb 6700 . Axis-2 motor required tools and equipment note article number equipment, etc. Lifting instructio...

  • Page 397

    Note article number equipment, etc. Used to release the motor brakes. - 24 vdc power supply used to secure lower arm. - lock screw, m16x120 3hac0207-1 leak-down tester 3hac15716-1 calibration pendulum toolkit content is defined in section standard toolkit on page 559 . - standard toolkit consumables...

  • Page 398

    Note action lock screw, m16x120 xx1200001116 insert the lock screw into the hole for the lock screw in the frame. Note do not tighten the lock screw using any tools! Do it manually! 5 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before ...

  • Page 399

    Note action xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor also will be removed. The motor shall be refitted in the same position. 4 use caution...

  • Page 400

    Note action bits extender: 3hac12342-1 xx1200001117 remove the attachment screws securing the motor. Use a bits extender in order to reach the screws. 4 guide pin, m12x150: 3hac13056-2 fit guide pins in opposite holes. 5 always use guide pins in pairs! Caution whenever parting/mating motor and gear-...

  • Page 401

    Refitting the motor these procedures describes how to refit the motor. Preparations prior to refitting motor note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 remove old paint residues and other contamina- tion from the contac...

  • Page 402

    Note action xx1200001135 remove the cover, if the motor is a new spare part. 6 securing the axis-2 motor note action guide pin, m10x150: 3hac15521-2 fit guide pins in opposite holes. 1 always use guide pins in pairs! Caution the motor weighs 26 kg. All lifting accessories used must be sized accordin...

  • Page 403

    Note action caution whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! 9 use caution and fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool. • make sure that the motor pinion is proper...

  • Page 404

    Connecting the motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001067 refit the cable gland cover. Note replace the gasket if damaged! 2 xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 continu...

  • Page 405

    Note action o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring and o-ring groove. 5 refit the o-ring. 6 xx1200001135 refit the motor cover with its attachment screw...

  • Page 406

    Note action xx1200001115 remove the lock screw used to secure the lower arm. 2 see filling oil into the axis-2 gearbox on page 145 . Refill the gearbox with oil. 3 calibration is described in a separate calib- ration manual enclosed with the calibration tools. Recalibrate the robot. 4 general calibr...

  • Page 407

    4.7.3 replacing the axis-3 motor location of the axis-3 motor the axis-3 motor is located as shown in the figure. Xx1200001113 spare part note spare part number spare part see product manual, spare parts - irb 6700 . Axis-3 motor required tools and equipment note article number equipment, etc. Lifti...

  • Page 408

    Note article number equipment, etc. Used to rotate the motor pinion. 3hac7887-1 rotation tool used to release the motor brakes. - 24 vdc power supply 3hac0207-1 leak-down tester 3hac15716-1 calibration pendulum toolkit content is defined in section standard toolkit on page 559 . - standard toolkit c...

  • Page 409

    Disconnecting the motor cables note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 xx1200001135 unscrew the attachment screws and washers and remove the motor cover. 2 xx1200001066 disconnect the motor cables. 3 xx1200001067 rem...

  • Page 410

    Note action use caution and pull out the motor cables. 5 removing the axis-3 motor note action before removing the motor, check that the axis-3 gearbox is completely drained. 1 danger when releasing the holding brakes of the motor, the upper arm will be movable and may fall down! Before continuing t...

  • Page 411

    Note action caution the motor weighs 24 kg. All lifting accessories used must be sized accordingly! 9 lifting accessory, motor: 3hac15534-1 apply the lifting accessory to the motor. 10 xx1200001125 when the motor is hanging in the lifting accessory, and the pinion no longer is mated to the gear, let...

  • Page 412

    Note action wipe clean the contact surfaces from any remain- ing contamination. 3 also wipe clean the o-ring groove. O-ring, 3hab3772-107 xx1200001019 check the o-ring. Replace if damaged! 4 xx1200001020 make sure the o-ring is seated in the groove. Tip lubricate the o-ring with some grease for a be...

  • Page 413

    Note action caution the motor weighs 24 kg. All lifting accessories used must be sized accordingly! 2 lifting accessory, motor: 3hac15534-1 apply the lifting accessory to the motor. 3 xx1200001129 note make sure the cable exit hole is turned the correct way. See figure! 4 xx1200001131 lift the motor...

  • Page 414

    Note action xx1200001129 use caution and push the motor in position while at the same time the motor pinion is slightly rotated. Pay attention to following points: • make sure the cable exit hole is turned the correct way. See figure! • mate the motor pinion properly to the gear of the gearbox. • do...

  • Page 415

    Connecting the motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001067 refit the cable gland cover. Note replace the gasket if damaged! 2 xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 continu...

  • Page 416

    Note action o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring and o-ring groove. 5 refit the o-ring. 6 xx1200001135 refit the motor cover with its attachment screw...

  • Page 417

    Note action calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. Recalibrate the robot. 3 general calibration information is included in section calibration information on page 537 . Danger make sure all safety requirements are met when performing the first...

  • Page 418

    4.7.4 replacing the axis-4 motor location of the axis-4 motor the axis-4 motor is located as shown in the figure. Xx1200001114 spare parts note spare part number spare part see product manual, spare parts - irb 6700 . Axis-4 motor required tools and equipment note article number equipment, etc. Used...

  • Page 419

    Note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard toolkit consumables note article number equipment, etc. Used to lubricate o-rings. 3hab3537-1 grease d=119x3 3hab3772-110 o-ring used on motor cover. D=102x3 3hab3772-107 o-ring used on motor ...

  • Page 420

    Note action xx1200001135 unscrew the attachment screws and washers and remove the motor cover. 2 xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor ...

  • Page 421

    Removing the motor note action caution use caution when releasing the brakes! Axis-4 can move unexpectedly! 1 to release the brakes, connect the 24 vdc power supply. 2 connect to connector r2.Mp4: • + = pin 2 • - = pin 5 xx1200001137 unscrew the attachment screws that secure the motor. 3 guide pin, ...

  • Page 422

    Refitting the motor these procedures describes how to refit the motor. Preparations prior to refitting motor note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 remove old paint residues and other contamina- tion from the contac...

  • Page 423

    Note action xx1200001135 remove the cover, if the motor is a new spare part. 6 securing the motor note action guide pin, m10x150: 3hac15521-2 apply two guide pins in opposite holes. 1 always use guide pins in pairs! Put the motor onto the guide pins. 2 xx1200001130 note make sure the cable exit hole...

  • Page 424

    Note action push the motor carefully in position while at the same time the motor pinion is slightly rotated. • make sure that the motor pinion is properly mated to the gear of the gearbox. • make sure that the motor pinion does not get damaged. • make sure that the direction of the cable exit is fa...

  • Page 425

    Note action xx1200001067 refit the cable gland cover. Note replace the gasket if damaged! 2 xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, ax...

  • Page 426

    Note action xx1200001135 refit the motor cover with its attachment screws. Note do not reuse the self-threading attachment screws! Replace with standard attachment screws. The threads will otherwise be damaged. Note make sure the o-ring is undamaged and properly fitted! 7 make sure that the covers a...

  • Page 427

    4.7.5 replacing the axis-5 motor location of the axis-5 motor the axis-5 motor is located inside the wrist, as shown in the figure. Xx1200001002 spare part note spare part number spare part see product manual, spare parts - irb 6700 . Axis-5 motor required tools note article number equipment, etc. U...

  • Page 428

    Required material note article number material used to lubricate o-rings. 3hab3537-1 grease consumables note article number equipment, etc. Used to lubricate o-rings. 3hab3537-1 grease d=119x3 3hab3772-110 o-ring used on motor cover. D=102x3 3hab3772-107 o-ring used on motor flange. Removing the axi...

  • Page 429

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 3 remove the complete ball joint housing with dresspack still fitted, from the bracket on the wist cover. 4 this is done in order to reach ...

  • Page 430

    Note action xx1300000486 remove the wrist cover. 3 xx1300000489 cut the cable straps that hold the cable harness to the heat protection plate. 4 xx1300000490 pull the cable harness to the side and re- move the heat protection plate. Note keep the heat protection plate somewhere safe until it shall b...

  • Page 431

    Note action xx1200001135 unscrew the attachment screws and washers and remove the motor cover. 2 xx1200001066 disconnect the motor cables. 3 xx1300000656 remove the cable gland cover by perform- ing the following steps: 1 open the inner screw a little (the one the arrow is pointing at). No need to r...

  • Page 432

    Removing the axis-5 motor note action bits extender: 3hac12342-1 xx1200001017 unscrew the attachment screws that secure the motor, using a bits extender. 1 caution whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! 2 removal tool m10 if needed fit rem...

  • Page 433

    Refitting the axis-5 motor the procedures describe how to refit the motor. Preparations note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 xx1200001019 clean the contact surfaces from any ...

  • Page 434

    Note action xx1200001020 make sure the o-ring is seated properly in the recess. 5 guide pin, m8x100: 3hac15520-1 apply two guide pins in opposite holes. 6 securing the motor note action caution whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! 1 rota...

  • Page 435

    Note action note make sure the cable exit hole is turned the correct way. Use caution and lower the motor down in position on the guide pins, while at the same time the motor pinion is slightly ro- tated. Make sure that: • the motor pinion is properly mated to the gear of the gearbox. • the motor pi...

  • Page 436

    Connecting the motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001016 refit the cable gland cover by performing the following steps: • slide the cable gland cover onto the inner screw. • refit and tighten the outer screw. • tighten the inner sc...

  • Page 437

    Note action o-ring, axis-5, 3hab3772-110 xx1200001021 check the o-ring on the motor. Replace if damaged! 4 xx1200001013 refit the motor cover with its attachment screws. Note do not refit the screws that will hold the heat protection plate at this point. Note do not reuse the self-threading attachme...

  • Page 438

    Note action xx1300000489 secure the cable harness with the cable straps to the heat protection plate. 7 make sure that the cover is tightly sealed. 8 concluding procedure note action xx1200001011 refit the heat protection plate. 1 xx1200001009 secure the cable harness to the heat pro- tection plate ...

  • Page 439

    Note action tightening torque: 10 nm. Xx1300000772 use caution and refit the wrist cover. In or- der not to damage the cable harness when the wrist cover is refitted, by following this method: 1 hold the cover in an angle. See fig- ure! 2 catch any part of the cable harness hanging down. 3 lift the ...

  • Page 440

    4.7.6 replacing the axis-6 motor location of axis-6 motor the axis-6 motor is located as shown in the figure. Xx1200001080 spare part note spare part number spare part see product manual, spare parts - irb 6700 . Axis-6 motor required tools and equipment note article number equipment, etc. Used to r...

  • Page 441

    Consumables note article number equipment, etc. Used to lubricate o-rings. 3hab3537-1 grease used on motor cover. 3hac033489-001 gasket d=102x3 3hab3772-107 o-ring used on motor flange. Removing the axis-6 motor use these procedures to remove the motor. Preparations note action xx1200001081 jog the ...

  • Page 442

    Note action xx1200001080 unscrew the attachment screws and re- move the motor cover. 2 xx1300000488 disconnect the motor cables. 3 removing the axis-6 motor note action 24 vdc power supply to release the brakes, connect the 24 vdc power supply . 1 connect to r2.Mp6-connector: • + = pin 2 • - = pin 5...

  • Page 443

    Note action caution whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! 3 if required, press the motor out of position by fitting the removal tool, motor to the at- tachment holes of the motor. 4 xx1200001091 remove the motor by lifting it straight up ...

  • Page 444

    Refitting the axis-6 motor use this procedure to refit the motor. Preparations prior to refitting motor note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 remove old paint residues and other contamina- tion from the contact sur...

  • Page 445

    Note action xx1200001135 remove the cover, if the motor is a new spare part. 6 securing the motor note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 to release the brakes, connect the 24 v...

  • Page 446

    Note action xx1200001094 check the gasket. Replace if damaged! 4 xx1200001091 fit the motor while at the same time push- ing the motor cables in through the cable gland. Make sure the motor pinion is properly mated with the gear of the axis-6 gearbox. Make sure the motor pinion is not dam- aged! 5 x...

  • Page 447

    Note action tightening torque: 24 nm secure the motor with its attachment screws. 6 screw dimension: m8x25 quality 12.9 gleitmo (4 pcs) xx1200001090 check that the gasket is fitted correctly. See performing a leak-down test on page 174 . Perform a leak-down test. 7 disconnect the 24 v dc power suppl...

  • Page 448

    Note action xx1200001082 refit the motor cover. 11 calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. Recalibrate the robot. 12 general calibration information is included in section calibration information on page 537 . Danger make sure all safety requir...

  • Page 449

    4.8 gearboxes 4.8.1 replacing the axis-1 gearbox location of the axis-1 gearbox the axis-1 gearbox is located as shown in the figure. Xx1200001183 spare parts note article number spare parts see product manual, spare parts - irb 6700 . Axis-1 gearbox consumables note article number equipment, etc us...

  • Page 450

    Note article number equipment, etc d=102x3 3hab3772-107 o-ring used on motor flange. - sealing ring required tools and equipment note article number equipment, etc. The capacity of the vessel must be sufficient to take the complete amount of oil. - oil collecting vessel one example of oil dispenser ...

  • Page 451

    Note article number equipment, etc. Content is defined in section standard toolkit on page 559 . - standard toolkit required documents note document number document name 3hac042927-001 technical reference manu- al - lubrication in gearboxes removing the axis-1 gearbox these procedures describe how t...

  • Page 452

    Note action xx1300000476 remove the mechanical stop pin by unscrew- ing the attachment screw. 5 xx1200001184 unscrew the attachment screws that secure the cable bracket. 6 xx1200001237 cut the cable strap inside the frame recess. 7 xx1200001240 lift up the part of the cable harness shown in the figu...

  • Page 453

    Note action xx1200001189 unscrew five of the six attachment screws inside the frame hole that secure the frame to the gearbox. Note leave the outermost screw fitted as a safety precaution! Xx1200001185 9 xx1200001238 unscrew five of the six attachment screws under the balancing device. Note leave th...

  • Page 454

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 attaching the lifting accessories note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressu...

  • Page 455

    Note action roundsling, 1.5 m: length: 1.5 m. Lifting capacity: 1,000 kg. Xx1200001209 run a roundsling through the hole in the frame. 5 xx1200001235 attach the roundsling to the shackle on the wrist and jog axis-3 slowly to stretch the roundsling. Note make sure the roundsling is stretched, so it c...

  • Page 456

    Note action lifting accessory (chain): 3hac15556-1 attach the upper arm lifting accessory to an overhead crane (or similar) and then to the lifting eye in the arm house and to a roundsling run through the wrist. 8 roundsling, 1 m: length: 1 m. Lift- ing capacity: 1,000 kg. Xx1200001236 disconnecting...

  • Page 457

    Note action xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor also will be removed. The motor shall be refitted in the same position. 4 use caution and pull out the motor cables. 5 removing t...

  • Page 458

    Note action caution whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! 6 removal tool m14: 3hac047108-001 if needed, use removal tools to help re- move the motor. 7 xx1200001072 use caution and lift the motor straight up to get the pinion away from th...

  • Page 459

    Note action xx1300000591 remove connectors in the base: • r1.Mp • r1.Smb 3 b a xx1300001972 m6x16 and plain washer large 6.4x17x3 a earth b disconnect the earth cable. 4 removing the cable harness in the base note action if used, use caution and pull out the dresspack hoses through the protection tu...

  • Page 460

    Note action xx1300000732 use caution and pull out the robot cable harness through the protection tube. 3 place the cable harness over the balancing device. 4 lifting away the complete arm system note action raise the overhead crane to stretch the chains and roundslings. 1 make sure that the roundsli...

  • Page 461

    Removing axis-1 gearbox note action xx1200001186 remove the attachment screws and washers that secure the gearbox to the base. 1 guide pin, m12x150: 3hac13056-2 fit two guide pins in opposite holes. Tip lubricate the guide pins with some grease to make the gearbox slide better. 2 always use guide pi...

  • Page 462

    Note action xx1200001188 use caution and lift the gearbox and put it somewhere safe. 7 i 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 ...

  • Page 463

    Note action caution the gearbox weighs 92 kg. All lifting accessories used must be sized accordingly! 4 xx1200001188 lift the gearbox up. 5 xx1200001244 remove the o-ring and wipe it clean. Note the o-ring needs to be cleaned also on a new spare part! 6 xx1200001231 wipe clean the contact surfaces f...

  • Page 464

    Note action xx1200001244 fit the o-ring in the groove of the gearbox. 9 xx1200001232 wipe clean the surfaces of the sealing tube and hole in axis-1 gearbox. 10 put grease on the protection tube. 11 guide pin, m12x150: 3hac13056-2 fit guide pins in opposite holes in the base. Tip lubricate the guide ...

  • Page 465

    Note action xx1200001188 use caution and lower the gearbox very carefully down over the guide pins and over the sealing tube. Note check that the o-ring is still fitted correctly when the gearbox is being fitted. 2 remove the guide pins. 3 remove the lifting accessory and the lifting eyes. 4 fit the...

  • Page 466

    Note action guide pin, m16x150: 3hac13120-2 apply guide pins in opposite holes in the gearbox. Note make sure that the guide pins are fitted in the correct holes in the gearbox! See fig- ures! 4 guide pin, m16x200: 3hac13120-3 always use guide pins in pairs! Position of guide pin one: xx1300000822 t...

  • Page 467

    Note action a c b xx1300001118 aligning tool a attachment screws (2 pcs) b correct fitting of the aligning tool. C fit the aligning tool. See figure how to fit the tool correctly. 7 caution the arm system weighs 1100 kg. All lifting accessories used must be sized accordingly! 8 see attaching the lif...

  • Page 468

    Preparations prior to refitting motor note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 remove old paint residues and other contamina- tion from the contact surfaces on both motor and gearbox. 2 wipe clean the contact surfaces...

  • Page 469

    Note action xx1200001135 remove the cover, if the motor is a new spare part. 6 securing the axis-1 motor note action guide pin, m12x150: 3hac13056-2 fit guide pins in opposite holes. 1 always use guide pins in pairs! Caution the motor weighs 21 kg. All lifting accessories used must be sized accordin...

  • Page 470

    Note action xx1200001072 lower the motor into position. • make sure that the motor pinion is properly mated to the gear in the gearbox. • make sure that the motor pinion does not get damaged. • make sure that the direction of the cable exit is facing the correct way. See figure! 7 bits extender: 3ha...

  • Page 471

    Refitting the cable harness in the base note action xx1300000732 use caution and run the cables down through the protection tube in this order: • r1.Mp • r1.Smb 1 xx1300000736 • make sure that the cables are not twisted. The cables shall be in line with its position on the base plate. • make sure th...

  • Page 472

    Note action b a xx1300001972 m6x16 and plain washer large 6.4x17x3 a earth b connect the earth cable. 5 if used, run the dresspack cables down through the protection tube in the base. 6 if used, run the dresspack hoses down through the protection tube in the base. 7 make sure that the hoses are runn...

  • Page 473

    Connecting the axis-1 motor cables note action xx1300000738 push the motor cables in through the cable gland opening. 1 xx1200001067 refit the cable gland cover. Note replace the gasket if damaged! 2 xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 ...

  • Page 474

    Note action o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring and o-ring groove. 5 refit the o-ring. 6 xx1200001135 refit the motor cover with its attachment screw...

  • Page 475

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 see filling oil into the axis-1 gearbox on page 140 . Refill oil in the gearbox. 3 xx1300000476 refit the mechanical stop pin and secure ...

  • Page 476

    Note action xx1200001246 refit the cable bracket on the frame. 7 calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. Recalibrate the robot. 8 general calibration information is included in section calibration information on page 537 . Danger make sure all ...

  • Page 477

    4.8.2 replacing the axis-2 gearbox space required beside this section describes how to replace the gearbox without needing to remove the cable harness and dresspack cable package (if installed) from the robot. The described procedure requires free space on the floor, in front of the position of the ...

  • Page 478

    Note article number equipment, etc. M12 3hac16131-1 lifting eye m16 3hac14457-4 lifting eye outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. - fender washer sa-10-8-na1 - lifting shackle length: 1.5 m. Lifting capacity: 1,000 kg. - roundsling, 1.5 m length: 1 m. Lifting capacity...

  • Page 479

    Note article number equipment, etc d=309.3x3.1 3hab3772-144 o-ring used on gearbox. Required documents note document number document name 3hac042927-001 technical reference manu- al - lubrication in gearboxes removing the axis-2 gearbox use these procedures to remove the gearbox. Follow the order of...

  • Page 480

    Note action danger do not use the distance tool: 3hac030662- 001 to unload or restore the pressure of the balancing device spring unit! This tool is only used to lock the spring unit in a compressed position, after axis-2 has been jogged to -20° or +20°. Fitting and removal of the tool shall only be...

  • Page 481

    Note action tightening torque: 45 nm fit the distance tool on the back of the balancing device using the four screws. Danger use caution when tightening the screws. The threads in the cover can be damaged if more tightening torque than 45 nm is used, risking that the unloading tool is not properly f...

  • Page 482

    Note action xx1200001278 remove the small vk-cover at the front shaft. 3 xx1200001279 remove screw and washer. 4 xx1200001280 apply the puller tool and remove the shaft in the front ear. 5 xx1200001281 put down the balancing device and let it rest on the frame. 6 continues on next page 482 3hac04426...

  • Page 483

    Note action remove the lifting accessory from the bal- ancing device. 7 robot position note action note when jogging the axis-2 into position check that the balancing device ear and the ear on the lower arm is not colliding! 1 xx1200001250 jog the robot into position: • axis-1: no significance as lo...

  • Page 484

    Note action lifting shackle: sa-10-8-na1 xx1200001234 fit a lifting shackle in the wrist lifting eye. 2 xx1200001251 in order to secure the roundsling from gliding when lifting: • no dresspack cable package installed: in- sert a m12x50 securing screw, not more than 10-15 mm, into the screw hole show...

  • Page 485

    Note action stretch the roundsling between the wrist and the lower arm by slowly jogging the axis-3. Note make sure the roundsling is stretched, in order to carry the weight of the lower arm. 8 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robo...

  • Page 486

    Note action lifting accessory (chain): 3hac15556-1 attach the upper arm lifting accessory to an overhead crane (or similar), then to the lifting eye in the arm house and to a roundsling run through the wrist. 13 roundsling, 1 m: length: 1 m. Lift- ing capacity: 1,000 kg. Xx1200001254 raise the overh...

  • Page 487

    Note action xx1200001135 unscrew the attachment screws and washers and remove the motor cover. 2 xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor ...

  • Page 488

    Note action danger when releasing the holding brakes of the motor, the lower arm will be movable and may fall down! Before continuing, the lower arm must be secured! See above! 2 to release the brake, connect the 24 vdc power supply. 3 connect to connector r2.Mp2, axis-2 mo- tor: • + = pin 2 • - = p...

  • Page 489

    Note action xx1200001118 use caution and remove the motor by slid- ing it out on the guide pins and then put it somewhere safe. 12 loosening the cable brackets use this procedure to lift the lower and upper arm unseparated. Note action how to remove the dresspack cable pack- age is described in more...

  • Page 490

    Note action xx1200001283 unscrew the screws of the cable bracket on the frame and let it hang loose. 3 removing and lifting away the lower and upper arm use this procedure to remove and lift the lower and upper arm unseparated. Note action guide pins: dimension and article number depends on variant....

  • Page 491

    Note action put three pallets on the floor, in front of the position of the mechanical stop. Note this position is only a recommendation. If it is not possible to put the arm system close enough to the robot and keep the cable harness partly fitted, it may by neces- sary to remove the cable harness ...

  • Page 492

    Note action leave one of the upper attachment screws and remove the rest. The remaining screw is used to prevent the gearbox from falling down. 2 caution the gearbox weighs 83 kg. All lifting accessories used must be sized accordingly! 3 remove the remaining screw left in the gearbox. 4 use two full...

  • Page 493

    Note action remove the o-ring and wipe it clean. Note this must also be done on a new spare part! 4 wipe clean the contact surfaces from any contamination. Note also wipe clean the o-ring groove. 5 check the condition of the o-ring. 6 replace if damaged! Lubricate the o-ring with some grease, for a ...

  • Page 494

    Note action o-ring, 3hab3772-107 xx1200001019 check the o-ring. Replace if damaged! 4 xx1200001020 make sure the o-ring is seated in the groove. Tip lubricate the o-ring with some grease for a better fitting in the groove. 5 xx1200001135 remove the cover, if the motor is a new spare part. 6 securing...

  • Page 495

    Note action caution the motor weighs 26 kg. All lifting accessories used must be sized accordingly! 2 lifting accessory, motor: 3hac15534-1 apply the lifting accessory. 3 xx1200001120 note make sure the cable exit hole is turned the correct way. 4 lift the motor and put it on the guide pins as close...

  • Page 496

    Note action bits extender: 3hac12342-1 secure the motor with its attachment screws and washers. 13 tightening torque: 47 nm. Use a bits extender in order to reach the screws. Screw dimension: m10x40 quality 12.9 gleitmo (4 pcs) xx1200001117 see performing a leak-down test on page 174 . Perform a lea...

  • Page 497

    Note action rotation tool: 3hac7887-1 if the hole pattern is not matching, use the rotation tool and adjust. 9 use caution and move the arms into posi- tion at the axis-2 gearbox on the guide pins. 10 the tightening torque depends on variant. Secure all now accessible attachment screws. 11 tightenin...

  • Page 498

    Note action xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring a...

  • Page 499

    Refitting the cabling use this procedure to refit the cabling. Note action use caution and push the cable harness into the lower arm. 1 xx1200001282 refit the axis-2 lower arm metal clamp and the axis-3 lower arm metal clamp located on the inside of the lower arm. Note the screws are reached from th...

  • Page 500

    Note action use caution and jog the robot to the calibration position (if not already done). 2 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 3 lifting shackle: sa-10-8-na1 apply the lifting accesso...

  • Page 501

    Note action tightening torque: 200 nm xx1200001279 secure the shaft with screw and washer. 9 xx1200001278 fit the vk-cover. 10 grease: 3hac042534-001 xx1300000783 unscrew both screws in link ear and fill the bear- ing with grease from the upper hole until the grease appears in the lower hole. 11 ref...

  • Page 502

    Note action xx1200001283 refit the cable bracket (if not already refit- ted). 2 danger do not use the distance tool: 3hac030662- 001 to unload or restore the pressure of the balancing device spring unit! This tool is only used to lock the spring unit in a compressed position, after axis-2 has been j...

  • Page 503

    Note action a xx0800000480 a distance tool: 3hac030662-001 remove the distance tool. 6 xx1300000554 refit the cover plate. 7 concluding procedure note action if the robot is equipped with dresspack, refit the brackets of the ball joint housings on the wrist. 1 see filling oil into the axis-2 gearbox...

  • Page 504

    Note action danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 44 . 4 504 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 4 repair 4.8.2 repla...

  • Page 505

    4.8.3 replacing the axis-3 gearbox space required beside this section describes how to replace the gearbox without needing to remove the cable harness and dresspack cable package (if installed) from the robot. The described procedure requires free space on the floor, at the right-hand side of the ba...

  • Page 506

    Note article number equipment, etc. One example of oil dispenser can be found in section type of lubrication in gearboxes on page 137 . - oil dispenser m12 3hac16131-1 lifting eye m16 3hac14457-4 lifting eye outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. - fender washer liftin...

  • Page 507

    Follow the order of the separate procedures according to the order they are presented. Caution while performing the following procedures, the cable harness will still be fitted or partly fitted to the robot. Use extreme caution not to cause any damage to the cable harness! Preparations note action i...

  • Page 508

    Note action xx1200001332 unscrew the two attachment screws that holds the bracket of the dresspack cable package (if one is fitted), and let it hang down with the rest of the dresspack cable package. 4 see draining the axis-3 gearbox on page 149 . Begin draining the gearbox. 5 disconnecting the axis...

  • Page 509

    Note action xx1200001066 disconnect the motor cables. 3 xx1200001067 remove the cable gland cover. Make sure the gasket is not damaged! Tip make a note in which direction the cable exit hole is facing, if the motor also will be removed. The motor shall be refitted in the same position. 4 use caution...

  • Page 510

    Note action xx1300000541 loosen the cable bracket on top of the arm house by removing the screws. 2 xx1300000543 loosen the cable bracket under the arm- house by removing the screws. 3 xx1300000544 open the velcro strap on cable fixing bracket. If equipped with dresspack, instead open the velcro str...

  • Page 511

    Note action xx1300000534 in order not to damage the cable harness later, it shall be moved over to the other side of the armhouse and be placed on the right side (as seen from behind) of the back lifting eye. See figure! 5 how to remove the dresspack is described in more detail in the product manual...

  • Page 512

    Note action lifting eye: 3hac16131-1 fit a lifting eye in the arm house, with a fender washer underneath. 2 fender washer: outer diameter: minimum 26 mm, hole diameter: 13 mm, thickness: 3 mm. Xx1200001134 caution the complete upper arm (including the wrist) weighs 200 kg. All lifting accessories us...

  • Page 513

    Note action danger when releasing the holding brakes of the motor, the upper arm will be movable and may fall down! Before continuing the upper arm must be secured! 2 to release the brakes, connect the 24 vdc power supply. 3 connect to connector r2.Mp3: • + = pin 2 • - = pin 5 bits extender: 3hac123...

  • Page 514

    Note action xx1200001125 when the motor is hanging in the lifting accessory, and the pinion no longer is mated to the gear, let the outer end of the motor hang lower so that it will hang in an angle. This position makes it easier to re- move the axis-3 motor with the axis-4 mo- tor still fitted. Cau...

  • Page 515

    Note action xx1300000747 remove all but one of the remaining attach- ment screws. 2 pallet only valid when replacing the axis-3 gearbox, with the cable harness still partly fitted! 3 put two pallets on the floor, in front of the robot, as shown in the figure. Note this position is only a recommendat...

  • Page 516

    Note action xx1300000553 place a piece of wood (or similar) under the arm house and lower the upper arm. Let the upper arm rest as shown in the fig- ure. This is done in order to keep the axis-3 gearbox in a vertical position and to get the best position to replace the gearbox. 7 removing the axis-3...

  • Page 517

    Note action loosen the gearbox from its fitting position, but only pull it out on the guide pins a little. Danger if pulled out to far on the guide pins before the lifting accessory is applied, there is a risk the gearbox may start to glide on the guide pins with a risk of falling down! 4 caution th...

  • Page 518

    Note action lifting accessory, gearbox: 3hac046128- 001 apply the lifting accessory to the gearbox. 3 lift the gearbox so that it rests on the side. 4 remove the o-ring and wipe it clean. Note this shall also be done on a new spare part! 5 check the condition of the o-ring. 6 replace if damaged! Wip...

  • Page 519

    Note action guide pin, m12x150: 3hac13056-2 fit two guide pins in opposite m12 holes. Tip lubricate the guide pins with some grease to make the upper arm slide better. 2 guide pin, m12x200: 3hac13056-3 always use guide pins in pairs! Xx1300000659 caution the complete upper arm (including the wrist) ...

  • Page 520

    Note action xx1300000659 remove the guide pins and fit the two re- maining m12 screws. 10 m12, tightening torque: 115 nm secure the remaining two m12 screws. 11 preparations prior to refitting motor note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pres...

  • Page 521

    Note action xx1200001020 make sure the o-ring is seated in the groove. Tip lubricate the o-ring with some grease for a better fitting in the groove. 5 xx1200001135 remove the cover, if the motor is a new spare part. 6 securing the axis-3 motor use this procedure to secure the motor. Note action fit ...

  • Page 522

    Note action xx1200001131 lift the motor on to the guide pins and let it hang with the outer end a little lower when resting on the guide pins. Do not push the motor pinion into the gear yet! This is done in order to fit the motor with the axis-4 motor still fitted. 5 remove the lifting accessory and...

  • Page 523

    Note action tightening torque: 47 nm secure the motor. 14 screw dimension: m10x30 quality 12.9 gleitmo (4 pcs) xx1200001126 remove the rotation tool. 15 see performing a leak-down test on page 174 . Perform a leak-down test. 16 disconnect the 24 vdc power supply. 17 refitting cable brackets use this...

  • Page 524

    Note action xx1300000541 fasten the cable bracket on top of the arm house. 4 xx1300000543 fasten the cable bracket under the arm- house. 5 xx1300000544 secure the cable harness with the velcro strap on the cable fixing bracket. If equipped with dresspack, instead secure both dresspack and cable harn...

  • Page 525

    Note action xx1200000054 refit the dresspack cable package into the ball joint housings on the lower arm and close them. 7 connecting the axis-3 and axis-4 motor cables use this procedure to connect the motor cables. Note action xx1300000738 push the motor cables in through the cable gland opening. ...

  • Page 526

    Note action xx1200001066 connect the motor cables. Connect in accordance with the markings on the connectors. 3 o-ring, axis-1: 3hab3772-111 check the o-ring. 4 o-ring, axis-2: 3hab3772-111 replace if damaged! O-ring, axis-3: 3hab3772-111 o-ring, axis-4: 3hab3772-110 xx1200001070 wipe clean o-ring a...

  • Page 527

    Concluding procedures note action remove the lifting accessory. 1 see filling oil into the axis-3 gearbox on page 150 . Refill oil in the gearbox. 2 xx1200001332 fit the bracket of the dresspack cable package (if one is fitted) under the arm- house with its screws. 3 xx1200001331 removed screw. A sc...

  • Page 528

    Note action danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 44 . 6 528 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. 4 repair 4.8.3 repla...

  • Page 529

    4.8.4 replacing the axis-6 gearbox location of the axis-6 gearbox the axis-6 gearbox is located as shown in the figure. Xx1300000824 spare parts note spare part number spare parts see product manual, spare parts - irb 6700 . Axis-6 gearbox required tools and equipment note article number equipment, ...

  • Page 530

    Note article number equipment, etc used on motor cover. 3hac033489-001 gasket d=151.99x3.53 3hab3772-58 o-ring used on gearbox. Removing the axis-6 gearbox use these procedures to remove the axis-6 gearbox. Preparations note action jog the robot to: • axis 1 = no significance (as long as the robot i...

  • Page 531

    Note action xx1200000036 if installed, remove the dresspack axis-6 support. 5 the figure shows the irb 6640. Jog axis 5 to -55°. 6 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 7 xx1300000825 remov...

  • Page 532

    Removing the turning disk note action xx1300000492 remove the attachment screws securing the turning disk. 1 xx1300000493 remove the turning disk. 2 removing the process turning disk use the procedure to remove the dresspack process disk, if one is fitted. Note action xx1300000599 remove the attachm...

  • Page 533

    Note action xx1300000600 remove the process turning disk. 2 the figure show irb 6640. Removing the gearbox note action xx1300000826 unscrew the attachment screws that secure the axis-6 gearbox. 1 caution whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is us...

  • Page 534

    Refitting the axis-6 gearbox use these procedures to refit the gearbox. Preparations note action danger make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 1 xx1300000828 remove the o-ring and wipe it clean. Note the o-ring needs to be cleaned also ...

  • Page 535

    Note action screw dimension and tightening torque depends on robot variant: 35 nm. Xx1300000826 secure the gearbox with its attachment screws. 3 see performing a leak-down test on page 174 . Perform a leak-down test. 4 jog axis-5 to horizontal position. 5 see filling oil into the axis-6 gearbox on p...

  • Page 536

    Concluding procedure note action xx1300000825 refit the synchronization plate axis-6. 1 calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. Recalibrate the robot. 2 general calibration information is included in section calibration information on page 537 ...

  • Page 537: 5 Calibration Information

    5 calibration information 5.1 introduction general this chapter includes general information about the different calibration methods and also the detailed procedures that do not require specific calibration equipment. When the robot system must be recalibrated, it is done according to the documentat...

  • Page 538

    5.2 calibration methods overview this section specifies the different types of calibration and the calibration methods that are supplied by abb. Types of calibration calibration method description type of calibration calibration pendulum (standard method) the calibrated robot is positioned at home p...

  • Page 539

    Calibration methods each calibration method is detailed in a separate manual. Following is a brief description of the methods available. 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...

  • Page 540

    5.3 calibration scale and correct axis position introduction this section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales/marks, irb 6700 axis 2 xx1300000869 axis 1 xx1300000868 axis 4 xx1300000871 axis 3 xx1300000870 axis 6 xx130000087...

  • Page 541

    5.4 calibration movement directions for all axes overview when calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on. Positive directions are shown in the graphic below. This is no...

  • Page 542

    5.5 updating revolution counters introduction this section describes how to do a rough calibration of each manipulator axis, which is updating the revolution counter value for each axis using the flexpendant. Step 1 - manually running the manipulator to the calibration position use this procedure to...

  • Page 543

    Action tap the mechanical unit in question. 2 a screen is displayed, tap rev. Counters . En0400000771 tap update revolution counters... . A dialog box is displayed warning that updating the revolution counters may change programmed manipulator positions: • tap yes to update the revolution counters. ...

  • Page 544

    5.6 checking the calibration position introduction check the calibration position before beginning any programming of the robot system. This may be done: • using a moveabsj instruction with argument zero on all axes. • using the jogging window on the flexpendant. Using a moveabsj instruction use thi...

  • Page 545: 6 Decommissioning

    6 decommissioning 6.1 environmental information hazardous material the table specifies some of the materials in the product and their respective use throughout the product. Dispose components properly to prevent health or environmental hazards. Example application material serial measurement board b...

  • Page 546

    6.2 scrapping of robot important when scrapping the robot danger when a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries: • always remove all batteries from the robot. If a battery is exposed to heat,...

  • Page 547

    6.3 decommissioning of balancing device general there is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly. The device must be dismantled by a...

  • Page 548

    Decommissioning at decommissioning company, balancing device the instruction below details how to decommission the balancing device. Contact abb robotics for further consultation. Note action danger there is stored energy built up by high tensioned compression springs inside the balancing device! Wh...

  • Page 549

    Note action use a cutting torch with a long shaft. Cut the coils of the springs inside the housing as specified below: • outer spring: cut at least five coils! • middle spring: cut at least four coils! • inner spring: cut at least four coils! 6 double-check the number of coils cut and make sure all ...

  • Page 550

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  • Page 551: 7 Reference Information

    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: - 551 © copyright 2013 abb. All rights reserved. 7 reference information 7.1 introduction.

  • Page 552

    7.2 applicable safety standards standards, en iso the manipulator system is designed in accordance with the requirements of: description standard safety of machinery - basic concepts, general principles for design - part 1: basic terminology, methodology en iso 12100 -1 safety of machinery - basic c...

  • Page 553

    Description standard safety standard for robots and robotic equipment ansi/ul 1740 (option 429-1) industrial robots and robot systems - general safety require- ments can/csa z 434-03 (option 429-1) 3hac044266-001 revision: - 553 © copyright 2013 abb. All rights reserved. 7 reference information 7.2 ...

  • Page 554

    7.3 unit conversion converter table use the following table to convert units used in this manual. Units quantity 39.37 in 3.28 ft. 1 m length 2.21 lb. 1 kg weight 0.035 ounces 1 g weight 14.5 psi 100 kpa 1 bar pressure 0.225 lbf 1 n force 0.738 lbf-ft 1 nm moment 0.264 us gal 1 l volume 554 3hac0442...

  • Page 555

    7.4 screw joints general this section describes how to tighten the various types of screw joints on the irb 6700. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. Unbrako screws unbrako is a special type of s...

  • Page 556

    • always tighten the joint by hand, and never use pneumatic tools. • use the correct tightening technique , that is do not jerk. Tighten the screw in a slow, flowing motion. • maximum allowed total deviation from the specified value is 10% ! Oil-lubricated screws with slotted or cross-recess head sc...

  • Page 557

    Tightening torque (nm) class 12.9, lubricated i tightening torque (nm) class 10.9, lubricated i dimension 950 790 m24 i lubricated with molycote 1000, gleitmo 603 or equivalent water and air connectors the following table specifies the recommended standard tightening torque for water and air connect...

  • Page 558

    7.5 weight specifications definition in installation, repair, and maintenance procedures, weights of the components handled are sometimes specified. 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 compo...

  • Page 559

    7.6 standard toolkit general all service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the stand...

  • Page 560

    7.7 special tools general all service instructions contain lists of tools required to perform the specified activity. 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 t...

  • Page 561

    Axis 6 gearbox axis 3 gearbox axis 2 gearbox axis 1 gearbox axis 6 motor axis 5 motor axis 4 motor axis 3 motor axis 2 motor axis 1 motor rear bearing (balancing device) spherical roller bearing (link ear) balancing device turning disk wrist upper arm lower arm brake release unit smb cable harness t...

  • Page 562

    Axis 6 gearbox axis 3 gearbox axis 2 gearbox axis 1 gearbox axis 6 motor axis 5 motor axis 4 motor axis 3 motor axis 2 motor axis 1 motor rear bearing (balancing device) spherical roller bearing (link ear) balancing device turning disk wrist upper arm lower arm brake release unit smb cable harness t...

  • Page 563

    Axis 6 gearbox axis 3 gearbox axis 2 gearbox axis 1 gearbox axis 6 motor axis 5 motor axis 4 motor axis 3 motor axis 2 motor axis 1 motor rear bearing (balancing device) spherical roller bearing (link ear) balancing device turning disk wrist upper arm lower arm brake release unit smb cable harness t...

  • Page 564

    7.8 lifting accessories and lifting instructions general many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure. The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction deliv...

  • Page 565: 8 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: - 565 © copyright 2013 abb. All rights reserved. 8 spare parts 8.1 spare part lists and ...

  • Page 566

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  • Page 567: 9 Circuit Diagrams

    9 circuit diagrams 9.1 about circuit diagrams overview the circuit diagrams are not included in this manual, but delivered as separate documents on the documentation dvd. See the article numbers in the tables below. Controllers article numbers for circuit diagrams product 3hac024480-005 circuit diag...

  • Page 568

    Article numbers for circuit diagrams product 3hac025744-001 circuit diagram - irb 6640 3hac13347-1 circuit diagram - irb 6650s 3hac025744-001 3hac025744-001 circuit diagram - irb 6660 3hac029940-001 3hac043446-005 circuit diagram - irb 6700 3hac13347-1 circuit diagram - irb 7600 3hac025744-001 568 3...

  • Page 569: Index

    Index a absolute accuracy, calibration, 539 additional mechanical stop location, 130 aluminum disposal, 545 axis 1 gearbox replacing, 449 mechanical stop replacing, 376 motor replacing, 386 axis 2 gearbox replacing, 477 motor replacing, 396 axis 3 gearbox replacing, 505 motor replacing, 407 axis 4 m...

  • Page 570

    Securing robot, 84 g gearbox axis 1 replacing, 449 axis 2 replacing, 477 axis 3 replacing, 505 inspecting oil level axis 1, 104 inspecting oil level axis 2, 107 inspecting oil level axis 3, 109 inspecting oil level axis 4, 111 inspecting oil level axis 5, 113 inspecting oil level axis 6, 115 oil cha...

  • Page 571

    P plastic disposal, 545 positive directions, axes, 541 protection classes, 54 protection standards, 552 r replacing axis-6 motor, 440 axis-5 motor, 427 axis-4 motor, 418 axis-3 gearbox, 505 axis-3 motor, 407 axis-2 gearbox, 477 axis-2 motor, 396 axis-1 gearbox, 449 axis-1 motor, 386 balancing device...

  • Page 572

    W weight axis-1 motor, 389, 392, 457, 469 base plate, 72, 76 robot, 71, 81, 460, 467, 558 working range restricting axis 1, 94 wrist replacing, 274 572 3hac044266-001 revision: - © copyright 2013 abb. All rights reserved. Index.

  • Page 574

    Contact us abb ab discrete automation and motion robotics s-721 68 vÄsterÅs, sweden 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 distri...