Professional Documents
Culture Documents
3HAC044266 PM IRB 6700-En
3HAC044266 PM IRB 6700-En
Product manual
IRB 6700
Trace back information:
Workspace 23C version a18
Checked in 2023-10-04
Skribenta version 5.5.019
Product manual
IRB 6700 - 235/2.65
IRB 6700 - 220/2.65 LID
IRB 6700 - 205/2.80
IRB 6700 - 200/2.80 LID
IRB 6700 - 175/3.05
IRB 6700 - 155/3.05 LID
IRB 6700 - 150/3.20
IRB 6700 - 145/3.20 LID
IRB 6700 - 200/2.60
IRB 6700 - 175/2.60 LID
IRB 6700 - 155/2.85
IRB 6700 - 140/2.85 LID
IRB 6700 - 300/2.70
IRB 6700 - 270/2.70 LID
IRB 6700 - 245/3.00
IRB 6700 - 220/3.00 LID
IRC5, OmniCore
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 16
How to read the product manual ...................................................................................................... 18
1 Safety 19
1.1 Safety information ............................................................................................. 19
1.1.1 Limitation of liability ................................................................................. 19
1.1.2 Requirements on personnel ...................................................................... 20
1.2 Safety signals and symbols ................................................................................. 21
1.2.1 Safety signals in the manual ...................................................................... 21
1.2.2 Safety symbols on manipulator labels ......................................................... 23
1.3 Robot stopping functions .................................................................................... 29
1.4 Safety during installation and commissioning ......................................................... 30
1.5 Safety during operation ...................................................................................... 33
1.6 Safety during maintenance and repair ................................................................... 34
1.6.1 Safety during maintenance and repair ......................................................... 34
1.6.2 Emergency release of the robot axes .......................................................... 37
1.6.3 Brake testing .......................................................................................... 38
1.7 Safety during troubleshooting .............................................................................. 39
1.8 Safety during decommissioning ........................................................................... 40
3 Maintenance 117
3.1 Introduction ...................................................................................................... 117
3.2 Maintenance schedule and expected component life ............................................... 118
3.2.1 Specification of maintenance intervals ........................................................ 118
3.2.2 Maintenance schedule ............................................................................. 119
3.2.3 Expected component life ......................................................................... 121
3.3 Inspection activities ........................................................................................... 122
3.3.1 Inspecting the motor seal ......................................................................... 122
3.3.2 Inspecting the oil level in axis-1 gearbox ..................................................... 124
3.3.3 Inspecting the oil level in axis-2 gearbox ..................................................... 129
3.3.4 Inspecting the oil level in axis-3 gearbox ..................................................... 132
3.3.5 Inspecting the oil level in axis-4 gearbox ..................................................... 135
3.3.6 Inspecting the oil level in axis-5 gearbox ..................................................... 137
3.3.7 Inspecting the oil level in axis-6 gearbox ..................................................... 139
3.3.8 Inspecting the balancing device ................................................................ 142
3.3.9 Inspecting the cable harness .................................................................... 146
3.3.10 Inspecting the information labels ................................................................ 148
3.3.11 Inspecting the axis-1 mechanical stop pin ................................................... 152
3.3.12 Inspecting the additional mechanical stops ................................................. 154
3.3.13 Inspecting the dampers ........................................................................... 156
3.3.14 Inspecting the signal lamp (option) ............................................................. 158
3.4 Replacement/changing activities .......................................................................... 160
3.4.1 Type of lubrication in gearboxes ................................................................ 160
3.4.2 Changing oil, axis-1 gearbox ..................................................................... 162
3.4.3 Changing oil, axis-2 gearbox ..................................................................... 169
3.4.4 Changing oil, axis-3 gearbox ..................................................................... 174
3.4.5 Changing oil, axis-4 gearbox ..................................................................... 180
3.4.6 Changing oil, axis-5 gearbox ..................................................................... 184
3.4.7 Changing oil, axis-6 gearbox ..................................................................... 188
3.4.8 Replacing the SMB battery ....................................................................... 193
3.5 Lubrication activities .......................................................................................... 196
3.5.1 Lubricating the spherical roller bearing, balancing device .............................. 196
3.6 Cleaning activities ............................................................................................. 198
3.6.1 Cleaning the IRB 6700 .............................................................................. 198
4 Repair 201
4.1 Introduction ...................................................................................................... 201
4.2 General procedures ........................................................................................... 202
4.2.1 Performing a leak-down test ...................................................................... 202
4.2.2 Mounting instructions for bearings ............................................................. 203
4.2.3 Mounting instructions for sealings .............................................................. 205
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 209
4.2.5 The brake release buttons may be jammed after service work ......................... 210
4.3 Lifting associated procedures .............................................................................. 211
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -220/2.65
LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID,
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID) ............................. 211
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700-300/2.70, -270/2.70
LID, -245/3.00, -220/3.00 LID) ..................................................................... 216
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID,
-150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85
LID) ...................................................................................................... 222
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID) ................................... 229
4.3.5 Attaching lifting accessories to the upper arm ............................................... 235
4.4 Complete robot ................................................................................................. 238
4.4.1 Removing the cable harness .................................................................... 238
5 Calibration 799
5.1 Introduction to calibration ................................................................................... 799
5.1.1 Introduction and calibration terminology ...................................................... 799
5.1.2 Calibration methods ................................................................................. 800
5.1.3 When to calibrate ................................................................................... 803
5.2 Synchronization marks and axis movement directions ............................................. 804
5.2.1 Synchronization marks and synchronization position for axes ......................... 804
5.2.2 Calibration movement directions for all axes ................................................ 806
5.3 Updating revolution counters ............................................................................... 807
5.3.1 Updating revolution counters on IRC5 robots ............................................... 807
5.3.2 Updating revolution counters on OmniCore robots ........................................ 811
5.4 Calibrating with Axis Calibration method ............................................................... 813
5.4.1 Description of Axis Calibration .................................................................. 813
5.4.2 Calibration tools for Axis Calibration ........................................................... 816
5.4.3 Installation locations for the calibration tools ............................................... 818
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 819
5.4.5 Reference calibration ............................................................................... 823
5.5 Calibrating with Calibration Pendulum method ....................................................... 825
5.6 Calibrating with Wrist Optimization method ........................................................... 826
5.7 Verifying the calibration ...................................................................................... 828
5.8 Checking the synchronization position .................................................................. 829
6 Decommissioning 831
6.1 Introduction to decommissioning ......................................................................... 831
Index 859
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
References
Documentation referred to in the manual, is listed below.
General
Revisions
Revision Description
- First edition.
A The following updates are done in this revision:
• The variants IRB 6700-200/2.60 and IRB 6700-155/2.85 are added.
• Some illustrations showing IRB 6640 are replaced with IRB 6700.
• The information is updated in Lifting with fork lift accessory. ABB
recommends that the fork lift accessories are removed before
powering up the robot.
B The following updates are done in this revision:
• The protection type Foundry Plus is added throughout the manual.
Continues on next page
10 Product manual - IRB 6700
3HAC044266-001 Revision: AB
© Copyright 2013 - 2023 ABB. All rights reserved.
Overview of this manual
Continued
Revision Description
C The following updates are done in this revision:
• The variants IRB 6700-300/2.70 and -245/3.00 are added
throughout the manual.
• The maximum allowed deviation in levelness of the base plate
and foundation is changed, see Securing the base plate on
page 66.
• Added information about which axes are affected by non-integer
gear ratio, see Updating revolution counters on page 807.
• Removed faulty listed washer from consumables tabe, section
Replacing the upper arm on page 303.
• Added tightening torque for R1.SMB and 7th axis connector, ses
Refitting the cable harness on page 262.
• Measurements added for transport support used on variants IRB
6700-300/2.70 and -245/3.00.
D The following updates are done in this revision:
• Number of attachment screws was wrong in Orienting and securing
the robot on page 79. Corrected to 8 pcs.
• Added an alternative tightening torque for robot attachment bolts,
see Orienting and securing the robot on page 79.
• Added information about guide pins, both when securing the robot
to the base plate and when securing it to a track motion carriage,
see Orienting and securing the robot on page 79.
• Updated base plate drawings and added information regarding
guide pins, see Securing the base plate on page 66.
• Thread lines were missing. Now added in figure.
• Figure updated so locating hole is shown at "12 o'clock".
E The following updates are done in this revision:
• Information regarding how to read the procedures in this product
manual are updated, see How to read the product manual on
page 18.
• New standard calibration method is introduced (Axis Calibration).
See Calibration on page 799.
• Information added regarding compatibility between new design
of turning disk and the axis-6 synchronization mark plate, see
Replacing the synchronization mark plate on page 374.
• Flattened cylindrical guide pin is removed for the base plate, re-
placed with a cylindrical. See Securing the base plate on page 66.
• O-ring type changed in Replacing the axis-1 gearbox (IRB 6700-
300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID) on page 631.
• Sections "Inspecting oil level" and "Changing oil in gear box" are
updated with information for 300/2.70 and 245/3.00.
Revision Description
F The following updates are done in this revision:
• Corrected the article number for the rotation tool to 3HAB7887-1.
• Removed the tool measuring ring for radial seal from special tools
list, since it is not used for the robot.
• Removed the article number for the leak-down tester, since it is
not a purchable equipment.
• Removed the article number for the threaded bar used for pressing
the rear balancing device bearing in place, since it is not a
purchable equipment.
• Corrected the article number for the fork lift from 3HAC047054-
002 to 3HAC047054-003.
• Edited information regarding deciding calibration routine in each
repair section.
• Added a warning that calibration pin must be inserted in the calib-
ration bushing until it snaps, see Description of Axis Calibration
on page 813.
• Added warning regarding risk of pinching, in Description of Axis
Calibration on page 813.
• Added information about inspection of calibration tool prior to
usage, see Examining the calibration tool on page 816.
• Added information about the calibration procedure, see Overview
of the calibration procedure on the FlexPendant on page 819, Re-
starting an interrupted calibration procedure on page 821.
• Added information about Axis Calibration when SafeMove is in-
stalled, see Axis Calibration with SafeMove option on page 821.
G The following updates are done in this revision:
• Removal tools for removing the motors are updated. New article
numbers for the tools.
H Published in release R16.2. The following updates are made in this revi-
sion:
• Drawing of base plate is not available for purchase, faulty inform-
ation removed in Securing the base plate on page 66.
• Type B motors are introduced throughout the manual.
• The figure of the turning disc is updated, the throughout holes are
removed and a table note is added, see Tool flange, standard on
page 97.
• Illustration regarding centering diameters on tool flange updated.
J Published in release R17.1. The following updates are made in this revi-
sion:
• Illustration for "Tool flange, standard" is updated.
• Bending radius for static floor cables added.
• Instructions for how to install the fork lift accessory set are re-
moved from the manual. The instructions are found in the user
documentation, enclosed with the fork lift accessory.
• Grease trade name changed (was Optimol PD0 - is Tribol GR 100-
0 PD)
• Article number for axis-4 motor o-ring is corrected.
• Spare part numbers for movable mechanical stop set axis 1 is
changed, and one new number is added.
• Motors updated, M12 instead of M14 holes on IRB6700 for removal
tool.
• Quality recommendations on foundation removed from manual.
Revision Description
K Published in release R17.2. The following updates are made in this revi-
sion:
• Caution about removing metal residues added in sections about
SMB boards.
• Information about Minimum resonance frequency added.
• Bending radius for static floor cables added.
• Applicable standards updated
• Added text regarding overhaul in section specification of mainten-
ance intervals.
• Section Start of robot in cold environments on page 115 added.
• Added information and dimensions of cylindrical and flattened
cylindrical guide pins used for securing the robot.
• Added new length of screws for securing the robot to a track mo-
tion.
• Updated information regarding replacement of brake release
board.
• Updated information regarding disconnecting and reconnecting
battery cable to serial measurement board.
• Definition of reference calibration clarified.
• Added information about flange sealant between axis-1 gearbox
and base.
L Published in release R18.1. The following updates are made in this revi-
sion:
• Information added about fatigue to Axis Calibration tool, see Cal-
ibration tools for Axis Calibration on page 816.
• Added sections in General procedures on page 202.
• Corrected the length of attachment screws for axis-1 and axis-2
motors.
• Guide tool for refitting the axis-1 gearbox is added to the repair
procedure and list of special tools.
• Safety restructured.
• Changed specification for axis-2 position before usage of distance
tool on the balancing device.
• The procedure for replacing the axis-3 gearbox is changed to using
a loose pinion as a tool during refitting of the upper arm.
• Added photos showing the appearance of the protection filter and
the transparent plug on motor oil evacuation hole.
• Note added to calibration chapter to emphasize the requirement
of equally dressed robot when using previously created reference
calibration values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
• Installation information of cooling fan for the axis-1 motor added.
M Published in release R18.2. The following updates are made in this revi-
sion:
• Added article number for axis-3 pinion tool.
N Published in release R18.2. The following updates are made in this revi-
sion:
• Updated references.
Revision Description
P Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint
or surface on the robot before replacing parts on page 209.
• New article numbers for manipulator cables in section Robot
cabling and connection points on page 104.
• Added new o-ring for axis-3 gearbox for IRB 6700-200/2.60, -
175/2.60 LID, -155/2.85, -140/2.85 LID.
Q Published in release 19D. The following updates are made in this revision:
• Added references to DressPack manual in Robot cabling and
connection points on page 104.
• Corrected article number for guide pin M12x200 and removal tool
M12. Deleted guide pin M12x250 from special tool list.
R Published in release 20A. The following updates are made in this revision:
• Added new protection plug for the front link ear.
• Replaced article number and name of grease, previously
3HAB3537-1.
• Clarified and added information in mounting instructions for rotat-
ing sealings, see Mounting instructions for sealings on page 205.
• Clarified text about position of robot and added table with depend-
encies between axes during Axis Calibration.
S Published in release 20B. The following updates are made in this revision:
• Added information about Wrist Optimization in calibration chapter.
T Published in release 20C. The following updates are made in this revision:
• New press equipment for unloading balancing device introduced.
New article number. User instructions for the equipment are en-
closed with the tool.
• Pallet removed from required tools tables.
U Published in release 20D. The following updates are made in this revision:
• Added o-ring for axis-6 gearbox, for IRB 6700-300/2.70, -270/2.70
LID, -245/3.00, -220/3.00 LID and IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID.
• Added o-ring for axis-6 motor flange, for IRB 6700-200/2.60, -
175/2.60 LID, -155/2.85, -140/2.85 LID.
V Published in release 21C. The following updates are made in this revision:
• User instructions for the dismantle and mounting tool
(3HAC028920-001) is now enclosed with the toolkit. User instruc-
tions are removed from this manual.
• Section Lifting the robot with lifting accessory added to Lifting the
robot on page 72.
• Text regarding fastener quality is updated, see Fastener quality
on page 98.
• Info about option Extended working range included, see Extended
working range, axis 1 (option) on page 99.
W Published in release 21D. The following updates are made in this revision:
• Added information for the OmniCore robot controller.
X Published in release 22A. The following updates are made in this revision:
• Oil change interval is corrected in maintenance schedule.
• Updated information about Gleitmo treated screws, see Screw
joints on page 844.
• Updated image of roundslings attached to lifting shackle.
• Removed information about inspecting fork lift accessories. In-
formation is found in enclosed documentation for the fork lift ac-
cessories.
Revision Description
Y Published in release 22B. The following updates are done in this revision:
• Added information about always replacing the o-rings on oil plugs
with new o-rings when refitting the plugs.
• Added LID robot variants throughout the manual (valid for Omni-
Core robot controller).
Z Published in release 22D. The following updates are done in this revision:
• Changed tightening torque from 24 Nm to 10 Nm on stop screw,
mechanical stop pin axis 1.
• Added a step for overall inspection of cabling after cable harness
has been replaced.
• New design on link ear bearings, balancing device.
AA Published in release 23B. The following updates are done in this revision:
• Added section Test run after installation, maintenance, or repair
on page 116.
• Added a step in motor replacement procedures for replacing the
protection filter with sight glass on new spare part motors for
manipulators with protection type Foundry Plus.
• Added axis positions for most stable transport position and re-
moved information about shipping position.
• Updates made based on feedback from University.
• Updated the torque value for transparent plug.
AB Published in release 23C. The following updates are done in this revision:
• Updated image of transportation position and updated table with
the axis angles.
• Added missing information for attachment holes.
Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics 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.
Tip
Product manuals
Manipulators, controllers, DressPack, and most other hardware is delivered with
a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Troubleshooting.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
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, software).
• How to install included or required hardware.
• How to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.
1 Safety
1.1 Safety information
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed as
intended.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
Introduction to symbols
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 additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 23.
The information labels can contain information in text.
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working space.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 832 for specification of allergenic materials
in the product, if any.
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.
Note
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no tools, loose screws, turnings, or other unexpected
parts remaining after maintenance or repair work.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Allergic reaction
Note
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
for the product.
Do not mix types of oil
Oil residues might be present in Make sure that protective gear
a drained gearbox and spilled like goggles/protective visor,
when separating a motor and gloves and arm protection are
gearbox during repair. always worn during this activity.
Put oil absorbent cloth or paper
Oil residues
at appropriate locations to catch
any oil residues.
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.
Contaminated oil in
gearboxes
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
Related information
See also the safety information related to installation and operation.
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 84.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the manipulator does
not result in additional hazards, for example, even more severe injuries on a trapped
person.
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.
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 verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the manipulator does not change position as the motors are switched off,
then the brake function is adequate.
Note
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
CAUTION
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.
General
See section Decommissioning on page 831.
If the robot is decommissioned for storage, take extra precaution to reset safety
devices to delivery status.
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
General
This chapter contains assembly instructions and information for installing the IRB
6700 at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
The technical data is detailed in section Technical data on page 43.
Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any installation
work.
Note
Always connect the IRB 6700 and the robot to protective earth and residual
current device (RCD) before connecting to power and starting any installation
work.
For more information see:
• Product manual - OmniCore V250XT
• Product manual - OmniCore V250XT Type A
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller
2.2 Unpacking
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.
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Weight, robot
The table shows the weight of the robot.
The weight does not include the weight of the DressPack.
Robot model Weight
IRB 6700 1300 kg
Note
The weight does not include tools and other equipment fitted on the robot.
The weight does not include the weight of the DressPack.
Mounting positions
The table shows valid mounting options for the manipulator.
Mounting option Installation angle Note
Floor mounted 0°
Note
The actual mounting angle must always be configured in the system parameters,
otherwise the performance and lifetime is affected.
Txy
Fz
Fxy
Tz
xx1100000521
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
Floor mounted
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.3 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
Minimum resonance 22 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see the application manual of the
time to have a controller software, section Motion Process
lower resonance Mode.
frequency than
recommended.
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated frequency. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Working range
xx1300001587
3114
320
1187 920
1908 2650
xx1300000281
1281 958
2039 2794
xx1300000282
3520
726
1527 1109
2314 3056
xx1300000283
1604 1067
2445 3200
xx1300000284
3065
282
1150 911
1859 2601
xx1300000341
1352 994
2106 2848
xx1300000340
3154
349
1187 957
1850 2720
xx1400001137
1518 1057
2097 2967
xx1400001138
R1
170°
xx1300001082
Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The transportation position is the most stable position.
Do not change the robot position before securing it to the foundation!
Transportation position
This figure shows the robot in its transportation position.
39°
34-
70 °
913 65
(645 CL)
670 65
xx1300000356
Note
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.
Illustration
F
G
A
200
E
D
780
377
1009
B 745 C
360
J
1009
H
360
xx1300000241
Pos Description
B Radius ax1, front = 532 mm (IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID)
Radius ax1, front = 600 mm (IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID)
C Radius ax1, back = 633 mm (IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID)
Radius ax1, back = 700 mm (IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID)
Robot variant A A D E F F G H J
LeanID LeanID
(LID) (LID)
IRB 6700-235/2.65 200 350 2300 1135 1670 1820 1,182.5 209 186
IRB 6700-205/2.80 200 350 2445 1280 1670 1820 1,182.5 186 209
IRB 6700-175/3.05 200 350 2300 1135 2080 2230 1,592.5 209 186
Robot variant A A D E F F G H J
LeanID LeanID
(LID) (LID)
IRB 6700-150/3.20 200 350 2445 1280 2080 2230 1,592.5 209 186
IRB 6700-200/2.60 200 350 2276 1125 1623 1773 1,142.5 197.5 193
IRB 6700-155/2.85 200 350 2276 1125 1873 2023 1,392.5 197.5 193
IRB 6700-300/2.70 220 380 2321 1145 1,718.5 1,878.5 1,212.5 222.5 187
IRB 6700-245/3.00 220 380 2321 1145 1,968.5 2,128.5 1,462.5 222.5 186
IRB 6700-220/2.65 LID - 350 2300 1135 - 1820 1,182.5 209 186
IRB 6700-200/2.80 LID - 350 2445 1280 - 1820 1,182.5 186 209
IRB 6700-155/3.05 LID - 350 2300 1135 - 2230 1,592.5 209 186
IRB 6700-145/3.20 LID - 350 2445 1280 - 2230 1,592.5 209 186
IRB 6700-200/2.60 LID - 350 2276 1125 - 1773 1,142.5 197.5 193
IRB 6700-140/2.85 LID - 350 2276 1125 - 2023 1,392.5 197.5 193
IRB 6700-270/2.70 LID - 380 2321 1145 - 1,878.5 1,212.5 222.5 187
IRB 6700-220/3.00 LID - 380 2321 1145 - 2,128.5 1,462.5 222.5 186
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 grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.
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 the
method described in this section.
Transportation in any other way can seriously damage the robot. If the robot
is incorrectly transported and the instructions are not followed, the robot is
not covered by the warranty and ABB will not accept any compensation claim.
xx0800000030
IRB 6700
C
D
xx0800000037
A Transport Support
B Hexagon socket head cap screw M16x140
C Threaded bar M10x200
D Nut M10
IRB 6700
xx0800000040
IRB 6700
250
220
40
0
R 11
R9
0
65
130
200
M10
50
30
A 5
30°
18
50
R2
12
R3
0
60 (10)
(52)
(62)
xx1300001603
General
This section describes how to fit the transport support to the robot in order to
secure the robot for transportation. The transport support is required if the robot
must be transported with mounted tools.
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.
xx0800000062
Action Note
1 Fit the transport support’s lower end to the Do not tighten the screw.
robot using the recommended screw joint, See attachment point for the specific ro-
(A) in figure. bot in the section Transport position with
a transport support on page 60.
2 Jog the robot into a position as near above
as possible to the recommended transport CAUTION
position for the specific robot, as specified
in section Transport position with a transport Do not try to jog the robot to the exact
support on page 60. position (max distance 1mm).
3 Use the brake release for axis 3 to reach the See attachment point for the specific ro-
final resting position on the transport support, bot in the section Transport position with
see the section Manually releasing the brakes a transport support on page 60
on page 84.
4 Tighten all the attachment screws, (A) and
(B), in the figure with the brake release for CAUTION
axis 3 still activated starting with the lower
attachment screw. Do not attempt to tighten any attachment
screws without first releasing the brakes.
This can seriously damage the robot.
Introduction
This procedure is a brief guide when installing the robot for the first time. Also see
Pre-installation procedure on page 42.
First installation
Use these procedures to install the IRB 6700.
Action Note
1 Transport the manipulator to its intended location.
2 Install the valid platform or prepare the foundation See Securing the base plate on
for the manipulator. page 66.
3 Lift and secure the manipulator to the plat- See Lifting the robot on page 72.
form/foundation. See Orienting and securing the ro-
bot on page 79.
4 Connect the manipulator to the controller. See
• Product manual - IRC5
• Product manual - IRC5 Pan-
el Mounted Controller
• Product manual - OmniCore
V250XT
• Product manual - OmniCore
V250XT Type A
5 Configure the safety settings. See
• Product manual - IRC5
• Product manual - IRC5 Pan-
el Mounted Controller
• Product manual - OmniCore
V250XT
• Product manual - OmniCore
V250XT Type A
6 How to start and run the robot is described in the See
product manual for the controller. • Product manual - IRC5
• Product manual - IRC5 Pan-
el Mounted Controller
• Product manual - OmniCore
V250XT
• Product manual - OmniCore
V250XT Type A
7 Install required equipment, if any.
• Safety lamp (option for IRC5) on page 108
8
DANGER
Required equipment
Hole configuration
xx0200000096
Action Note
1
CAUTION
CAUTION
Lift and move the base plate very slowly. If the base
plate starts to swing it is a risk for injuries or damage.
453
87
0
G H
(A)
B
D
D
800
12x M 24
B 1 A B
90°
10
4x 9
°
Ref A-B
3x 25
0°
448
90°
°
37,5
475
(B)
10°
A
°
7,5
A
2x
E
°
15
°
4x
25
4x
0
27
C C
F E
7)
(H
±1
±1
A
2x
20
18
1x
2x
45
+0,018 3x
1,6
2x 12H7 0 4 P7 -0,017
5 45 -0,042
0,1 A B 1,5
2
±1
E-E A-A
13
32
48
4x
xx1500000246
Pos Description
A, B Hole for guide pin, cylindrical, see Guide pins on page 69
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)
B
23 47 0+0,5
,5
,01 7
- 0 0,00
8
+
45 K7
1,6
3x
45
13
°
37,5
48
CL 2x R22,5 B-B
2x
R
D
3x 90°
3x
4
3x
C-C R1
xx1500000247
2x 271
2x 774
87
69
5x M16
0
16x 22
923 ±1
878 896
855
786 773
721
538
( 950)
448
358
175
110 123
18 41 +3
-1
0 0 50
27±1
27
2x206
2x363
2x 543
2x726
2x 860
2x 904
87±1
933 ±1
50
0
(1020)
2x 119,9
2x 278,3
2x132,8
2x224,1
87
0
50x45° (2x)
25
R5
2x
804 813,9
784,6 784,8
697,2 680,1
681,9 672,5
2x 598
4x 18
16x R 50
2x 298
214,1 223,5
198,8 215,9
111,4 111,2
92 82,1
0 0
27 27
2x203
2x703
619
677
794
787,6
87
xx1500000249
Guide pins
25g6
(A)
15
18
12k6
XX1500000248
Pos Description
A Cylindrical guide pin (x2)
(A)
(B)
B-B
B B
Pos Description
A Cylindrical guide pin (x2)
B M5 x 40. Tightening torque 6 Nm. (x2)
Note
All screws and pins are delivered in a plastic bag together with the base plate.
B A
B
B
A
xx1500000312
Required equipment
Base plate
This section details how to secure the base plate to the foundation.
Action Note
1 Make sure the foundation is levelled.
2
CAUTION
3 Position base plate in relation to the robot Shown in figure Base plate, orienting
work location using the grooves in the base grooves and leveling bolts on page 70.
plate.
4 Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 65.
5 Use the base plate as a template and drill at- Attachment holes: 16 pcs.
tachment holes as required by the selected
bolt dimension.
6 Fit the base plate and use the levelling bolts Shown in figure Base plate, orienting
to level the base plate. grooves and leveling bolts on page 70.
7 If required, fit strips of sheet metal underneath
the base plate to fill any gaps.
8 Secure the base plate to the foundation with
screws and sleeves.
9 Recheck the four contact surfaces on the Maximum allowed deviation all over the
base plate to make sure the base plate is base plate, from one contact surface to
levelled and flat. the other: 0.3 mm.
If it is not, use pieces of sheet metal or similar
to bring the base plate to a levelled position.
(A)
10 Fit the enclosed guide pins to the base plate. 800
Note
B B
xx1500000250
Lifting methods
The robot may be lifted and transported using a fork lift, provided that available
special aids are used.
This section specifies available special aids and references to valid user
documentation for the lifting accessories.
Required documents
Action Note
1 Lift the robot according to the user instructions
enclosed with the fork lift accessory.
General
This section contains a general overview of how to lift the complete robot using
special lifting accessory.
Note
The user manual may be out of date. The latest revision is available for download
via myABB Business Portal, www.abb.com/myABB.
xx0200000153
Required equipment
Note
Please refer to the enclosed user instruction for instruction how to place the
manipulator in an correct position. Attempting to lift a manipulator in any other
position may result in the robot tipping over, causing severe damage or injury!
Action Note
1 Run the overhead crane to a position above
the robot.
2 Position the robot as detailed in enclosed in- Article number is specified in Required
struction! equipment on page 73.
Release the brakes, if required, as de-
tailed in section Manually releasing the
brakes on page 84.
3 Fit the lifting accessory to the robot as de- Article number is specified in Required
scribed in the enclosed instruction! equipment on page 73.
Go to the user instructions enclosed with the
lifting accessory.
DANGER
4
CAUTION
5
WARNING
6 Raise overhead crane to lift the robot. Make sure all hooks and attachments
maintain their correct positions while
lifting the robot!
Always move the robot at very low
speeds, making sure it does not tip.
C
B
Required equipment
See quantity of roundslings in figure Attaching the roundslings on page 75.
Action Note
1 Jog the robot into position:
• Axis 1: calibration position (0°)
39°
• Axis 2: -45° 34-
• Axis 3: +65°
• Axis 4: no significance 70 °
• Axis 5: +70°
• Axis 6: no significance
WARNING
(645 CL)
670 65
xx1300000356
Action Note
1 Fit lifting eyes to the outer holes on each
corner of the base.
xx1200001301
xx1200001302
2 Run roundslings through the lifting eyes Make sure the roundslings do not rub
and fasten them in an overhead crane. against any sharp edges.
Roundsling, 2.5 m (4 pcs)
CAUTION
xx1300001572
Action Note
3 Attach a securing roundsling at the rear Length for the roundsling is given in the
according to figure. table Attaching the roundslings on
page 75.
Note
xx1300001573
4 Attach a securing roundsling at the front Length for the roundsling is given in the
according to figure. table Attaching the roundslings on
page 75.
Note
xx1300001574
5
CAUTION
6
WARNING
CAUTION
General
This section details how to orient and secure the robot to the base plate in order
to run the robot safely.
It also contains information about securing the robot to a track motion.
0,3 A
8x
8x 53
,5
49
30
16
8x
2x
8)
H
45
24
25
,5
3x
(
4x
20
2 x4
5°
4x 45 H7
0,12 2x 25 H8
0,12
D-D
4x 90° E-E
(A) 4x
800
15
°
D
52,
5°
E
(A)
E
xx1300000243
Pos Description
A Holes for guide pins (x2)
Required equipment
It is necessary to use guide pins when securing the robot to a base plate or a track
motion.
25g6
(A)
15
18
12k6
XX1500000248
Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the robot to the base plate/foundation or to a track motion IRBT 6004/7004.
Suitable screws, lightly lubricated: M24 x 100 (installation on base plate/foundation)
Quantity: 8 pcs
Quality: 8.8
Screw tightening yield point utilization 90% (v=0.9)
factor (v) (according to VDI2230):
Suitable washer: 4 mm flat washer
Tightening torque: 550 Nm (screws lubricated with Molykote 1000)
600-725 Nm, typical 650 Nm (screws none or
lightly lubricated)
Action Note
(A)
1 Fit two guide pins to the guide pin holes in the 800
base plate.
Note
B B
xx1500000250
Note
xx1500000319
Pos Description
A Cylindrical guide pin
Note
There are versions with a flattened cylindrical guide pin in left rear of the base.
xx1500000320
Pos Description
A Cylindrical guide pin.
C Adapter for guide pin (fitted to the carriage at delivery)
D Distance plate (fitted to the carriage at delivery)
Note
There are versions with a flattened cylindrical guide pin in left rear of the base.
It is important that the flattened pin is aligned in correct direction.
xx1200000964
Action Note
3 Release the holding brake on a particular robot
axis by pressing the corresponding button on the
internal brake release unit.
The brake will function again as soon as the button
is released.
xx0600002937
2.4.7 Loads fitted to the robot, stopping time and braking distances
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 operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant
• Operating manual - OmniCore
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
extra equipment on page 90). Maximum allowed arm load depends on center of
gravity of arm load and robot payload.
Note
All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.
xx1300000262
Upper arm
Allowed extra load on the upper arm housing, in addition to the maximum handling
weight, is M1 ≤ 50 kg with a distance (a) ≤ 500 mm from the center of gravity in the
axis-3 extension.
M1
a
(A)
M1
xx1400002019
A Mass center
(A)
400
200
xx1300000866
A Center of gravity 50 kg
(150)
(109) (2x M12) 12
(150)
(2x M12)
J
D A
F
160
H
3x M10
C
40
80 0,3
197
80
190
CL Axis 5 90
4x M12 22 B
2x M8 16 100
J M12 19
106 (4x M12 22)
B
K 328
53
CL Axis 3
110 2x M12 19 L
220 B
K
CL Axis 4
M12 20
13
8
M
R117
4x
52, 5 °
5° 52, (M12 19) (2x M12 19)
N M
A-A B-B
xx1300000263
A Allowed position for attachment holes, M12 through. Be careful not to touch the cables when drilling.
Variant Bi C D E F G H J K L M N
IRB 6700-235/2.65 R=216 270 400 652.5 365 437 349 147 33 102 104 210
IRB 6700-205/2.80 R=216 270 500 652.5 365 437 349 147 33 102 104 210
IRB 6700-175/3.05 R=216 270 400 652.5 365 437 349 147 33 102 104 210
IRB 6700-150/3.20 R=216 270 500 652.5 365 437 349 147 33 102 104 210
IRB 6700-200/2.60 R=204.5 270 400 650.5 365 437 315 143 43 102 95 210
IRB 6700-155/2.85 R=204.5 270 400 650.5 365 437 315 143 43 102 95 210
IRB 6700-300/2.70 R=230 310 450 652.5 376 467 405 152 12 117 98.5 215.5
IRB 6700-245/3.00 R=230 310 450 652.5 376 467 405 152 12 117 98.5 215.5
IRB 6700Inv-300/2.60 R=230 310 450 652.5 425.6 467 405 152 12 117 98.5 215.5
IRB 6700I-300/2.60
IRB 6700Inv-245/2.90 R=230 310 450 652.5 425.6 467 405 152 12 117 98.5 215.5
IRB 6700I-245/2.90
i Smallest circumscribed radius axis-4.
CL Axis 3 H
(2x M8)
B 2x M8
265
30 D
465
(M8) M8
C
(2x M8)
2x M8 E
D CL Axis 2
50 33
4x M10 20
60
L
(2x M8)
(2x M8)
C-C
A 190 M
90
D
328
80
40
2x M8 12
CL Axis 5
100
xx1300000264
Variant Ai B C D E F G H J K L M
IRB 6700-235/2.65 R=456 433 418 403 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-205/2.80 R=456 438 423 408 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-175/3.05 R=456 433 418 403 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-150/3.20 R=456 438 423 408 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-200/2.60 R=440 425 410 395 113 197 193 255 320 303.5 500 13.8
IRB 6700-155/2.85 R=440 425 410 395 113 197 193 255 320 303.5 500 13.8
IRB 6700-245/3.00 R=468 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700-300/2.70 R=468 453 438 423 80 222.5 187 265 350 273.5 523.5 15
i Smallest circumscribed radius axis-3.
(150)
(109) (2x M12)
(150) 12
(2x M12)
J
D A
160
H
3x M10
C
40
80 0,3
197
80
190
CL Axis 5 90
4x M12 22 B
2x M8 16 100
J M12 19
106 (4x M12 22)
328
K
B 53
CL Axis 3
110 2x M12 19 L
220 B
K
CL Axis 4
M12 20
13
8
M
R117
4x
52, 5 °
5° 52, (M12 19) (2x M12 19)
N M
A-A B-B
xx1300000263
A Allowed position for attachment holes, M12 through. Be careful not to touch the cables when drilling.
Variant Bi C D E F G H J K L M N
IRB 6700-235/2.65 R=216 270 400 652.5 365 437 349 147 33 102 104 210
IRB 6700 - 220/2.65 LID R=216 270 400 652.5 365 437 349 147 33 102 104 210
IRB 6700-205/2.80 R=216 270 500 652.5 365 437 349 147 33 102 104 210
IRB 6700 - 200/2.80 LID R=216 270 500 652.5 365 437 349 147 33 102 104 210
IRB 6700-175/3.05 R=216 270 400 652.5 365 437 349 147 33 102 104 210
IRB 6700 - 155/3.05 LID R=216 270 400 652.5 365 437 349 147 33 102 104 210
IRB 6700-150/3.20 R=216 270 500 652.5 365 437 349 147 33 102 104 210
IRB 6700 - 145/3.20 LID R=216 270 500 652.5 365 437 349 147 33 102 104 210
IRB 6700-200/2.60 R=204.5 270 400 650.5 365 437 315 143 43 102 95 210
IRB 6700 - 175/2.60 LID R=204.5 270 400 650.5 365 437 315 143 43 102 95 210
IRB 6700-155/2.85 R=204.5 270 400 650.5 365 437 315 143 43 102 95 210
IRB 6700 - 140/2.85 LID R=204.5 270 400 650.5 365 437 315 143 43 102 95 210
IRB 6700-300/2.70 R=230 310 450 652.5 376 467 405 152 12 117 98.5 215.5
IRB 6700 - 270/2.70 LID R=230 310 450 652.5 376 467 405 152 12 117 98.5 215.5
IRB 6700-245/3.00 R=230 310 450 652.5 376 467 405 152 12 117 98.5 215.5
IRB 6700 - 220/3.00 LID R=230 310 450 652.5 376 467 405 152 12 117 98.5 215.5
IRB 6700Inv-300/2.60 R=230 310 450 652.5 425.6 467 405 152 12 117 98.5 215.5
IRB 6700I - 300/2.60
IRB 6700I - 270/2.60 LID R=230 310 450 652.5 425.6 467 405 152 12 117 98.5 215.5
IRB 6700Inv-245/2.90 R=230 310 450 652.5 425.6 467 405 152 12 117 98.5 215.5
IRB 6700I - 245/2.90
IRB 6700I - 210/2.90 LID R=230 310 450 652.5 425.6 467 405 152 12 117 98.5 215.5
i Smallest circumscribed radius axis-4.
CL Axis 3 H
(2x M8)
B 2x M8
265
30 D
465
(M8) M8
C
(2x M8)
2x M8 E
D CL Axis 2
50 33
4x M10 20
60
L
(2x M8)
(2x M8)
C-C
A 190 M
90
D
328
80
40
2x M8 12
CL Axis 5
100
xx1300000264
Variant Ai B C D E F G H J K L M
IRB 6700-235/2.65 R=456 433 418 403 80 208.5 186 255 320 303.5 500 13.8
IRB 6700 - 220/2.65 LID R=477 433 418 403 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-205/2.80 R=456 438 423 408 80 208.5 186 255 320 303.5 500 13.8
IRB 6700 - 200/2.80 LID R=477 438 423 408 80 208.5 186 255 320 303.5 500 13.8
IRB 6700 - 155/3.05 LID R=465 433 418 403 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-175/3.05 R=477 433 418 403 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-150/3.20 R=456 438 423 408 80 208.5 186 255 320 303.5 500 13.8
IRB 6700 - 145/3.20 LID R=477 438 423 408 80 208.5 186 255 320 303.5 500 13.8
IRB 6700-200/2.60 R=440 425 410 395 113 197 193 255 320 303.5 500 13.8
Variant Ai B C D E F G H J K L M
IRB 6700 - 175/2.60 LID R=472 425 410 395 113 197 193 255 320 303.5 500 13.8
IRB 6700-155/2.85 R=440 425 410 395 113 197 193 255 320 303.5 500 13.8
IRB 6700 - 140/2.85 LID R=472 425 410 395 113 197 193 255 320 303.5 500 13.8
IRB 6700-300/2.70 R=468 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700 - 270/2.70 LID R=481 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700-245/3.00 R=468 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700 - 220/3.00 LID R=481 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700Inv-300/2.60 R=468 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700I - 300/2.60
IRB 6700I - 270/2.60 LID R=481 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700Inv-245/2.90 R=468 453 438 423 80 222.5 187 265 350 273.5 523.5 15
IRB 6700I - 245/2.90
IRB 6700I - 210/2.90 LID R=481 453 438 423 80 222.5 187 265 350 273.5 523.5 15
i Smallest circumscribed radius axis-3.
Extra cover
There is an extra cover for LeanID variants (upper arm cover). So that value A for
LeanID variants is different.
There is an extra cover for LID variants (upper arm cover). So that value A for LID
variants is different.
190
90
(13.8)
328
xx2100002054
16 ±1
30° A
11x
0,5 X 45°
6x R11
200 h8 - 0,072
0
+0,035
160
0 100 H7
3x R70
22
1x45 12
0,02 A
2,5
M12
101
45°
A-A
+1 B
+2 3x R 0,8 0 18°
A
3x R 0,8 -0,4
)
re
bo
er
+0,018
nt
18 H7 0
ou
(C
0,2 C D B
2
24 +
0
45°
,5
68
1,
°
306
0,3 C D
23 max.
18 min.
25
m
in
1
.(
H
7)
28
A
+2 0
11x M12
0,2 A B
.
in
m
CL C-D
,4
17
B-B
61
xx1300000280
The turning disc for robot variants IRB 6700-200/2.60 and IRB 6700-155/2.85 was
redesigned when Axis Calibration was introduced for IRB 6700. Prior to Axis
Calibration the holes on the disc were through. On the current turning disc the
holes are not through.
A
C 8 ( 100 H7)
1x45
E
160
18
0,3 E F
0,07 E
12 H7 15
200 h8
100 H7
11xM12
F
12x
30°
C C-C
xx1300000290
Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.
Overview
The working range of axis 1 can be extended on a floor-mounted robot, from the
default range limited by mechanical stops. The working range can be extended to
±220°.
CAUTION
The option Extended work range enables an extension of the working range for
axis 1, through a software configuration. With this option installed, the working
range can exceed the range limited by the mechanical stop on axis 1. The working
range shall be limited through the option SafeMove.
A risk analysis must be done to ensure that no risks remain when using option
Extended work range, to limit the working range, and before removing the
mechanical stops.
For information about the option SafeMove, see Application manual - Functional
safety and SafeMove2 (IRC5) or Application manual - Functional safety and
SafeMove (OmniCore).
If the mechanical stop is removed, then the manipulator should have a marking
for this, for example, a label. If the robot is delivered with the option Extended
work range, then such a label is included on delivery.
Action Note/Illustration
1 Configure the safety setup and verify it by
test.
2 Hold the mechanical stop pin in a firm grip,
and remove it by unscrewing the attach-
ment screw.
xx2100001705
Related information
The system parameters are described in detail in the reference manual, see
References on page 10.
For more information about SafeMove, see Application manual - Functional safety
and SafeMove2 (IRC5) or Application manual - Functional safety and SafeMove
(OmniCore).
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 restricted:
• Axis 1, hardware (mechanical stop) and software.
• Axis 2, software.
• Axis 3, software.
This section describes how to install hardware that restricts the working range.
Note
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°
in both directions.
B
C
A B
xx1300001971
A Attachment screws M12x70 quality 12.9 Gleitmo 603 (2 pcs per additional
mechanical stop)
B Movable mechanical stop
C Mechanical stop pin axis-1
Required equipment
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.
DANGER
CAUTION
Verify that the serial number is according to the number(s) in the Declaration of
Incorporation (DoI).
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the controller to
the robot motors.
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.
A
B
xx1600002016
A Diameter
B Diameter x10
xx1500001600
Note
Description
A signal lamp with a yellow fixed light can be mounted on the robot, as a safety
device.
Installation
See the assembly instruction delivered with the signal lamp.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.
xx1800000156
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 6700 via myABB Business Portal,
www.abb.com/myABB.
Required consumables
Action Note
1 Move the robot to its synchronization position.
2
DANGER
xx1800000157
xx1800000159
Action Note
5 Fit the fan unit sheets around the motor and fasten
them to each other by tightening the six screws.
xx1800000158
xx1800000160
Action Note
1 Remove the rear cover plate.
xx1800000161
xx1800000162
Action Note
3 The bracket on the delivered fan cable must be
fitted at a distance of 1,150 mm from the base
connector. 1150
xx1800000163
If adjustment is needed: measure the distance
and make a mark with a pen or a piece of self
adhesive. Loosen the cable bracket nuts and
move the bracket to the mark. Tighten the nuts
with 10 Nm after adjustment.
4 Loosen the frame cable clamp by unscrewing the
screws.
xx1300000542
5 Run the cabling up through the base and frame. Cable straps
Make a loop of the fan cable and use cable straps
to strap it to the other cables.
xx1800000164
xx1800000166
Action Note
B
7 Run the cable out through the side of the frame,
at the axis-1 motor and connect the fan cable
connector to the cooling fan.
8 Strap the fan cable to the axis-1 and axis-2 motor
cables.
xx1800000165
xx1300000542
xx1800000167
xx1800000161
Action Note
12 Install additional cabling to and inside the control- Cabling and connection points are
ler. specified in Fan cables (option) on
page 106.
Adjustments in RobotWare
Action Note
1 Modify the settings in RobotWare to include the Change the settings by using the
cooling fans. Modify Controller System Wizard
in the System Builder of RobotStu-
dio. Read more about modifying
the system in Operating manu-
al - RobotStudio.
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
If the program consists of large wrist movements, it is possible that the reorientation
velocity, which is always high in predefined velocities, needs to be included in the
ramping up.
Safe handling
Use the following procedure after installation, maintenance, or repair, before
initiating motion.
DANGER
Initiating motion without fulfilling the following aspects, may increase the risk for
injury or cause damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Verify that all safety equipment is installed, as designed for the application.
6 Verify that no personnel are inside the safeguarded space.
7 If maintenance or repair has been done, verify the function of the part that was main-
tained.
8 Verify the application in the operating mode manual reduced speed.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before initiating motion.
3 Maintenance
3.1 Introduction
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the IRB 6700 is connected to power, always make sure that the IRB 6700 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
For more information see:
• Product manual - OmniCore V250XT
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller
• Robot cabling and connection points on page 104.
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 6700:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB Connected Services and its Assessment tools can help you to identify the
real stress level of your robot, and define the optimal ABB support to maintain your
robot working.
Contact your local ABB Customer Service to get more information.
Every 18 months
Every 24 months
Every 36 months
Every 6 months
Regularly
Cleaning activities
Cleaning the IRB 6700 on
Cleaning the robot x
page 198
Inspection activities
Inspecting the motor seal
Inspecting the motor seal ii x
on page 122
Inspect the oil level in the
actual gearbox if there is
a suspected leakage, after
Inspecting the oil level in gearboxes an oil change or a
maintenance or repair
activity where draining
and filling oil is required.
Inspecting the balancing
Inspecting the balancing device x
device on page 142
Inspecting the cable
Inspecting the robot harness x iii
harness on page 146
Inspecting the cable
Inspecting the velcro straps x
harness on page 146
Inspecting the information
Inspecting the information labels x
labels on page 148
Inspecting the dampers
Inspecting the dampers x
on page 156
Every 18 months
Every 24 months
Every 36 months
Every 6 months
Regularly
Maintenance activities Reference
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
xx1500001057
xx2200002188
Action Note
1
DANGER
2
WARNING
Note
xx1200000950
xx1500001655
Required tools
Required documents
2
WARNING
Action Note
4 Open the oil plug.
xx1200000950
xx1500001655
xx1300000692
Action Note
6 IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID
Check the oil level.
Required oil level is: 0 - 10 mm below the
oil plug hole.
7 Add or drain oil, if required. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
in gearboxes.
Further information about how to drain or
fill with oil is found in section Changing oil,
axis-1 gearbox on page 162.
8 Refit the oil plug with a new o-ring. O-ring, G 1/2": 3HAC061327-059
Tightening torque: 24 Nm.
9
DANGER
xx1200000952
Tightening torque: 24 Nm
Required documents
2
WARNING
xx1200000952
Action Note
8
DANGER
xx1200000955
xx1500001645
Tightening torque: 24 Nm
Required tools
Required documents
Action Note
5 Open the oil plug.
xx1200000955
xx1500001645
xx1200000957
Tightening torque: 24 Nm
Required tools
Required documents
Action Note
2
DANGER
xx1200000957
xx1200000959
Tightening torque: 24 Nm
Required tools
Required documents
Action Note
2
DANGER
xx1200000959
xx1600002049
Tightening torque: 24 Nm
Required tools
Required documents
xx1600002049
6 Method 1
Check the oil level. Required oil level is:
• IRB 6700-235/2.65, -220/2.65 LID, -
205/2.80, -200/2.80 LID, -175/3.05, -
155/3.05 LID, -150/3.20, -145/3.20
LID
50 mm ± 5 mm below the sealing
surface of the oil plug.
• IRB 6700-200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID
50 mm ± 5 mm below the sealing
surface of the oil plug.
• IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID
45 mm ± 5 mm below the sealing
surface of the oil plug.
xx1300000693
Action Note
7 Method 2
Rotate axis 5 +77°.
Required oil level is: 0 - 10 mm below the
oil plug hole.
8 Add or drain oil, if required. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
in gearboxes.
Further information about how to drain or
fill with oil is found in section Changing oil,
axis-6 gearbox on page 188.
9 Refit the oil plug with a new o-ring. O-ring, G 1/4": 3HAC061327-060
Tightening torque: 24 Nm.
10
DANGER
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.
xx1300000413
Required tools
Visual inspection, no tools are required.
Required material
Equipment Article number Note
Maintenance kit, link ear 3HAC045815-001 The maintenance kit contains:
• End cover
• Radial sealing with dust
lip, 50x68x8 (2 pcs)
• O-ring 85x3
• Spherical roller bearing
• Washer
Maintenance kit, cradle 3HAC045822-001 Includes:
• bearings and seals
• VK cover.
xx1000000207
A Shaft
B Radial sealing with dust lip, 50x68x8 (2 pcs)
C O-ring, 85x3
D End cover
Action Note
1 Clean the area at the front ear from contamina-
tion.
2 Run the robot for some minutes, in order to
move the balancing device piston.
3
DANGER
Action Note
1
DANGER
xx1300000423
xx1300001096
Required tools
Visual inspection, no tools are needed.
Action Note
2 Make an overall inspection of the cable
harness in order to detect wear and dam-
age.
Pay special attention to the areas of axis-
2 and axis-3 movement, shown in the fig-
ure. Make sure the cabling is not damaged
between the cable brackets in these areas.
xx1300001095
Note
Replace if damaged.
xx1300001094
8 Replace the cable harness if wear, cracks See Removing the cable harness on
or damage is detected. page 238.
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 23.
Illustration 1
E E
K M B
N E
J
E
F
F
F
xx1300001093
Illustration 2
J
N
S
P J N
R
C A
E N
T
J
G
L
xx1300001085
Description Illustration
A Calibration label
B Instruction label
Before dismantling see product manual
xx0900000816
C Instruction label
Lifting of robot
45°
65°
! !
20°
°
70 4x
890 50
570 55
3HAC 046732-001 / 00
xx1300001084
D Instruction label
3HAC 8225-1/xx
Brake release 3
4
5
6
Moving robot
Brake release buttons
! 1
2
xx1300001083
xx1300001086
J Warning label
Heat 3HAC 4431-1/06
xx1300001087
29454489-16
xx1700000984
K Warning label
Tip risk when loosening bolts
!
3HAC 9191-1/02
xx1300001088
L Warning label
4 6
5
Moving robot 3
3HAC 17804-1/02
1
xx1300001089
M Warning label
Keep areas around the balancing device
free from objects !
3HAC 020611-001/ 03
xx1300001090
N Warning label
Flash
xx1300001091
P Rating label
R Absolute accuracy label
S UL label
T Label
Extended rotation ±220°
No mechanical stop
See user documentation
! EPS
3HAC 021761-001/02
xx1300001092
Inspecting, labels
Action Note
1
DANGER
WARNING
Mechanical stop pin can not be fitted onto robot if the option 561-1 Extended
working range is used for axis 1.
xx1200001073
Required equipment
Visual inspection, no tools are required.
Note
B
C
A B
xx1300001971
A Attachment screws M12x70 quality 12.9 Gleitmo 603 (2 pcs per additional
mechanical stop)
B Movable mechanical stop
C Mechanical stop pin axis-1
Required equipment
Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx1300000414
Required equipment
Visual inspection, no tools are required.
Inspecting, dampers
The procedure below details how to inspect the dampers.
Note
Action Note
1
DANGER
xx1300000414
4 If any damage is detected, the damper must be Spare part number is found in Product
replaced with a new one. manual, spare parts - IRB 6700/IRB
Attachment screws: M6x60. 6700Inv.
Locking liquid: Loctite 243.
xx1600002089
Action Note
2
DANGER
3 If the lamp is not lit, trace the fault by: Article number is specified in Re-
• inspecting whether the signal lamp is broken. quired tools and equipment on
If so, replace it. page 158.
• inspecting cable connections.
• measuring the voltage in the connectors of
motor axis 3 (=24V).
• inspecting the cabling. Replace the cabling if
a fault is detected.
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 lubrication.
Location of gearboxes
The figure shows the location of the gearboxes.
xx1400000189
A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 4
E Gearbox, axis 5
F Gearbox, axis 6
Equipment
Equipment Note
Oil dispenser Includes pump with outlet pipe.
Use the suggested dispenser or a similar one:
• Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring
xx1500001654 xx1500001644
Required documents
2
WARNING
3
CAUTION
Action Note
4 Remove the protective cap from the nipple
of the oil hole and connect the oil dis-
penser.
xx1200000948
WARNING
xx1200000950
Note
7
WARNING
2
WARNING
xx1200000948
Note
xx1200000950
Action Note
5 Refill the gearbox with oil with the oil dis- Type of oil and total amount is detailed in
penser. Technical reference manual - Lubrication
in gearboxes.
Note
Action Note
6 Inspect the oil level. IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
-200/2.80 LID, -175/3.05, -155/3.05 LID, -
150/3.20, -145/3.20 LID
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,
-140/2.85 LID
xx1200000950
xx1300000692
Action Note
xx1500001655
10
DANGER
xx1200000951 xx1200000952
Required documents
2
WARNING
3
CAUTION
xx1200000951
Action Note
5 Remove the plug from the vent hole.
WARNING
xx1200000952
Note
7
WARNING
Action Note
2
WARNING
xx1200000951
Note
xx1200000952
5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.
Action Note
6 Inspect the oil level at the vent hole (level
plug).
xx1200000952
xx1200000954
xx1200000955
xx1500001645
Required documents
3
WARNING
4
CAUTION
Action Note
5 Remove the protective cap from the nipple
of the oil hole and connect the oil dis-
penser.
xx1200000954
WARNING
xx1200000955
xx1500001645
Note
Action Note
8
WARNING
3
WARNING
xx1200000954
Action Note
5 Remove the plug from the vent hole.
Note
xx1200000955
xx1500001645
Action Note
7 Inspect the oil level at the vent hole (level
plug).
xx1200000955
xx1500001645
xx1200000957
xx1200000956
Required documents
3
WARNING
4
CAUTION
xx1200000956
Action Note
7 Remove the oil plug from the fill/level hole.
Note
xx1200000957
8
WARNING
9 Refill oil or refit the oil plugs with new o- O-ring, G 1/2": 3HAC061327-059
rings. Tightening torque: 24 Nm.
3
WARNING
Action Note
4 Open the fill/level plug.
xx1200000957
5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.
6 Inspect the oil level. The level is measured at the fill hole.
xx1200000957
xx1200000958 xx1200000959
Required documents
Action Note
2
DANGER
3
WARNING
4
CAUTION
xx1200000958
Note
xx1200000959
8
WARNING
Action Note
9 Refill oil or refit the oil plug with a new o- O-ring, G 1/2": 3HAC061327-059
ring. Tightening torque: 24 Nm.
3
WARNING
xx1200000959
5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.
Action Note
6 Inspect the oil level at the oil fill/level hole
(level plug).
xx1200000959
xx1200000963
xx1200000962
Required documents
3
WARNING
4
CAUTION
xx1200000962
Note
xx1200000963
Action Note
8
WARNING
9 Refill oil or refit the oil plugs with new o- O-ring, G 1/4": 3HAC061327-060
rings. Tightening torque: 24 Nm.
3
WARNING
xx1200000963
5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.
Action Note
6 Check the oil level. Method 1:
Note
xx1200000963
xx1300000693
Action Note
8
DANGER
Note
The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an un-synchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
WARNING
xx1200001069
Required tools
3
ELECTROSTATIC DISCHARGE (ESD)
CAUTION
2
ELECTROSTATIC DISCHARGE (ESD)
xx1200001069
xx1300000773
Consumables
2
CAUTION
3 Unscrew both screws in link ear and fill the Grease: 3HAA1001-294
bearing with grease from the upper hole
until the grease appears in the lower hole.
xx1300000783
DANGER
General
To secure high uptime it is important that the IRB 6700 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 6700.
Note
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 122.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Foundry Plus Yes Yes. With light Yes. It is highly re- Yes i .
cleaning deter- commended that It is highly recommended
gent or spirit. the water contains that the water and steam
a rust-prevention contains rust preventive,
solution. without cleaning deter-
gents.
i Perform according to section Cleaning with water and steam on page 199.
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
1 See Cleaning methods on page 199 for exceptions.
2 See Cleaning methods on page 199 for exceptions.
• Clean the cables if they have a crusty surface, for example from dry release
agents.
Cooling fans
Inspect the air supply inlet of the the motor cooling fans. Clean to remove any
contamination that could hinder the air supply.
4 Repair
4.1 Introduction
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Note
When replacing a part on the IRB 6700, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 19 before commencing any
service work.
Note
If the IRB 6700 is connected to power, always make sure that the IRB 6700 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.
For more information see:
• Product manual - OmniCore V250XT
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller
Required equipment
Action Note
1 Finish the refitting procedure of the motor or gear in
question, but do not refill the gearbox with oil before
performing the leak-down test.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2 Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
Greasing of bearings
Note
General
This section describes how to mount different types of sealings.
Equipment
Rotating sealings
The following procedures describe how to fit rotating sealings.
CAUTION
Radial sealings
A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only
one side of the sealing is static with a metal insert.
xx2300000433
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 205.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip
Note
Action Note
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
Action Note
3 Check the o-ring grooves and mating surfaces.
They should be free of pores, contamination
and obvious scratches/damage.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx2300000950
4.2.5 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 release buttons may be jammed after
refitting.
DANGER
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes.
Note
Some sections have similar titles. Make sure to use the correct section, to find
information about a certain IRB 6700 variant.
This section describes how to attach lifting accessories to variants IRB
6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID,
-150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85
LID.
How to attach lifting accessories to variants IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID see section 4.3.2 Attaching lifting accessories to complete
arm system.
Required tools
xx1200001132
2
DANGER
xx1200001133
4 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1
xx1200001234
5 Run a roundsling through the hole in the frame. Roundsling, 1.5 m: Length: 1.5 m.
Attach the roundsling choked. See figure! Lifting capacity: 2,000 kg.
xx1200001209
xx1400000730
WARNING
xx1200001235
8 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer. Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.
xx1400002196
Fender washer
xx1200001134
xx1200001236
Note
Some sections have similar titles. Make sure to use the correct section, to find
information about a certain IRB 6700 variant.
This section describes how to attach lifting accessories to variants IRB
6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID.
How to attach lifting accessories to variants IRB 6700-235/2.65, -220/2.65 LID,
-205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB
6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID see section 4.3.1 Attaching
lifting accessories to complete arm system.
xx1400002080
Required tools
Action Note
1 Jog the robot into position:
• Axis 1: no significance (as long as the robot
is secured to the foundation)
• Axis 2: -45°
• Axis 3: +65°
• Axis 4: 0°
• Axis 5: +90°
• Axis 6: calibration position (0°)
2
DANGER
Action Note
1
DANGER
2
CAUTION
Action Note
3 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1
xx1200001133
4 Fit a lifting eye to the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer. Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.
xx1400002196
xx1200001134
Tip
xx1400002107
xx1400000728
A Upper arm
B Shackle
C Roundsling
D Hole in frame
Action Note
2 Connect the roundsling with a shackle. Lifting shackle SA-10-8-NA1
xx1400000729
Note
xx1400002108
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID)
Note
Some sections have similar titles. Make sure to use the correct section, to find
information about a certain IRB 6700 variant.
This section describes how to attach lifting accessories to variants (IRB
6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID,
-150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85
LID).
How to attach lifting accessories to variants IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID see section 4.3.4 Attaching lifting accessories to an
unseparated lower and upper arm.
xx1200001254
Required tools
xx1200001250
3
DANGER
xx1200001133
3 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1
xx1200001234
xx1200001251
xx1200001252
xx1200001253
Note
9
DANGER
xx1400002196
xx1200001134
xx1400000355
xx1200001254
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID)
Note
Some sections have similar titles. Make sure to use the correct section, to find
information about a certain IRB 6700 variant.
This section describes how to attach lifting accessories to variants IRB
6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID.
How to attach lifting accessories to variants IRB 6700-235/2.65, -220/2.65 LID,
-205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB
6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID, see section 4.3.3 Attaching
lifting accessories to an unseparated lower and upper arm.
xx1400002104
Required tools
Action Note
1
Note
xx1200001250
3
DANGER
xx1400002106
4 Run a roundsling around the lower arm, place it Roundsling, 2.5 m: Length: 2.5 m.
accordingly: Lifting capacity: 2,000 kg.
• With no DressPack cable package installed:
Place the roundsling beneath the securing
screw.
• With DressPack cable package installed:
Place the roundsling beneath the ball joint
housing on the outside of the lower arm.
xx1400002105
Action Note
6 Connect both ends of the roundsling with a
shackle.
xx1400000729
Note
8
DANGER
9 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer: Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.
xx1400002196
xx1200001134
Action Note
10 Attach the Lifting accessory (chain) to an over- Lifting accessory (chain):
head crane (or similar), then to the lifting eye in 3HAC15556-1
the arm house and to the lifting eye in the wrist.
xx1400002104
xx1200001308
Required equipment
Robot position
Action Note
1 Jog the robot to the position:
• Axis-1: no significance
• Axis-2: -65°
• Axis-3: +65°
• Axis-4: 0°
• Axis-5: no significance
• Axis-6: no significance
xx1200001255
xx1200001133
Action Note
3 Fit a lifting eye in the arm house, with a Lifting eye: 3HAC16131-1
fender washer underneath. Fender washer: Outer diameter: minimum
26 mm, maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.
xx1400002196
xx1200001134
4 Attach the upper arm lifting accessory Lifting accessory (chain): 3HAC15556-1
(chain) to an overhead crane (or similar)
and then to the lifting eye in the arm house
and in the wrist.
xx1200001308
xx1400002197
xx1300001096
Note
Handle the cables carefully to avoid any scratches or damage that lead to leakage
when the system is pressurized.
Action Note
1 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: -60°
• Axis 3: +60°
• Axis 4: 0°
• Axis 5: +90°
• Axis 6: No significance.
Note
2
DANGER
3
Note
xx1400000208
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.
xx1400000355
xx1400000206
Action Note
4 Remove the wrist cover.
xx1300002247
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.
xx1500001030
xx1300000490
Action Note
6 Cut the cable ties that hold the cable har- Choose figure depending on which plate
ness to the plate. is installed on the robot.
Note
Tip
xx1500001029
xx1300000489
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and re-
move the motor cover.
xx1200001080
xx1300000488
xx1300000484
Action Note
5 Unscrew the M4 screw that holds the carri-
er.
Note
xx1300000485
xx1300001113
xx1300000666
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 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 from the motor.
2 Remove the outer screw.
3 Slide the cable gland cover away
from the inner screw. Make sure the
gasket is not damaged.
Tip
Action Note
1
DANGER
xx1200001135
Action Note
3 Make sure the o-ring is present.
xx1200001070
xx1200001066
Tip
xx1200001067
Action Note
1 Remove the cover.
Note
Foundry Plus:
Use caution not to damage the gasket, not
to loose the washers on the cover sealing
or not to loose the inserts fitted on the
cover.
xx1200000045
xx1700001803
xx1700000690
Action Note
4 If used, push the DressPack tube a little
backwards.
xx1400000720
5
Tip
xx1300000557
Action Note
7 Unscrew the attachment screw that secures
the axis-4 metal clamp inside the arm tube.
Note
xx1700000340
xx1700000339
xx1300000543
Action Note
9 Cut the cable tie at the cable fixing bracket.
Note
xx1300001973
Cable guide.
xx1300000544
xx1300000541
Action Note
11 Remove the cable harness out from the Person 1, working at the side hole:
wrist.
Tip
xx1300000746
12 Remove the cable harness out of the arm Person 1, working at side hole:
tube, at the back of the upper arm.
Tip
Note
Action Note
1
DANGER
xx1300000561
3 Disconnect connectors:
• R1.MP
• R1.SMB
xx1300000591
xx1400000366
Action Note
5 Disconnect the earth cable. Screw dimension : M6x16
Washer dimension : 6.4x17x3
xx1400000354
xx1400000078
Note
xx1400000088
Action Note
1 Foundry Plus.
Cut the cable tie that hold the axis-1 and
axis-2 motor cables on the protection
plates.
xx1400000722
2 Foundry Plus.
Disassemble the protection plates by re-
moving five of the attachment screws (three
M10x30 and two of the M5x12 screws).
xx1400000723
3 Foundry Plus.
Remove the two protection plates.
xx1400000724
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.
Tip
xx1200001067
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
xx1300000829
CAUTION
xx1300000669
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
xx1300000670
Action Note
1 If equipped with DressPack, pull out the
DressPack cables through the protection
tube and place them carefully over the
balancing device.
2 Pull out the robot cable harness through
the protection tube.
xx1300000732
Action Note
1 Unscrew the attachment screws that hold
the metal clamp frame.
xx1300000542
xx1200001237
xx1300001114
Action Note
4 Unscrew the screws and washers that
holds the bracket with the SMB unit, and
remove the SMB unit.
Put the SMB unit in an ESD bag until it shall
be refitted.
xx1300000730
xx1300000655
Note
xx1300000560
Action Note
7 Use caution and pull out the cable harness
through the hole in the frame.
Tip
xx1700001587
Action Note
1 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
xx1300000540
xx1300000733
xx1300001096
Spare part
Consumables
Gasket 3HAC033489-001/
Used on axis-6 motor cover.
3HAC044252-001
Cable ties -
Weatherstrip 3HAC053986-001
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.
Robot position
If the robot axes have been re-positioned after the cable harness has been removed,
make sure to restore the initial robot position before refitting the cable harness.
See Preparations before removing the cable harness on page 238.
Preparations before refitting the cable harness in the base, frame and lower arm
Note
Handle the cables carefully to avoid any scratches or damage that lead to leakage
when the system is pressurized.
Action Note
1
DANGER
Action Note
2 Tie the axis-5 and axis-6 connectors and
carrier into a bundle with tape. This is done
to facilitate the procedure and to avoid
damaging the parts during the procedure.
This will also make it easier to run the cable
harness through the inside of the robot.
xx1300000668
xx1300000733
Note
Note
xx1300000735
Action Note
1 Run the cables through the protection tube
in this order:
• R1.MP
• R1.SMB
If necessary, lubricate the cables with
grease to make them run more smoothly.
xx1300000732
xx1300000736
xx1300000591
Action Note
5 Connect the earth cable. Screw dimension: M6x16.
Washer dimension: 6.4x17x3.
xx1400000354
xx1400000078
xx1200000052
Action Note
10 Refit the base cover.
xx1300000561
Action Note
1 Remove the old sealant without damaging O-ring, 21522012-429
the equipment before removing the o-ring
located on the SMB/BU cover.
xx1300000737
xx1300000560
Action Note
5 Fit the SMB/BU cover in its hole with the Screws: 3 pcs.
attachment screws from inside the SMB
recess without damaging the o-ring.
Note
xx1300000655
Note
xx1300000593
xx1300000655
Action Note
8 Secure the cable harness to the bracket
inside the frame hole, with a cable tie.
xx1200001237
xx1300000542
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
Action Note
3 Connect the battery cable to the SMB unit.
Make sure the lock snaps into place during refit-
ting.
xx1300000729
xx1300000728
xx1300000730
xx1700000978
Action Note
7 Pull out the battery cable through the recess for
the battery.
xx1300000834
xx1300000669
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Action Note
1
Tip
Action Note
2 Run the upper end of the cable harness up
through the lower arm.
xx1300000733
Note
xx1300000734
xx1300000595
Action Note
5 Refit the axis-3 lower arm metal clamp
located on the inside of the lower arm.
Note
xx1300000558
Action Note
1 Refit the metal clamp on top of the arm
house.
xx1300000541
xx1300000543
Action Note
4
Tip
A B C D
5 Foundry Plus:
Make sure that the gasket underneath the
cover is correctly fitted. Replace if dam-
aged.
The gasket is covered with adhesive on the
side facing the upper arm cover. The three
washers are pressed into the holes in the
gasket. Make sure all three washers are
fitted.
xx1400000382
A Gasket
B Cable guide
C Washer
D Cover
Action Note
6 Run the cable harness through the cable Person 1, working at the side hole:
guide and then into and through the upper
arm tube.
Tip
Note
Note
xx1400000356
xx1300000820
Action Note
7 Use caution and push the cable harness Person 1, working at the side hole:
into the wrist.
Tip
xx1300000746
Note
xx1700000340
xx1700000339
Action Note
9 Refit the side cover.
Note
Foundry Plus:
• Make sure the gasket is fitted cor-
rectly on the side cover
• Use attachment screws made of
stainless steel to fit the side cover.
xx1300000557
xx1700000690
xx1400000092
Action Note
12 Fit the cover insert around the new cabling Cover insert: 3HAC048520-001.
and secure it with a weatherstrip.
xx1700001803
Weatherstrip: 3HAC053986-001.
xx1700001804
Note
Foundry Plus:
• Make sure the gasket is fitted cor-
rectly
• Use attachment screws made of
stainless steel to fit the cover.
xx1200000045
Action Note
14 Secure the cable harness to the cable fixing
bracket with a cable tie.
Note
xx1300001973
xx1300000544
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Note
xx1200001067
Action Note
3 Connect the motor cables.
Connect in accordance with the markings
on the connectors.
xx1200001066
xx1200001070
Tip
7
CAUTION
Action Note
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Action Note
1 Push the motor cables in through the cable
gland opening.
xx1300000738
Note
xx1200001016
Action Note
3 Connect the connectors.
Connect in accordance with the markings
on the connectors.
xx1200001015
4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).
xx1200001021
5
CAUTION
Action Note
6 Refit the motor cover with its attachment Screws: M5x12.
screws.
Note
Note
Note
7 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
Note is installed on the robot.
xx1500001029
xx1300000489
Action Note
8 Fit the heat protection plate with the Choose figure depending on which plate
screws. is installed on the robot.
Screws: M5x12.
xx1500001030
xx1300000490
Action Note
1 Make sure that the cable harness is placed
in a way that it will not be damaged when
the cover is fitted.
xx1600002061
xx1300000596
xx1300000667
Action Note
4 Push the carrier carefully into position.
xx1300001113
Note
Tip
xx1300000484
Action Note
7 Reconnect the connectors to the axis-6
motor.
Note
xx1300000488
xx1200001095
9
CAUTION
xx1200001080
Concluding procedure
Action Note
1 Make sure that the cable harness is placed
in a way that it will not be damaged when
the wrist cover is fitted.
xx1600002061
xx1300000596
xx1400000383
Action Note
3 Refit the wrist cover. In order not to dam-
age the cable harness when the wrist cover
is refitted, use this method:
1 Hold the cover slightly tilted below
the wrist.
2 Put the cable harness inside the
cover.
3 Lift the cover, still tilted.
4 Move the upper part of the cover into
position.
5 Secure the cover with its attachment xx1300000772
screws.
Tightening torque: 10 Nm.
4 Foundry Plus: See figure above!
Refit protection plugs.
5 If used, refit the DressPack cable package
on the wrist.
6 Make an overall inspection of the installed See Inspecting the cable harness on
cable harness. page 146.
7 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
8
DANGER
xx1300000740
Spare part
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
xx1300000829
CAUTION
xx1300000669
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
Action Note
3 Remove the screws and washers that secure the SMB
unit bracket.
xx1300000730
4 Pull out the SMB unit a little and disconnect the con-
nectors from the SMB board:
• R1.SMB1-3, R1.SMB4-6 and R2.SMB
• Battery cable connector R2.G.
Disconnect the battery cable by pressing down
the upper lip of the R2.G connector to release
the lock while pulling the connector upwards.
xx1300000728
xx1700000993
xx1300000731
Action Note
1
DANGER
Action Note
2
ELECTROSTATIC DISCHARGE (ESD)
xx1300000729
xx1300000728
xx1300000730
xx1700000978
Action Note
7 Pull out the battery cable through the recess for
the battery.
xx1300000834
xx1300000669
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx1300000829
Concluding procedures
Action Note
1 Update the revolution counters. See Updating revolution counters on
IRC5 robots on page 807.
2
DANGER
xx1300000741
Spare part
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
xx1300000743
xx1300000742
CAUTION
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
xx1300000670
Action Note
1 Unscrew the attachment screws that secure the brake
release unit bracket.
xx1300000744
2 Fasten the brake release unit to the bracket. Maximum tightening torque: 5
Nm.
3 Refit the bracket with the brake release unit fitted.
Make sure the unit is placed as straight as possible
on the bracket! The push buttons can otherwise get
jammed when the SMB cover is refitted.
xx1300000744
xx1700000978
WARNING
Note
xx1300000742
Action Note
7
WARNING
xx1300000743
xx1300000483
Spare part
Consumables
Parts needed to be replaced after removal.
Equipment, etc. Article number Note
Grease 3HAC042536-001 Shell Gadus S2
Used to lubricate o-rings.
Note
There is an alternative method to remove the upper arm if only the axis-3 gearbox
shall be replaced. This alternative method describes how to remove the upper
arm with the robot cable harness still partly fitted. See Replacing the axis-3
gearbox on page 748.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog the robot to a position where it is best
to remove tools and other equipment fitted
to wrist and upper arm.
Action Note
3
DANGER
Action Note
1 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
2
DANGER
Action Note
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.
xx1400000355
xx1400000206
xx1300002247
Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.
xx1500001030
xx1300000490
Action Note
6 Cut the cable ties that hold the cable har- Choose figure depending on which plate
ness to the plate. is installed on the robot.
Note
Tip
xx1500001029
xx1300000489
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 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 from the motor.
2 Remove the outer screw.
3 Slide the cable gland cover away
from the inner screw. Make sure the
gasket is not damaged.
Tip
Action Note
1
DANGER
xx1200001080
Action Note
3 Disconnect the motor cables.
xx1300000488
xx1300000484
Note
xx1300000485
Action Note
6 Pull out the carrier from its position.
xx1300001113
xx1300000666
Action Note
1
DANGER
xx1200001135
Action Note
3 Make sure the o-ring is present.
xx1200001070
xx1200001066
Tip
xx1200001067
Action Note
1 Remove the cover.
Note
Foundry Plus:
Use caution not to damage the gasket, not
to loose the washers on the cover sealing
or not to loose the inserts fitted on the
cover.
xx1200000045
xx1700001803
xx1700000690
Action Note
4 If used, push the DressPack tube a little
backwards.
xx1400000720
5
Tip
xx1300000557
Action Note
7 Unscrew the attachment screw that secures
the axis-4 metal clamp inside the arm tube.
Note
xx1700000340
xx1700000339
xx1300000543
Action Note
9 Cut the cable tie at the cable fixing bracket.
Note
xx1300001973
Cable guide.
xx1300000544
xx1300000541
Action Note
11 Remove the cable harness out from the Person 1, working at the side hole:
wrist.
Tip
xx1300000746
12 Remove the cable harness out of the arm Person 1, working at side hole:
tube, at the back of the upper arm.
Tip
Note
xx1200001133
3 Fit a lifting eye in the arm house, with a Lifting eye: 3HAC16131-1
fender washer underneath. Fender washer: Outer diameter: minimum
26 mm, maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.
xx1400002196
xx1200001134
Action Note
4 Attach the upper arm lifting accessory Lifting accessory (chain): 3HAC15556-1
(chain) to an overhead crane (or similar)
and then to the lifting eye in the arm house
and in the wrist.
xx1200001308
xx1400002197
Preparations before removing the upper arm - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80
LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID
Action Note
1 Remove two attachment screws (M12) in Guide pin, M12x150: 3HAC13056-2
opposite holes and replace them with guide Guide pin, M12x200: 3HAC13056-3
pins.
Always use guide pins in pairs.
Note
Tip
xx1300000659
Action Note
2 Leave one of the remaining attachment
screws fitted, remove the other screws.
xx1300000747
Preparations before removing the upper arm - IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-3
Always use guide pins in pairs.
Note
Tip
xx1300002245
xx1300002246
Preparations before removing the upper arm - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Note
Tip
xx1400002563
xx1400002564
Action Note
1
Note
xx1400002197
Action Note
2 Remove the remaining attachment screw IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
and let the upper arm slide out from the -200/2.80 LID, -175/3.05, -155/3.05 LID, -
lower arm with support from the guide pins. 150/3.20, -145/3.20 LID
xx1300001610
xx1700000059
CAUTION
Action Note
4 This step is only valid when the upper arm
is removed due to replacement of the axis-
3 gearbox:
Place pieces of wood (or similar) under arm
house and wrist. Lower the upper arm, and
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 axis-3 gearbox,
if applicable. xx1300000553
Action Note
1 Wipe clean all contact surfaces.
2 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply Mercasol on the surface on the lower casol 3110 Waxcoat. Recommended drying
arm as shown in the figure. time is 24h.)
CAUTION
xx1700001880
Tip
xx1700000058
Action Note
4 IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, Guide pin, M12x150: 3HAC13056-2
-140/2.85 LID Guide pin, M12x200: 3HAC13056-3
Fit two guide pins in opposite M12 holes Always use guide pins in pairs.
in the axis-3 gearbox.
Tip
xx1400000361
Tip
xx1700000056
Securing the upper arm - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and put it on the guide
pins.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
In order to release the brakes, connect the
24 VDC power supply.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1400000359
Action Note
7 Remove the guide pins and fit the two re-
maining M12 screws.
xx1300000659
8 Secure the upper arm by tightening the at- Tightening torque depends on screw dimen-
tachment screws. sion.
Tightening torque, M16: 300 Nm
Tightening torque, M12: 120 Nm
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Securing the upper arm - IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and put it on the guide
pins.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
In order to release the brakes, connect the
24 VDC power supply.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
Action Note
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1300002246
xx1300002245
8 Secure the upper arm by tightening the at- M12, tightening torque: 120 Nm
tachment screws.
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Securing the upper arm - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and bring it towards the
lower arm.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
Connect the 24 VDC power supply, to re-
lease the brakes.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
Disconnect and remove the 24 VDC power
supply after finding the position.
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1700000057
Action Note
7 Remove the guide pins and fit the two re-
maining screws.
8 Secure the upper arm by tightening the at- M16, tightening torque: 300 Nm
tachment screws.
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1 Refit the metal clamp on top of the arm
house.
xx1300000541
xx1300000543
Action Note
A B C D
5 Foundry Plus:
Make sure that the gasket underneath the
cover is correctly fitted. Replace if dam-
aged.
The gasket is covered with adhesive on the
side facing the upper arm cover. The three
washers are pressed into the holes in the
gasket. Make sure all three washers are
fitted.
xx1400000382
A Gasket
B Cable guide
C Washer
D Cover
6 Run the cable harness through the cable Person 1, working at the side hole:
guide and then into and through the upper
arm tube.
Tip
Note
Note
xx1400000356
xx1300000820
Action Note
7 Use caution and push the cable harness Person 1, working at the side hole:
into the wrist.
Tip
xx1300000746
Note
xx1700000340
xx1700000339
Action Note
9 Refit the side cover.
Note
Foundry Plus:
• Make sure the gasket is fitted cor-
rectly on the side cover
• Use attachment screws made of
stainless steel to fit the side cover.
xx1300000557
xx1700000690
xx1400000092
Action Note
12 Fit the cover insert around the new cabling Cover insert: 3HAC048520-001.
and secure it with a weatherstrip.
xx1700001803
Weatherstrip: 3HAC053986-001.
xx1700001804
Note
Foundry Plus:
• Make sure the gasket is fitted cor-
rectly
• Use attachment screws made of
stainless steel to fit the cover.
xx1200000045
Action Note
14 Secure the cable harness to the cable fixing
bracket with a cable tie.
Note
xx1300001973
xx1300000544
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Action Note
1 Push the motor cables in through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover by performing
the following steps:
• Slide the cable gland cover onto the
inner screw.
• Refit and tighten the outer screw.
• Tighten the inner screw. Make sure
that the gasket is not damaged.
Note
xx1200001016
xx1200001015
4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).
xx1200001021
5
CAUTION
Action Note
6 Refit the motor cover with its attachment Screws: M5x12.
screws.
Note
Note
Note
7 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
Note is installed on the robot.
xx1500001029
xx1300000489
Action Note
8 Fit the heat protection plate with the Choose figure depending on which plate
screws. is installed on the robot.
Screws: M5x12.
xx1500001030
xx1300000490
Action Note
1 Make sure that the cable harness is placed
in a way that it will not be damaged when
the cover is fitted.
xx1600002061
xx1300000596
xx1300000667
Action Note
4 Push the carrier carefully into position.
xx1300001113
Note
Tip
xx1300000484
Action Note
7 Reconnect the connectors to the axis-6
motor.
Note
xx1300000488
xx1200001095
9
CAUTION
xx1200001080
Action Note
1 Foundry Plus:
Inspect the gasket. Replace if damaged.
Put washers in the holes of the gasket.
xx1400000383
Concluding procedure
Action Note
1 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
Action Note
2
DANGER
Note
Do not, under any circumstances, open the cover on the axis-5 gearbox! It is
strictly forbidden to do any repair work on the axis-5 gearbox.
xx1300002248
xx1300000597
Spare part
Consumables
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Remove tools and other equipment fitted
to the wrist.
Action Note
3 If used, open the DressPack axis-6 cable
support and remove the DressPack cable
package from the process turning disk.
Note
xx1400000208
xx1400000223
Clamp jaw
4 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
5
DANGER
Action Note
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.
xx1400000355
xx1400000206
xx1300002247
Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.
xx1500001030
xx1300000490
Action Note
6 Cut the cable ties that hold the cable har- Choose figure depending on which plate
ness to the plate. is installed on the robot.
Note
Tip
xx1500001029
xx1300000489
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and re-
move the motor cover.
xx1200001080
xx1300000488
xx1300000484
Action Note
5 Unscrew the M4 screw that holds the carri-
er.
Note
xx1300000485
xx1300001113
xx1300000666
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 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 from the motor.
2 Remove the outer screw.
3 Slide the cable gland cover away
from the inner screw. Make sure the
gasket is not damaged.
Tip
Action Note
1
CAUTION
CAUTION
xx1300000673
Action Note
3
Note
Action Note
1 If used, remove the bracket with the part
of the ball joint housing still fitted.
xx1700000691
Tip
xx1300000748
xx1300000749
Action Note
4 Pull out the wrist a bit, onto the guide pins.
This is done to be able to remove the cable
harness from the wrist in a safe way.
CAUTION
xx1300000750
xx1300000769
xx1300000770
Action Note
1
DANGER
Action Note
3 Foundry Plus:
Apply Mercasol on the surfaces shown in
the figure.
C
A
xx1400000371
4 Fit two guide pins in opposite holes in the Guide pin, M12x150: 3HAC13056-2
wrist. Always use guide pins in pairs.
Tip
xx1700001595
Action Note
1
CAUTION
Action Note
2 Attach a roundsling to the wrist as shown Roundsling, 1 m: Length: 1 m, lifting capa-
in the figure. city: 1,000 kg.
CAUTION
xx1300000673
3
Note
Action Note
1 Lift the wrist and insert the guide pins into
the holes of the arm tube.
Tip
xx1300000770
xx1300000769
Action Note
3 Mount the four sealing plate nuts on the
tube shaft.
4 Slide the wrist into fitting position.
xx1300000771
xx1300000749
xx1300000748
Action Note
1 Push the motor cables in through the cable
gland opening.
xx1300000738
Note
xx1200001016
xx1200001015
Action Note
4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).
xx1200001021
5
CAUTION
Note
Note
Note
Action Note
7 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
Note is installed on the robot.
xx1500001029
xx1300000489
Action Note
8 Fit the heat protection plate with the Choose figure depending on which plate
screws. is installed on the robot.
Screws: M5x12.
xx1500001030
xx1300000490
Action Note
1 Make sure that the cable harness is placed
in a way that it will not be damaged when
the cover is fitted.
xx1600002061
xx1300000596
xx1300000667
Action Note
4 Push the carrier carefully into position.
xx1300001113
Note
Tip
xx1300000484
Action Note
7 Reconnect the connectors to the axis-6
motor.
Note
xx1300000488
xx1200001095
9
CAUTION
xx1200001080
Concluding procedure
Action Note
1 Make sure that the cable harness is placed There are two versions of the heat protec-
in a way so it will not be damaged when tion plates.
the wrist cover is fitted. Choose figure depending on which plate
is installed on the robot.
xx1500001672
xx1300000596
xx1400000383
Action Note
3 Refit the wrist cover. Use this method not
to damage the cable harness:
1 Hold the cover tilted. See figure!
2 Catch any part of the cable harness
hanging down.
3 Lift the cover, still held tilted.
4 Move the upper part of the cover into
position.
5 Secure the cover with its attachment
screws.
xx1300000772
xx1300000491
Spare part
Consumables
Action Note
1 Run the robot to a position most comfort-
able for the removal of the turning disc.
Action Note
2
DANGER
Action Note
1 - IRB 6700-235/2.65, -220/2.65 LID, -
205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID
Remove the screws and washers, that se-
cure the turning disc.
xx1300000492
xx1300002302
xx1400002195
Action Note
4 Remove the turning disc.
xx1300000493
xx1500000873 xx1500000874
xx1500000877 xx1500000878
Use the holes closest to the synchronization Use the holes at the back end of the synchron-
mark. ization plate.
Action Note
1 If new turning disc spare part is installed: See Replacing the synchronization mark
verify that the correct synchronization mark plate on page 374.
plate for axis-6 is installed on the wrist.
2 Wipe clean the contact surfaces.
3 Foundry Plus: A B
Apply Mercasol on the surfaces on turning
disc and axis-6 gearbox as shown in the
figure.
xx1400000385
xx1300000492
xx1300002302
Action Note
6 IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, Tightening torque: 70 Nm
-220/3.00 LID Attachment screws: M10x25, Steel 12.9
Secure the turning disc with its attachment Gleitmo 603, (21 pcs)
screws and washers. Washers: Steel 11x17x25 (21 pcs)
xx1400002195
Concluding procedure
Action Note
1
DANGER
xx1400001391
Consumables
Action Note
1 Run the robot to a position most comfort-
able for the removal of the process turning
disc.
Action Note
2
DANGER
Action Note
1 IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
-200/2.80 LID, -175/3.05, -155/3.05 LID, -
150/3.20, -145/3.20 LID
Remove the 24 M8 screws and washers,
that secure the process turning disc.
xx1400001392
xx1400001394
Action Note
3 IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID
Remove the 21 M10 screws and washers,
that secure the process turning disc.
xx1400001395
xx1400001393
If ordering a new turning disc, the synchronization mark plate required is enclosed
with the spare part. Check if the robot is already equipped with a compatible plate
or if it needs to be replaced. The difference is shown in the figures.
Incompatible axis-6 synchronization mark Compatible axis-6 synchronization mark
plate on robot plate on robot
xx1500000873 xx1500000874
xx1500000877 xx1500000878
Use the holes closest to the synchronization Use the holes at the back end of the synchron-
mark. ization plate.
Action Note
1 If new turning disc spare part is installed: See Replacing the synchronization mark
verify that the correct synchronization mark plate on page 380.
plate for axis-6 is installed on the wrist.
2 Wipe clean the contacts surfaces.
3 Foundry Plus: A B
Apply Mercasol on the surfaces on the
process turning disc and axis-6 gearbox
as shown in the figure.
xx1400000385
Action Note
4 IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, Tightening torque: 35 Nm.
-200/2.80 LID, -175/3.05, -155/3.05 LID, - Attachment screws: M8x25, Steel 12.9
150/3.20, -145/3.20 LID Gleitmo 603 (24 pcs)
Secure the process turning disc with its Washers: Steel 8.4x13x1.5 (24 pcs)
attachment screws and washers.
xx1400001392
xx1400001394
Action Note
6 IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, Tightening torque: 70 Nm
-220/3.00 LID Attachment screws: M10x25, Steel 12.9
Secure the process turning disc with its Gleitmo 603, (21 pcs)
attachment screws and washers. Washers: Steel 11x17x25 (21 pcs)
xx1400001395
Concluding procedure
Action Note
1
DANGER
xx1300000786
Spare part
Consumables
DANGER
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2
DANGER
Action Note
1 Jog the robot to:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: 0°
• Axis 4: 0°
• Axis 5: +90°
• Axis 6: 0°
2 Connect the 24 VDC power supply, release 24 VDC power supply
the brakes and move the axis 5 manually
into +90°.
Connect to R2.MP5-connector:
• + = pin 2
• - = pin 5
xx1200001081
3
DANGER
Unloading the balancing device springs with the robot and locking position with the Distance tool
Use this procedure to unload the balancing device with the help of the robot, and
lock the balancing device springs in a compressed position, using the Distance
tool (3HAC030662-001).
Action Note
1
DANGER
DANGER
xx1300000554
Action Note
5 Fit the Distance tool on the back of the Tightening torque: 45 Nm
balancing device using the four screws. Attachment screws: M10 quality 12.9 (4
pcs)
DANGER
xx0800000480
Action Note
1 Jog axis-2 to the calibration position (if not
already in this position).
Action Note
2
DANGER
xx1300000661
6 Fit the lifting accessory (chain) to the Lifting accessory (chain): 3HAC15556-1
shackle and raise to unload the weight.
Action Note
1 Remove the protection plug or VK cover at It is possible to drive a screwdriver (or
the link ear (depends on shaft version). similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.
xx1200001278
xx1900002311
xx1900002146
Action Note
3 Unscrew the attachment screw and washer.
xx1200001279
xx0900000813
DANGER
xx1200001283
xx1200001281
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.
xx1400000355
xx1400000206
xx1300002247
Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.
xx1500001030
xx1300000490
Action Note
6 Cut the cable ties that hold the cable har- Choose figure depending on which plate
ness to the plate. is installed on the robot.
Note
Tip
xx1500001029
xx1300000489
Action Note
1 Unscrew the screws that hold the bracket
and let it hang free.
xx1200001184
Action Note
2 If used, open the ball joint housings on the
lower arm and remove the DressPack.
xx1400000195
xx1200001332
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.
Tip
xx1200001067
Action Note
1
DANGER
xx1200001135
Action Note
3 Make sure the o-ring is present.
xx1200001070
xx1200001066
Tip
Action Note
1
DANGER
xx1200001080
xx1300000488
xx1300000484
Action Note
5 Unscrew the M4 screw that holds the carri-
er.
Note
xx1300000485
xx1300001113
xx1300000666
Action Note
1 Remove the cover.
Note
Foundry Plus:
Use caution not to damage the gasket, not
to loose the washers on the cover sealing
or not to loose the inserts fitted on the
cover.
xx1200000045
xx1700001803
xx1700000690
Action Note
4 If used, push the DressPack tube a little
backwards.
xx1400000720
5
Tip
xx1300000557
Action Note
7 Unscrew the attachment screw that secures
the axis-4 metal clamp inside the arm tube.
Note
xx1700000340
xx1700000339
xx1300000543
Action Note
9 Cut the cable tie at the cable fixing bracket.
Note
xx1300001973
Cable guide.
xx1300000544
xx1300000541
Action Note
11 Remove the cable harness out from the Person 1, working at the side hole:
wrist.
Tip
xx1300000746
12 Remove the cable harness out of the arm Person 1, working at side hole:
tube, at the back of the upper arm.
Tip
Note
xx1200001133
3 Fit a lifting eye in the arm house, with a Lifting eye: 3HAC16131-1
fender washer underneath. Fender washer: Outer diameter: minimum
26 mm, maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.
xx1400002196
xx1200001134
Action Note
4 Attach the upper arm lifting accessory Lifting accessory (chain): 3HAC15556-1
(chain) to an overhead crane (or similar)
and then to the lifting eye in the arm house
and in the wrist.
xx1200001308
xx1400002197
Preparations before removing the upper arm - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80
LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID
Action Note
1 Remove two attachment screws (M12) in Guide pin, M12x150: 3HAC13056-2
opposite holes and replace them with guide Guide pin, M12x200: 3HAC13056-3
pins.
Always use guide pins in pairs.
Note
Tip
xx1300000659
Action Note
2 Leave one of the remaining attachment
screws fitted, remove the other screws.
xx1300000747
Preparations before removing the upper arm - IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-3
Always use guide pins in pairs.
Note
Tip
xx1300002245
xx1300002246
Preparations before removing the upper arm - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Note
Tip
xx1400002563
xx1400002564
Action Note
1
Note
xx1400002197
Action Note
2 Remove the remaining attachment screw IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
and let the upper arm slide out from the -200/2.80 LID, -175/3.05, -155/3.05 LID, -
lower arm with support from the guide pins. 150/3.20, -145/3.20 LID
xx1300001610
xx1700000059
CAUTION
Action Note
4 This step is only valid when the upper arm
is removed due to replacement of the axis-
3 gearbox:
Place pieces of wood (or similar) under arm
house and wrist. Lower the upper arm, and
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 axis-3 gearbox,
if applicable. xx1300000553
Action Note
1
DANGER
Note
xx1300000540
Action Note
4 Remove the cable harness from inside the
lower arm.
xx1300000733
5
CAUTION
Removing the lower arm - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1 Raise the lifting accessory to unload the
lower arm.
2 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Tip
xx1300000788
Action Note
3 Remove all but one of the remaining attach-
ment screws and washers that secure the
lower arm to the axis 2 gearbox.
xx1300000789
Removing the lower arm - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1 Raise the lifting accessory to unload the
lower arm.
2 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Tip
xx1400002181
Action Note
3 Remove all but one of the remaining attach-
ment screws that secure the lower arm to
the axis-2 gearbox.
xx1400002182
Action Note
1
DANGER
2 Apply Mercasol on the surface on the lower Rust preventive: 3HAC034903-001 (Mer-
arm as shown in the figure. casol 3110 Waxcoat. Recommended drying
time is 24h.).
CAUTION
xx1700001879
Action Note
3 Valid for variants: IRB 6700-235/2.65, - Guide pin, M16x150: 3HAC13120-2
220/2.65 LID, -205/2.80, -200/2.80 LID, - Always use guide pins in pairs.
175/3.05, -155/3.05 LID, -150/3.20, -145/3.20
LID.
Valid for variants: IRB 6700-200/2.60, -
175/2.60 LID, -155/2.85, -140/2.85 LID.
Fit two guide pins in opposite holes in the
axis-2 gearbox.
Tip
xx1700000055
Tip
xx1400002189
5
CAUTION
Securing the lower arm to the axis-2 gearbox - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80
LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,
-140/2.85 LID
Action Note
1
CAUTION
xx1300000819
xx1300000790
Action Note
5 Secure the lower arm with its attachment Tightening torque M16: 300 Nm
screws and washers. Attachment screws: M16x50 quality steel
12.9 Gleitmo (21 pcs)
Washers: steel 17x25x3 (21 pcs)
xx1300000789
xx1300000788
Securing the lower arm to the axis-2 gearbox - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00
LID
Action Note
1 Lift the lower arm onto the guide pins and
slide it into position.
Action Note
2 In case the hole pattern of the lower arm Rotation tool
and gearbox does not match: 24 VDC power supply
• Remove the motor cover.
• Apply the rotation tool on the motor
shaft.
• Connect the 24 VDC power supply.
• Release the brakes.
• Rotate pinion and gear with the rota-
tional tool until the holes matches.
Connect 24 VDC the power supply to con-
nector R2.MP2:
• + = pin 2
• - = pin 5
xx1300000819
xx1400002190
xx1400002181
Action Note
8 Remove the lifting accessory from the
lower arm.
Action Note
1 Wipe clean all contact surfaces.
2 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply Mercasol on the surface on the lower casol 3110 Waxcoat. Recommended drying
arm as shown in the figure. time is 24h.)
CAUTION
xx1700001880
Tip
xx1700000058
Action Note
4 IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, Guide pin, M12x150: 3HAC13056-2
-140/2.85 LID Guide pin, M12x200: 3HAC13056-3
Fit two guide pins in opposite M12 holes Always use guide pins in pairs.
in the axis-3 gearbox.
Tip
xx1400000361
Tip
xx1700000056
Securing the upper arm - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and put it on the guide
pins.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
In order to release the brakes, connect the
24 VDC power supply.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1400000359
Action Note
7 Remove the guide pins and fit the two re-
maining M12 screws.
xx1300000659
8 Secure the upper arm by tightening the at- Tightening torque depends on screw dimen-
tachment screws. sion.
Tightening torque, M16: 300 Nm
Tightening torque, M12: 120 Nm
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Securing the upper arm - IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and put it on the guide
pins.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
In order to release the brakes, connect the
24 VDC power supply.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
Action Note
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1300002246
xx1300002245
8 Secure the upper arm by tightening the at- M12, tightening torque: 120 Nm
tachment screws.
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Securing the upper arm - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and bring it towards the
lower arm.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
Connect the 24 VDC power supply, to re-
lease the brakes.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
Disconnect and remove the 24 VDC power
supply after finding the position.
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1700000057
Action Note
7 Remove the guide pins and fit the two re-
maining screws.
8 Secure the upper arm by tightening the at- M16, tightening torque: 300 Nm
tachment screws.
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1
Tip
xx1300000733
Note
xx1300000734
Action Note
4 Before fitting the remaining axis-3 lower
arm cable bracket inside the lower arm,
check that it will stay twisted a little
between the metal clamps, after fitting, as
shown in the figure. Do not change the po-
sition of the brackets!
xx1300000595
Note
xx1300000558
Action Note
1 Refit the metal clamp on top of the arm
house.
xx1300000541
Action Note
2 Refit the arm house metal clamp.
xx1300000543
A B C D
5 Foundry Plus:
Make sure that the gasket underneath the
cover is correctly fitted. Replace if dam-
aged.
The gasket is covered with adhesive on the
side facing the upper arm cover. The three
washers are pressed into the holes in the
gasket. Make sure all three washers are
fitted.
xx1400000382
A Gasket
B Cable guide
C Washer
D Cover
Action Note
6 Run the cable harness through the cable Person 1, working at the side hole:
guide and then into and through the upper
arm tube.
Tip
Note
Note
xx1400000356
xx1300000820
Action Note
7 Use caution and push the cable harness Person 1, working at the side hole:
into the wrist.
Tip
xx1300000746
Note
xx1700000340
xx1700000339
Action Note
9 Refit the side cover.
Note
Foundry Plus:
• Make sure the gasket is fitted cor-
rectly on the side cover
• Use attachment screws made of
stainless steel to fit the side cover.
xx1300000557
xx1700000690
xx1400000092
Action Note
12 Fit the cover insert around the new cabling Cover insert: 3HAC048520-001.
and secure it with a weatherstrip.
xx1700001803
Weatherstrip: 3HAC053986-001.
xx1700001804
Note
Foundry Plus:
• Make sure the gasket is fitted cor-
rectly
• Use attachment screws made of
stainless steel to fit the cover.
xx1200000045
Action Note
14 Secure the cable harness to the cable fixing
bracket with a cable tie.
Note
xx1300001973
xx1300000544
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Note
xx1200001067
Action Note
3 Connect the motor cables.
Connect in accordance with the markings
on the connectors.
xx1200001066
xx1200001070
Tip
7
CAUTION
Action Note
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Action Note
1 Push the motor cables in through the cable
gland opening.
xx1300000738
Note
xx1200001016
Action Note
3 Connect the connectors.
Connect in accordance with the markings
on the connectors.
xx1200001015
4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).
xx1200001021
5
CAUTION
Action Note
6 Refit the motor cover with its attachment Screws: M5x12.
screws.
Note
Note
Note
7 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
Note is installed on the robot.
xx1500001029
xx1300000489
Action Note
8 Fit the heat protection plate with the Choose figure depending on which plate
screws. is installed on the robot.
Screws: M5x12.
xx1500001030
xx1300000490
Action Note
1 Make sure that the cable harness is placed
in a way that it will not be damaged when
the cover is fitted.
xx1600002061
xx1300000596
xx1300000667
Action Note
4 Push the carrier carefully into position.
xx1300001113
Note
Tip
xx1300000484
Action Note
7 Reconnect the connectors to the axis-6
motor.
Note
xx1300000488
xx1200001095
9
CAUTION
xx1200001080
Action Note
1 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
is installed on the robot.
xx1500001029
xx1300000489
Action Note
2 Fit the heat protection plate with the Choose figure depending on which plate
screws. is installed on the robot.
xx1500001030
xx1300000490
xx1600002061
xx1300000596
Action Note
4 Foundry Plus:
Inspect the gasket. Replace if damaged.
Put washers in the holes of the gasket.
xx1400000383
Action Note
7 Refit the bracket to the frame.
xx1200001184
xx1200001332
xx1400000195
Action Note
2 Use caution and jog the robot to the calibration
position (if not already done).
3
DANGER
4 Apply the lifting accessory to the balancing device Lifting shackle: SA-10-8-NA1
(if not already done). Lifting accessory (chain):
3HAC15556-1
5 Remove all residue of Loctite in the screw hole of
the shaft.
6 Wipe all contact surfaces inside the recess clean
from contamination.
7 Align the balancing device link ear with the hole
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
Apply Mercasol on the surfaces on the shaft and
front ear.
A
A
C
xx1400000368
Action Note
9 Lubricate the shaft and place it to the front ear.
Note
Foundry Plus:
Do not lubricate surfaces where Mercasol is ap-
plied.
xx1200001280
10 Press in the shaft using the dismantle and Dismantle and mounting tool:
mounting tool, according to user instructions en- 3HAC028920-001
closed with the equipment. User instructions are enclosed with
the tool.
xx0900000813
DANGER
xx1300000782
12 Secure the shaft with screw and washer. Tightening torque: 180 Nm
xx1200001279
Action Note
13 Fit the protection plug or a new VK-cover (de-
pends on shaft version).
xx1200001278
xx1900002311
14 Unscrew both screws in link ear and fill the bear- Grease: 3HAA1001-294
ing with grease from the upper hole until the
grease appears in the lower hole.
xx1300000783
15 Refit the two screws and wipe clean from residual Tightening torque:
grease. 10 Nm
xx1900002146
Action Note
1 Remove the lifting accessory from the bal-
ancing device.
Action Note
2 Refit the cable bracket (if not already refit-
ted).
xx1200001283
3
DANGER
Action Note
6 Remove the distance tool.
xx0800000480
xx1300000554
Concluding procedure
Action Note
1 Remove the lifting accessory.
2 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
Action Note
3
DANGER
xx1300000773
Spare part
Consumables
DANGER
DANGER
DANGER
Never remove or fit the Distance tool on a balancing device which can not be
unloaded by the robot. There is a severe risk of personal injury.
Unloading the balancing device springs and locking position with the Hydraulic press equipment, balancing
device
Use this procedure to unload and lock the balancing device in unloaded position
with the Hydraulic press equipment, balancing device (3HAC074411-001).
Action Note
1 Jog axis-2 to the calibration position.
2
DANGER
DANGER
xx1300000554
Action Note
4 Unload the balancing device with the press Hydraulic press equipment, balancing
equipment in order to make the piston rod device: 3HAC074411-001
and front ear adjustable when pulling the User instructions are enclosed with the
shaft out. tool.
xx0900000813
DANGER
Unloading the balancing device springs with the robot and locking position with the Distance tool
Use this procedure to unload the balancing device with the help of the robot, and
lock the balancing device springs in a compressed position, using the Distance
tool (3HAC030662-001).
Action Note
1
DANGER
Action Note
4 Remove the cover plate on the back of the
balancing device.
DANGER
xx1300000554
xx0800000480
Action Note
1 Verify that the balancing device is un- See Unloading the balancing device on
loaded. page 455.
2 Jog axis-2 to the calibration position (if not
already in this position).
3 Fit a lock screw through the hole for the Lock screw, M16x120
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, to avoid accidents or
damage.
xx1200001116
4
DANGER
Action Note
7 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1
xx1300000661
8 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.
Action Note
1 Remove the protection plug or VK cover at It is possible to drive a screwdriver (or
the link ear (depends on shaft version). similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.
xx1200001278
xx1900002311
Action Note
2 Remove the two screws.
xx1900002146
xx1200001279
xx0900000813
DANGER
Action Note
5 Remove the attachment screws of the cable
bracket on the frame and let it hang loose.
xx1200001283
xx1200001281
Action Note
1 Check that the link ear is in a position
where it is possible to apply the dismantle
and mounting tool. If not, adjust with the
lifting accessory.
2 Unscrew the attachment screws securing
the end cover, remove end cover and radial
sealing with a screwdriver.
xx1300000774
Action Note
3 Remove the o-ring.
xx1300000775
4 Pull the spherical roller bearing out togeth- Dismantle and mounting tool:
er with the radial sealing and washer using 3HAC028920-001
the dismantle and mounting tool, according User instructions are enclosed with the
to user instructions enclosed with the tool.
equipment.
xx0900000813
DANGER
Action Note
1 Wipe clean all contact surfaces from resid-
ual grease.
Action Note
2 Refit the washer.
xx1300000778
3 Put the radial sealing on the Press tool J. Press tool J included in tool set Dismantle
and mounting tool
Note
xx1300000839
xx1300000777
Action Note
6 Press in the spherical roller bearing using Dismantle and mounting tool:
the dismantle and mounting tool, according 3HAC028920-001
to user instructions enclosed with the User instructions are enclosed with the
equipment. tool.
xx0900000813
DANGER
xx1300000775
8 Apply Locking liquid on the screws and Loctite 2400 (or equivalent Loctite 243), -
secure the end cover with the radial sealing
ring.
xx1300000774
4 Apply the lifting accessory to the balancing device Lifting shackle: SA-10-8-NA1
(if not already done). Lifting accessory (chain):
3HAC15556-1
5 Remove all residue of Loctite in the screw hole of
the shaft.
6 Wipe all contact surfaces inside the recess clean
from contamination.
7 Align the balancing device link ear with the hole
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
Apply Mercasol on the surfaces on the shaft and
front ear.
A
A
C
xx1400000368
Action Note
9 Lubricate the shaft and place it to the front ear.
Note
Foundry Plus:
Do not lubricate surfaces where Mercasol is ap-
plied.
xx1200001280
10 Press in the shaft using the dismantle and Dismantle and mounting tool:
mounting tool, according to user instructions en- 3HAC028920-001
closed with the equipment. User instructions are enclosed with
the tool.
xx0900000813
DANGER
xx1300000782
12 Secure the shaft with screw and washer. Tightening torque: 180 Nm
xx1200001279
Action Note
13 Fit the protection plug or a new VK-cover (de-
pends on shaft version).
xx1200001278
xx1900002311
14 Unscrew both screws in link ear and fill the bear- Grease: 3HAA1001-294
ing with grease from the upper hole until the
grease appears in the lower hole.
xx1300000783
15 Refit the two screws and wipe clean from residual Tightening torque:
grease. 10 Nm
xx1900002146
Action Note
1 Remove the lifting accessory from the bal-
ancing device.
Action Note
2 Refit the cable bracket (if not already refit-
ted).
xx1200001283
xx1200001116
4 Foundry Plus:
Apply Mercasol in the hole for the locking
screw.
xx1400000372
Action Note
5 If the balancing device springs have been
locked in unloaded position with the Dis-
tance tool:
Jog axis-2 to:
• -30° or +30°.
DANGER
xx0900000813
DANGER
7 Apply flange sealant and refit the cover Screws: M10 quality 12.9.
plate on the back of the balancing device. Tightening torque: 50 Nm.
Flange sealant for conical fittings: Loctite
5400 (or equivalent Loctite 577).
xx1300000554
xx1300000660
Spare part
Consumables
xx1900002309 xx1900002310
DANGER
xx1300000554
Action Note
4 Unload the balancing device with the press Hydraulic press equipment, balancing
equipment in order to make the piston rod device: 3HAC074411-001
and front ear adjustable when pulling the User instructions are enclosed with the
shaft out. tool.
xx0900000813
DANGER
Action Note
1 Verify that the balancing device is un- See Unloading the balancing device on
loaded. page 473.
2 Jog axis-2 to the calibration position (if not
already in this position).
3 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.
xx1200001116
4
DANGER
Action Note
5 Remove any equipment, if fitted, on or
close to the balancing device.
Action Note
1
CAUTION
xx1300000661
3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.
xx1300000662
xx1700002189
Action Note
3 Unscrew the attachment screws on each
shaft.
xx1300000663
xx1300000664
5 Use the removal tool and pull the shaft out Dismantle and mounting tool:
a few millimeters, just long enough for the 3HAC028920-001
balancing device to go free. User instructions are enclosed with the
tool.
xx0900000813
DANGER
Action Note
1 Remove the protection plug or VK cover at It is possible to drive a screwdriver (or
the link ear (depends on shaft version). similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.
xx1200001278
xx1900002311
xx1900002146
Action Note
3 Unscrew the attachment screw and washer.
xx1200001279
xx0900000813
DANGER
xx1200001283
xx1200001281
Concluding procedure
Action Note
1 Remove the balancing device.
2 If the same balancing device shall be refit-
ted, the Distance tool 3HAC030662-001
must stay fitted during the time the balan-
cing device is removed from the robot.
DANGER
Action Note
1
CAUTION
Action Note
2 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1
xx1300000661
3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.
DANGER
xx1300000554
Action Note
2 Unload the balancing device with the press Hydraulic press equipment, balan-
equipment in order to make the piston rod and cing device: 3HAC074411-001
front ear adjustable when pulling the shaft out. User instructions are enclosed with
the tool.
xx0900000813
DANGER
xx1300000838
Action Note
4 Apply the refitting tool and press the shafts Dismantle and mounting tool:
into position one at a time. 3HAC028920-001
User instructions are enclosed with the
tool.
xx0900000813
DANGER
5 Foundry Plus: C
xx1400000367
xx1300000664
Action Note
7 Apply Loctite 243 on the screws and secure M16x70 quality steel 12.9 Gleitmo 603
the shafts on both sides. Tightening torque: 280 Nm
xx1300000663
xx1300000837
xx1300000832
4 Apply the lifting accessory to the balancing device Lifting shackle: SA-10-8-NA1
(if not already done). Lifting accessory (chain):
3HAC15556-1
5 Remove all residue of Loctite in the screw hole of
the shaft.
6 Wipe all contact surfaces inside the recess clean
from contamination.
7 Align the balancing device link ear with the hole
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
Apply Mercasol on the surfaces on the shaft and
front ear.
A
A
C
xx1400000368
Action Note
9 Lubricate the shaft and place it to the front ear.
Note
Foundry Plus:
Do not lubricate surfaces where Mercasol is ap-
plied.
xx1200001280
10 Press in the shaft using the dismantle and Dismantle and mounting tool:
mounting tool, according to user instructions en- 3HAC028920-001
closed with the equipment. User instructions are enclosed with
the tool.
xx0900000813
DANGER
xx1300000782
12 Secure the shaft with screw and washer. Tightening torque: 180 Nm
xx1200001279
Action Note
13 Fit the protection plug or a new VK-cover (de-
pends on shaft version).
xx1200001278
xx1900002311
14 Unscrew both screws in link ear and fill the bear- Grease: 3HAA1001-294
ing with grease from the upper hole until the
grease appears in the lower hole.
xx1300000783
15 Refit the two screws and wipe clean from residual Tightening torque:
grease. 10 Nm
xx1900002146
Action Note
1 Remove the lifting accessory from the bal-
ancing device.
Action Note
2 Refit the cable bracket (if not already refit-
ted).
xx1200001283
xx1200001116
4 Foundry Plus:
Apply Mercasol in the hole for the locking
screw.
xx1400000372
Action Note
5 If the balancing device springs have been
locked in unloaded position with the Dis-
tance tool:
Jog axis-2 to:
• -30° or +30°.
DANGER
xx0900000813
DANGER
7 Apply flange sealant and refit the cover Screws: M10 quality 12.9.
plate on the back of the balancing device. Tightening torque: 50 Nm.
Flange sealant for conical fittings: Loctite
5400 (or equivalent Loctite 577).
xx1300000554
xx1300000785
Spare parts
Consumables
DANGER
Action Note
3
DANGER
DANGER
xx1300000554
xx0800000480
Action Note
9
DANGER
Action Note
1 Jog axis-2 to the calibration position (if not
already in this position).
2 Fit a locking screw through the hole for the Lock screw, M16x120
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.
xx1200001116
3
DANGER
Action Note
5
CAUTION
xx1300000661
7 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.
Note
Action Note
1 Remove the VK cover using one of the re- VK cover, 90x12: 3HAA2166-28
commended methods: Position for screwdriver:
• Drive a screwdriver (or similar)
through the VK cover, as close as
possible to the center of the VK
cover, and bend out the cover. If not
making a hole in the center of the
VK cover, there is a risk of damaging
the bearing inside. The damaged VK
cover must be replaced with a new.
• Remove the protection screw from
the vent hole and use air pressure
through the hole to blow out the
cover. The cover can be reused if
not damaged.
xx1300000662
xx1700002189
xx1300000663
Action Note
4 Remove the retaining ring bore.
xx1300000664
xx1300000838
xx0900000813
DANGER
Action Note
7 IRB 6700 -300/2.70, -245/3.00. Dismantle and mounting tool:
Pull out the shaft end with the groove ball 3HAC028920-001
bearing using the dismantle and mounting User instructions are enclosed with the
tool, according to user instructions en- tool.
closed with the equipment.
xx0900000813
DANGER
Action Note
1 Wipe clean all contact surfaces from resid-
ual grease and other contamination inside
the recess.
2 Foundry Plus: C
xx1400000367
Action Note
3 Apply some grease in the hole for the
bearing in the cradle.
Note
4 Apply a threaded bar into the hole in the Dismantle and mounting tool:
balancing device using the dismantle and 3HAC028920-001
mounting tool, according to user instruc- User instructions are enclosed with the
tions enclosed with the equipment. tool.
xx0900000813
DANGER
xx1700000343
6 Apply locking liquid on the attachment Loctite 2400 (or equivalent Loctite 243), -
screw.
Action Note
7 While using the screw driver between the Tightening torque: 280 Nm.
cradle and balancing device as a distance
tool, tighten the attachment screw com-
pletely.
Secure the balancing device.
xx1300000663
Action Note
1 Remove the lifting accessories.
Concluding procedure
Action Note
1 Refit the retaining ring bore.
xx1300000664
Action Note
2 Refit the VK-cover. VK cover, 90x12, 3HAA2166-28
Note
xx1700002189
xx1300000832
xx1300000833
Action Note
7 Apply flange sealant and refit the cover Screws: M10 quality 12.9.
plate on the back of the balancing device. Tightening torque: 50 Nm.
Flange sealant for conical fittings: Loctite
5400 (or equivalent Loctite 577).
xx1300000554
8
DANGER
xx1300000475
Spare part
Required consumables
Action Note
1 IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
-200/2.80 LID, -175/3.05, -155/3.05 LID, -
150/3.20, -145/3.20 LID
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,
-140/2.85 LID
Jog the robot to this position:
• axis 1 = -5°
xx1300000479
Note
xx1300000478
3
DANGER
CAUTION
xx1300000476
Action Note
5 Remove the stop pin.
xx1300000477
Action Note
1 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply Mercasol on the surfaces shown in casol 3110 Waxcoat. Recommended drying
the figure, on stop pin and in the hole as time is 24h.).
shown in the figure.
xx1400000378
xx1300000477
Action Note
3 Apply locking liquid on the set screw, and Loctite 2400 (or equivalent Loctite 243)
secure the stop pin. Set screw: M10x20
xx1300000476
4.7 Motors
xx1200001064
Spare parts
Consumables
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog the robot to the synchronization posi-
tion.
3
DANGER
Action Note
1 Foundry Plus.
Cut the cable tie that hold the axis-1 and
axis-2 motor cables on the protection
plates.
xx1400000722
2 Foundry Plus.
Disassemble the protection plates by re-
moving five of the attachment screws (three
M10x30 and two of the M5x12 screws).
xx1400000723
3 Foundry Plus.
Remove the two protection plates.
xx1400000724
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.
Tip
xx1200001067
Action Note
1
DANGER
xx1200001071
Action Note
5 If needed, use removal tools to help loosen Removal tool kit M12 and M14:
the motor. 3HAC057339-002
Required dimension of removal tool de-
pends on motor type A or B, see Identifying
the motor by article number on page 839
Used to push out the motor, if necessary.
Always use removal tools in pairs.
6
CAUTION
DANGER
9 Use caution and lift the motor straight up Lifting accessory (chain): 3HAC15556-1
to get the pinion parted from the gear. Lifting accessory, motor: 3HAC14459-1.
xx1200001072
xx1200001019
Tip
xx1200001020
Action Note
5 If the motor is a new spare part, remove the cover.
xx1200001135
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION
Action Note
5 Release the brakes of the axis-1 motor with Brake release tool: 3HAC081310-001
the brake release tool. User instructions are enclosed with the
1 Turn off the brake release tool. tool.
2 Connect the tool to the R2.MP1
connector.
3 Release the brakes by turning on the
brake release tool and pressing the
brake release button on the tool.
DANGER
Note
6
CAUTION
xx1200001072
Action Note
8 Secure the motor with its attachment Bits extender: 3HAC12342-1
screws and washers. Tightening torque: 50 Nm.
Use a bits extender to reach the screws. Screws: M10x30 Steel 12.9 Gle
603+Geo500 (4 pcs)
xx1200001071
9 Perform a leak-down test (if not already See Performing a leak-down test on
done). page 202.
10 Disconnect the brake release tool / 24 VDC
power supply.
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Concluding procedure
Use this procedure for the concluding refitting.
Action Note
1 Foundry Plus:
Refit the protection plates with three
M10x30 and two M5x12 attachment screws.
Note
xx1400000723
Action Note
2 Foundry Plus:
Secure the axis-1 and axis-2 motor cables
with a cable tie.
xx1400000722
xx1200001112
Spare parts
Consumables
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Drain the oil from the gearbox. See Draining the axis-2 gearbox on
page 170.
3 Jog the robot to the calibration position.
4
DANGER
Action Note
5 Insert the lock screw into the frame. If Lock screw, M16x120
needed, adjust the position of axis-2 to
make it possible to insert the lock screw.
The lock screw is used to secure the weight
of the lower arm, in order to avoid acci-
dents or damage.
Note
xx1200001116
6
DANGER
Action Note
1
DANGER
xx1200001135
Action Note
3 Make sure the o-ring is present.
xx1200001070
xx1200001066
Tip
xx1200001067
Action Note
1 Before removing the motor, make sure that
the axis-2 gearbox is completely drained.
Action Note
2
DANGER
xx1200001117
6
CAUTION
7 If required, press the motor out of its posi- Removal tool kit M12 and M14:
tion by using the removal tool in opposite 3HAC057339-002
holes of the motor. Removal tool kit M12 and M14:
3HAC057339-002
Depending on motor type A or B, see
Identifying the motor by article number on
page 839
Always use removal tools in pairs.
8 Disconnect the 24 VDC power supply.
Action Note
9
CAUTION
xx1200001118
Action Note
3 Fit a new o-ring.
xx1200001019
Tip
xx1200001020
xx1200001135
Action Note
6 Protection type Foundry Plus Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 20 Nm ±10%
If the motor is a new spare part, the evacuation Tightening torque, protection filter:
hole protection filter must be replaced with a 10 Nm ±10%
transparent plug/sight glass (enclosed with the
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
On the axis-6 motor there are two protection filters
that must be replaced with transparent plugs/sight
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION
xx1200001120
Action Note
7 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
8 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP2, axis-2 mo-
tor:
• + = pin 2
• - = pin 5
9
CAUTION
xx1200001117
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Note
xx1200001067
xx1200001066
Action Note
4 Inspect the o-ring. O-ring, axis-1: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
Note file)
O-ring, axis-2: 3HAB3772-111 (circular
Replace if damaged. profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)
xx1200001070
Tip
7
CAUTION
Action Note
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Concluding procedure
Action Note
1 Use caution and jog axis-2 a little to facilit-
ate the removal of the lock screw.
2 Remove the lock screw securing the lower Lock screw, M16x120
arm.
xx1200001115
Action Note
3 Foundry Plus:
Apply Mercasol in the hole for the lock
screw.
xx1400000372
4 Refill the gearbox with oil. See Filling oil into the axis-2 gearbox on
page 171.
5 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
6
DANGER
xx1200001113
Spare part
Consumables
Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.
Tip
xx1200001067
xx1200001126
Action Note
5 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
Tip
6
CAUTION
7 If required, press the motor out of position Removal tool kit M12 and M14:
by using the removal tool in the remaining 3HAC057339-002
holes for the motor. Removal tool kit M12 and M14:
3HAC057339-002
Depending on motor type A or B, see
Identifying the motor by article number on
page 839
Always use removal tools in pairs.
8 Use caution and lift the motor out on the
guide pins, in order to get the pinion away
from the gear, and let the motor rest on
the guide pins.
9
CAUTION
10 Fasten the lifting accessory to the motor. Lifting accessory, motor: 3HAC15534-1
Attach the lifting chain to the accessory Lifting accessory (chain): 3HAC15556-1
and an overhead crane.
11 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.
CAUTION
Action Note
13 Remove the motor by lifting it straight out. Make sure the pinion is not damaged.
xx1200001131
xx1200001019
Action Note
4 Make sure the o-ring is seated in the groove.
Tip
xx1200001020
xx1200001135
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
3 Apply the lifting accessories to the motor. Lifting accessory, motor: 3HAC15534-1
Note
xx1700000273
xx1200001131
Action Note
7 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP3:
• + = pin 2
• - = pin 5
8
CAUTION
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Concluding procedure
Use this procedure for the concluding refitting.
Action Note
1 Remove the equipment used to unload the
upper arm.
2 Refill the gearbox with oil. See Filling oil into the axis-3 gearbox on
page 177.
3 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
Action Note
4
DANGER
xx1200001114
Spare parts
Consumables
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog the robot into position:
• axis 1 = no significance.
• axis 2 = -65°
• axis 3 = upper arm pointing straight
up (if possible).
With the robot in this position, there is no
need to drain oil from the axis-4 gearbox
when the motor is replaced.
3 If there is no space to position the upper
arm pointed straight up, drain the axis-4
gearbox.
4
DANGER
Action Note
1
DANGER
xx1200001135
Action Note
3 Make sure the o-ring is present.
xx1200001070
xx1200001066
Tip
xx1200001067
Action Note
1
CAUTION
Action Note
2 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP4:
• + = pin 2
• - = pin 5
3 Unscrew the attachment screws that secure
the motor.
xx1200001137
4 Apply two guide pins in opposite holes. Guide pin, M8x150: 3HAC15520-2
Always use guide pins in pairs.
5
CAUTION
6 Press the motor out of position by fitting Removal tool kit M12 and M14:
the removal tool in the remaining attach- 3HAC057339-002
ment holes for the motor. Always use removal tools in pairs.
7
CAUTION
xx1200001138
xx1200001019
Tip
xx1200001020
Action Note
5 If the motor is a new spare part, remove the cover.
xx1200001135
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
1 Apply two guide pins in opposite holes. Guide pin, M8x150: 3HAC15520-2
Always use guide pins in pairs.
Action Note
2 Put the motor onto the guide pins.
xx1700000291
3
Note
xx1200001130
4
CAUTION
5 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
This requires two persons co-operating, if
the motor is installed from above (if the
upper arm is pointing upwards).
6 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP2:
• + = pin 2
• - = pin 5
Action Note
7
CAUTION
xx1200001137
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Concluding procedure
Action Note
1 Refill the gearbox with oil, if gearbox has See Filling oil into the axis-4 gearbox on
been drained. page 182.
2 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
3
DANGER
xx1500001899
Spare part
Consumables
Required tools
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
Action Note
2 Jog the robot to this position:
• Axis 2: +25°
• Axis 3: +35°
xx1200001005
3 Jog axis 4 to this position: With the robot in this position, there is no
• Axis 4: +90° need to drain oil from the axis-5 gearbox
when the motor is replaced.
xx1400000719
4
DANGER
Action Note
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.
xx1400000355
xx1400000206
xx1300002247
Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.
xx1500001030
xx1300000490
Action Note
6 Cut the cable ties that hold the cable har- Choose figure depending on which plate
ness to the plate. is installed on the robot.
Note
Tip
xx1500001029
xx1300000489
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
xx1200001070
xx1200001066
Action Note
5 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 from the motor.
2 Remove the outer screw.
3 Slide the cable gland cover away
from the inner screw. Make sure the
gasket is not damaged.
Tip
Action Note
1 Unscrew the attachment screws that secure Bits extender: 3HAC12342-1
the motor, using a bits extender.
xx1200001017
2
CAUTION
3 If needed, fit removal tools in opposite Removal tool kit M12 and M14:
holes. 3HAC057339-002
Always use removal tools in pairs.
Action Note
4
CAUTION
xx1200001018
Action Note
1
DANGER
Action Note
2 Wipe clean the contact surfaces from any
contamination.
Also wipe clean the o-ring groove.
xx1200001019
xx1200001020
6 Apply two guide pins in opposite holes. Guide pin, M8x100: 3HAC15520-1
Action Note
1
CAUTION
Action Note
2 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
3 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
Connect to connector R2.MP5:
• + = pin 2
• - = pin 5
4
CAUTION
5 Use caution and lower the motor into posi- Rotation tool, 3HAB7887-1
tion on the guide pins, while at the same
time rotating the motor pinion slightly.
Make sure that:
• the motor pinion is properly mated
to the gear of the gearbox.
• the motor pinion does not get dam-
aged.
• the direction of the cable exit is fa-
cing the same way as before remov-
al.
xx1200001018
Action Note
7 Secure the motor with its attachment Tightening torque: 24 Nm.
screws and washers. Screw dimension: M8x30 quality 12.9
Gleitmo(4 pcs)
xx1200001017
Action Note
1 Push the motor cables in through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover by performing
the following steps:
• Slide the cable gland cover onto the
inner screw.
• Refit and tighten the outer screw.
• Tighten the inner screw. Make sure
that the gasket is not damaged.
Note
xx1200001016
xx1200001015
4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).
xx1200001021
5
CAUTION
Action Note
6 Refit the motor cover with its attachment Screws: M5x12.
screws.
Note
Note
Note
7 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
Note is installed on the robot.
xx1500001029
xx1300000489
Action Note
8 Fit the heat protection plate with the Choose figure depending on which plate
screws. is installed on the robot.
Screws: M5x12.
xx1500001030
xx1300000490
Concluding procedure
Action Note
1 Make sure that the cable harness is placed There are two versions of the heat protec-
in a way that it will not be damaged when tion plates.
the wrist cover is fitted. Choose figure depending on which plate
is installed on the robot.
xx1500001672
xx1300000596
xx1400000383
Action Note
3 Refit the wrist cover. In order not to dam-
age the cable harness when the wrist cover
is refitted, use this method:
1 Hold the cover slightly tilted below
the wrist.
2 Put the cable harness inside the
cover.
3 Lift the cover, still tilted.
4 Move the upper part of the cover into
position.
5 Secure the cover with its attachment xx1300000772
screws.
Tightening torque: 10 Nm
4 Foundry Plus:
Refit protection plugs.
5 If used, refit the DressPack cable package
on the wrist.
6 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
7
DANGER
xx1200001080
Spare part
Consumables
Action Note
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 814.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog the robot to a position where axis 5
can be positioned with the motor pointing
straight up at an acceptable working posi-
tion.
With axis 5 in this position it is possible to
replace the motor without draining the oil
from the axis-6 gearbox.
xx1200001081
3
DANGER
Action Note
4 Remove the wrist cover.
xx1300002247
Action Note
1
DANGER
xx1200001080
xx1300000488
Action Note
4 Unscrew the attachment screws that hold
the cable bracket.
xx1300000484
Note
xx1300000485
xx1300001113
xx1300000666
Action Note
1 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
Connect to R2.MP6-connector:
• + = pin 2
• - = pin 5
2 Unscrew the motor attachment screws.
xx1200001090
3
CAUTION
4 If required, press the motor out of position Removal tool kit M12 and M14:
by fitting the removal tool, motor to the at- 3HAC057339-002
tachment holes of the motor. Always use removal tools in pairs.
5
CAUTION
Action Note
6 Remove the motor by lifting it straight up
from the gear while at the same time pick-
ing out the motor cables from the motor.
Make sure the motor pinion is not dam-
aged!
xx1200001091
xx1200001096
Action Note
2 Remove any old paint residues or other contam-
ination from the contact surfaces on both the
motor and the mating parts.
Wipe clean the contact surfaces and the o-ring
groove.
3 Fit a new o-ring.
xx1200001019
Tip
xx1200001020
xx1200001135
Action Note
6 Protection type Foundry Plus Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 20 Nm ±10%
If the motor is a new spare part, the evacuation Tightening torque, protection filter:
hole protection filter must be replaced with a 10 Nm ±10%
transparent plug/sight glass (enclosed with the
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
On the axis-6 motor there are two protection filters
that must be replaced with transparent plugs/sight
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
1
DANGER
Action Note
4 Check the gasket.
Replace if damaged.
xx1200001094
5
CAUTION
Action Note
6 Fit the motor while, at the same, time
pushing 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!
xx1200001091
xx1200001097
7 Check that the gasket is fitted correctly. Screws: M8x25 Steel 8.8-A2F (4 pcs)
Secure the motor with its attachment Tightening torque: 24 Nm
screws.
xx1200001090
Action Note
8 Refit the axis-6 motor cables by carefully
pushing them and the carrier into position.
xx1300001113
Note
xx1300000485
xx1300000484
Action Note
13 Reconnect the connectors.
xx1200001084
xx1200001095
xx1200001082
Concluding procedure
Action Note
1 Make sure that the cable harness is placed There are two versions of the heat protec-
in a way that it will not be damaged when tion plates.
the wrist cover is fitted. Choose figure depending on which plate
is installed on the robot.
xx1500001672
xx1300000596
xx1400000383
Action Note
3 Refit the wrist cover. In order not to dam-
age the cable harness when the wrist cover
is refitted, use this method:
1 Hold the cover slightly tilted below
the wrist.
2 Put the cable harness inside the
cover.
3 Lift the cover, still tilted.
4 Move the upper part of the cover into
position.
5 Secure the cover with its attachment xx1300000772
screws.
Tightening torque: 10 Nm
4 Foundry Plus:
Refit protection plugs.
5 If used, refit the DressPack cable package
on the wrist.
6 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
7
DANGER
4.8 Gearboxes
4.8.1 Replacing the axis-1 gearbox (IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
-200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60,
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Note
This section describes how to replace the gearbox on variants IRB 6700-235/2.65,
-220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID.
How to replace the gearbox on variants IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID see Replacing the axis-1 gearbox (IRB 6700-300/2.70,
-270/2.70 LID, -245/3.00, -220/3.00 LID) on page 631.
xx1200001183
Spare parts
Consumables
Required documents
Action Note
4 Jog the robot into position: The specified position of axis-1 is re-
• axis 1 = -5° quired for removal of the mechanical stop
• axis 2 = 0° pin.
xx1300000478
5
DANGER
CAUTION
xx1300000476
xx1200001184
Action Note
8 Cut the cable tie inside the frame recess.
xx1200001237
xx1200001240
Note
xx1200001189
xx1200001185
Action Note
11 Unscrew five of the six attachment screws
under the balancing device.
Note
xx1200001238
xx1200001239
Robot position
Use this procedure to jog the robot into position.
Valid for variants IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID,
-175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID.
Action Note
1 Jog the robot into position:
• Axis 1: no significance as long as the robot
is secured to the foundation.
• Axis 2: -40°
• Axis 3: +65° (approximately)
• Axis 4: calibration position (0°)
• Axis 5. +90°
• Axis 6: calibration position (0°)
xx1200001132
2
DANGER
Valid for variants IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID,
-175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID.
Action Note
1
DANGER
2
CAUTION
xx1200001133
4 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1
xx1200001234
Action Note
5 Run a roundsling through the hole in the frame. Roundsling, 1.5 m: Length: 1.5 m.
Attach the roundsling choked. See figure! Lifting capacity: 2,000 kg.
xx1200001209
xx1400000730
WARNING
xx1200001235
8 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer. Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.
xx1400002196
Fender washer
xx1200001134
Action Note
9 Attach the Lifting accessory (chain) to an over- Lifting accessory (chain):
head crane (or similar) and then to the lifting eye 3HAC15556-1
in the arm house and to a roundsling run through Roundsling, 1 m: Length: 1 m, lift-
the wrist. ing capacity: 1,000 kg.
xx1200001236
Action Note
1 Foundry Plus.
Cut the cable tie that hold the axis-1 and
axis-2 motor cables on the protection
plates.
xx1400000722
2 Foundry Plus.
Disassemble the protection plates by re-
moving five of the attachment screws (three
M10x30 and two of the M5x12 screws).
xx1400000723
Action Note
3 Foundry Plus.
Remove the two protection plates.
xx1400000724
Action Note
1
DANGER
xx1200001135
xx1200001070
Action Note
4 Disconnect the motor cables.
xx1200001066
Tip
xx1200001067
Action Note
1
DANGER
Action Note
2 Unscrew the attachment screws and Bits extender: 3HAC12342-1
washers.
Use a bits extender to reach the screws.
xx1200001071
5 If needed, use removal tools to help loosen Removal tool kit M12 and M14:
the motor. 3HAC057339-002
Required dimension of removal tool de-
pends on motor type A or B, see Identifying
the motor by article number on page 839
Used to push out the motor, if necessary.
Always use removal tools in pairs.
6
CAUTION
Action Note
8 Release the brakes of the axis-1 motor with Brake release tool: 3HAC081310-001
the brake release tool. User instructions are enclosed with the
1 Turn off the brake release tool. tool.
2 Connect the tool to the R2.MP1
connector.
3 Release the brakes by turning on the
brake release tool and pressing the
brake release button on the tool.
DANGER
9 Use caution and lift the motor straight up Lifting accessory (chain): 3HAC15556-1
to get the pinion parted from the gear. Lifting accessory, motor: 3HAC14459-1.
xx1200001072
Action Note
1
DANGER
Action Note
2 Remove the base cover.
xx1300000561
3 Disconnect connectors:
• R1.MP
• R1.SMB
xx1300000591
xx1400000366
xx1400000354
Action Note
6 If used, remove the attachment screws that
secure the bracket.
This is done to facilitate removal of the
DressPack hoses.
xx1400000078
Note
xx1400000088
Action Note
1 If equipped with DressPack, pull out the
DressPack cables through the protection
tube and place them carefully over the
balancing device.
2 Pull out the robot cable harness through
the protection tube.
xx1300000732
Tip
xx1700001635
xx1700001636
Action Note
5 Use caution and lift the complete arm sys-
tem.
xx1700001637
Action Note
1 Remove the attachment screws and washers
that secure the gearbox to the base.
xx1200001186
Action Note
2 Fit two guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2
Guide pin, M12x200: 3HAC13056-3
Tip
xx1700001653
CAUTION
xx1700002193
4
CAUTION
Action Note
5 Attach the lifting accessory (chain) to the Lifting accessory (chain): 3HAC15556-1
gearbox.
xx1700002194
xx1700001655
WARNING
xx1400001983
xx1300000779
2 Fit guide pins in opposite holes in the base. Guide pin, M12x150: 3HAC13056-2
Guide pin, M12x200: 3HAC13056-3
Tip Always use guide pins in pairs.
xx1700001642
Preparations of gearbox
Use this procedure to do the necessary preparations before refitting the gearbox.
Action Note
1 Fit two lifting eyes manually in opposite holes Lifting eye: 3HAC14457-4
in the gearbox.
CAUTION
xx1700002190
xx1700002191
3
CAUTION
Action Note
4 Wipe clean the contact surfaces from any
contamination.
Also wipe clean the o-ring groove.
xx1200001245
Note
xx1200001244
xx1700002192
Action Note
1 Fit the guide for the gear on top of the protec- Guide for reduction gear: 3HAC043870-
tion tube. 009.
It protects the protection tube from getting
damaged when the gearbox is being fitted.
xx1700002037
Note
xx1700001641
xx1200001186
Action Note
6 Torque tighten all screws. Tightening torque: 120 Nm.
7 Remove the guide for the reduction gear.
xx1700002038
Action Note
1 Remove old residues of flange sealant and
other contamination from the contact sur-
faces on the gearbox.
2 Wipe clean the contact surfaces from any
remaining contamination.
3 Apply flange sealant on the contact surface Flange sealant: - (Loctite 574)
of the gearbox.
xx1700002198
4 Wipe clean the o-ring groove in the gearbox O-ring: 3HAB3772-164 or 3HAC061327-002
and the new o-ring. (depends on gearbox variant, see Product
manual, spare parts - IRB 6700).
5 Lubricate the new o-ring with grease and
fit it to the gearbox. Grease: 3HAC042536-001.
xx1700001658
Action Note
6 Apply guide pins in opposite holes in the Guide pin, M16x200: 3HAC13120-3
gearbox.
Note
Tip
xx1300000823
xx1300000822
xx1700001659
Action Note
1
CAUTION
xx1200001236
Action Note
7 Lift the arm system to mounting position, Position of Guide pin, M16x200:
and verify that the hole pattern match and
that the guide pins will enter the correct
holes in the frame.
Note
xx1300000823
xx1300000822
8 Lower the arm system to align the longest Position of Guide pin, M16x200:
guide pin into the hole.
Note
xx1300000823
Action Note
9 Lower the arm system to align the other Position of Guide pin, M16x150:
guide pin into the hole.
xx1300000822
xx1700002040
xx1700002041
Action Note
B
11 Fit the aligning tool according to figure. A
xx1300001118
A Aligning tool
B Attachment screws (2 pcs)
C Correct fitting of the aligning tool.
Tightening torque: 24 Nm.
12 Lower the arm system slowly until the
heads of the gearbox attachment screws
are starting to disappear inside the frame
edge.
Verify visually from the side and from the
xx1700002042
front/back that the frame is coming down
completely level against the gearbox. If the
frame is somewhat tilted, adjust the lifting
position with the overhead crane.
Note
xx1700002043
While lowering the complete arm system,
check that the cylindrical pin is fitted cor-
rectly.
13 When the arm system is in position, fit the Attachment screws: M16x110 (16 pcs)
accessible attachment screws manually
(no tools).
14 Use caution and lower the complete arm
system into position on top of the gearbox.
15 Secure the complete arm system to the Tightening torque: 300 Nm.
axis-1 gearbox with its attachment screws.
16 Remove the two guide pins and replace Tightening torque: 300 Nm.
with attachment screws.
Tighten the remaining, accessible attach-
ment screws.
17 Perform a leak-down test. See Performing a leak-down test on
page 202.
18 Remove the aligning tool, after the leak-
down test is completed successfully.
19 Remove the lifting accessories.
xx1200001019
Tip
xx1200001020
xx1200001135
Action Note
6 Protection type Foundry Plus Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 20 Nm ±10%
If the motor is a new spare part, the evacuation Tightening torque, protection filter:
hole protection filter must be replaced with a 10 Nm ±10%
transparent plug/sight glass (enclosed with the
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
On the axis-6 motor there are two protection filters
that must be replaced with transparent plugs/sight
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION
Action Note
5 Release the brakes of the axis-1 motor with Brake release tool: 3HAC081310-001
the brake release tool. User instructions are enclosed with the
1 Turn off the brake release tool. tool.
2 Connect the tool to the R2.MP1
connector.
3 Release the brakes by turning on the
brake release tool and pressing the
brake release button on the tool.
DANGER
Note
6
CAUTION
xx1200001072
Action Note
8 Secure the motor with its attachment Bits extender: 3HAC12342-1
screws and washers. Tightening torque: 50 Nm.
Use a bits extender to reach the screws. Screws: M10x30 Steel 12.9 Gle
603+Geo500 (4 pcs)
xx1200001071
9 Perform a leak-down test (if not already See Performing a leak-down test on
done). page 202.
10 Disconnect the brake release tool / 24 VDC
power supply.
Action Note
1 Run the cables through the protection tube
in this order:
• R1.MP
• R1.SMB
If necessary, lubricate the cables with
grease to make them run more smoothly.
xx1300000732
Action Note
2 Run the cables correctly aligned:
• Make sure that the cables are not
twisted. Each cable must be in line
with its position on the base plate.
• Make sure that the R1.SMB cable
will run on the correct side of the
R1.MP1, see the figure.
xx1300000736
xx1300000591
xx1400000354
Action Note
6 If used, run the DressPack cables through
the protection tube in the base.
7 If used, run the DressPack hoses through
the protection tube in the base.
Make sure that the hoses are running cor-
rectly and are not twisted!
8 If used, fit the bracket that hold the
DressPack to the frame.
xx1400000078
xx1200000052
xx1300000561
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Note
xx1200001067
xx1200001066
Action Note
4 Inspect the o-ring. O-ring, axis-1: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
Note file)
O-ring, axis-2: 3HAB3772-111 (circular
Replace if damaged. profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)
xx1200001070
Tip
7
CAUTION
Action Note
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Concluding procedure
Action Note
1 Remove the lifting accessory.
2 Turn on the power to the robot and jog to:
• axis 1 = -5°
• axis 2 = +10°
3
DANGER
Action Note
6 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply Mercasol on the surfaces shown in casol 3110 Waxcoat. Recommended drying
the figure, on stop pin and in the hole as time is 24h.).
shown in the figure.
xx1400000378
7 Refit the mechanical stop pin and secure Locking liquid: - (Loctite 2400 (or equivalent
it with the attachment screw. Loctite 243)).
Apply locking liquid on the screw. Tightening torque: 10 Nm
xx1300000476
xx1200001237
Action Note
9 Refit the cable bracket on the frame.
xx1200001246
4.8.2 Replacing the axis-1 gearbox (IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID)
Note
This section describes how to replace the gearbox on variants IRB 6700-300/2.70,
-270/2.70 LID, -245/3.00, -220/3.00 LID.
How to replace the gearbox on variants IRB 6700-235/2.65, -220/2.65 LID,
-205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB
6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID see Replacing the axis-1
gearbox (IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05,
-155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID,
-155/2.85, -140/2.85 LID) on page 590.
xx1200001183
Spare parts
Consumables
Required documents
Action Note
2 Move the robot to synchronization position. The axis-1 must be in 0 position to make
it possible to remove the mechanical stop
pin.
3
DANGER
4 Remove tools and other equipment fitted on This is done to achieve the best stability
the turning disc. of the complete arm system, when it is
DressPack can stay fitted for the time being. resting by itself, after it has been re-
moved.
5 Hold the mechanical stop pin in a firm grip,
and remove it by unscrewing the attachment
screw.
CAUTION
xx1400002179
6 Begin draining the axis-1 gearbox. See Draining the axis-1 gearbox on
page 163.
7 Loosen 14 of the 18 attachment screws as
far as it is possible at this point.
The four screws that are left in place, diagon-
ally located to each other, work as an anvil
for the axis 1 rotation when unscrewing the
hub later on.
xx1400002169
Note
Action Note
8 Foundry Plus.
Cut the cable tie that hold the axis-1 and axis-
2 motor cables on the protection plates.
xx1400000722
9 Foundry Plus.
Disassemble the protection plates by remov-
ing five of the attachment screws (three
M10x30 and two of the M5x12 screws).
xx1400000723
10 Foundry Plus.
Remove the two protection plates.
xx1400000724
Robot position
Action Note
1 Jog the robot into position:
• Axis 1: no significance (as long as the robot
is secured to the foundation)
• Axis 2: -45°
• Axis 3: +65°
• Axis 4: 0°
• Axis 5: +80°
• Axis 6: no significance
xx1200001132
2
DANGER
Action Note
1
DANGER
2
CAUTION
Action Note
3 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1
xx1200001133
4 Fit a lifting eye to the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer. Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.
xx1400002196
xx1200001134
Tip
xx1400002107
xx1400000728
A Upper arm
B Shackle
C Roundsling
D Hole in frame
Action Note
2 Connect the roundsling with a shackle. Lifting shackle SA-10-8-NA1
xx1400000729
Note
xx1400002108
Action Note
1
DANGER
xx1200001135
xx1200001070
xx1200001066
Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.
Tip
xx1200001067
Action Note
1
DANGER
xx1200001071
Action Note
5 If needed, use removal tools to help loosen Removal tool kit M12 and M14:
the motor. 3HAC057339-002
Required dimension of removal tool de-
pends on motor type A or B, see Identifying
the motor by article number on page 839
Used to push out the motor, if necessary.
Always use removal tools in pairs.
6
CAUTION
DANGER
9 Use caution and lift the motor straight up Lifting accessory (chain): 3HAC15556-1
to get the pinion parted from the gear. Lifting accessory, motor: 3HAC14459-1.
xx1200001072
Action Note
1
DANGER
xx1300000561
3 Disconnect connectors:
• R1.MP
• R1.SMB
xx1300000591
xx1400000366
Action Note
5 Disconnect the earth cable. Screw dimension : M6x16
Washer dimension : 6.4x17x3
xx1400000354
xx1400000078
Note
xx1400000088
Action Note
1 If equipped with DressPack, pull out the
DressPack cables through the protection
tube and place them carefully over the
balancing device.
Action Note
2 Pull out the robot cable harness through
the protection tube.
xx1300000732
Action Note
1 Check that the axis-1 gearbox is drained and
then remove the draining equipment.
2 Raise the overhead crane to stretch all lifting
accessories.
3 Remove the two protection plugs or M16
screws on the left and right hand side of the
frame and install guide pins in the holes.
Tip
xx1700000320
xx1700000321
Action Note
4 Unscrew the remaining attachment screws
as far as it is possible at this point.
xx1400002169
Note
5
CAUTION
CAUTION
Note
Action Note
1 Remove the back plate.
xx1400002171
2 Fit two lifting eyes in opposite holes in the Lifting eye: 3HAC14457-4
gearbox.
CAUTION
xx1700000323
3
CAUTION
Action Note
4 Attach the lifting accessory. Lifting accessory (chain): 3HAC15556-1
xx1700000324
xx1400002180
xx1000000364
Action Note
8 With base and gearbox safely resting on the
support legs, unscrew the attachment screws
that secure the gearbox to the base, from
underneath the base.
Tip
xx1700001375
10 Fit two guide pins in opposite holes. Guide pin, M20x180: 3HAC048814-002
Always use guide pins in pairs.
Tip
xx1700000337
Action Note
11
CAUTION
xx1700000566
xx1700001378
xx1400002175
Action Note
1 If not already done, fit and secure the four
support legs to the foundation. Then lift up
and secure the base on top of the legs.
xx1000000364
CAUTION
xx1700000325
3
CAUTION
Action Note
4 Attach the lifting accessory and lift the gear- Lifting accessory (chain): 3HAC15556-1
box.
xx1700000326
xx1700000567
xx1400002175
Action Note
8 Apply flange sealant to the mounting interface Flange sealant: Loctite 574 (-).
on the gearbox.
xx1700001384
9 Fit guide pins in opposite holes in the gear- Guide pin, M20x180: 3HAC048814-002
box. Always use guide pins in pairs.
Tip
xx1700000327
Action Note
1 Before the gearbox is being fitted, place the If the attachment screws are not fitted like
attachment screws that will secure the gear- this at this point, it will be almost im-
box to the frame, temporarily in their holes possible to fit the screws later when the
and lock screws with the old o-ring. This is gearbox is resting on the base.
done to prevent the screws from falling out.
Note
xx1400002176
Action Note
2 Make sure that the locating pin in the base
will match its hole in the gearbox.
xx1400002177
Note
Note
xx1700000328
O-ring: 3HAB3772-97.
xx1400002178
Action Note
5 Fit the attachment screws that secure the Attachment screws: M20x60 (12 pcs)
gearbox to the base, from underneath.
xx1400002172
Tip
xx1700001374
Action Note
11 Refit the protection tube to the base. Secure Screws: M6x16 (2 pcs).
with the two attachment screws. Tightening torque: 10 Nm.
Apply locking liquid on the screws. Locking liquid: Loctite 2400 (or equivalent
Loctite 243) (-).
xx1700001375
Action Note
1
CAUTION
Action Note
1 Remove the sealing ring and the radial seal-
ing from the frame.
xx1700000569
A Sealing ring
B Radial sealing with dust lip
2 Remove old residues of flange sealant and
other contamination from the contact sur-
faces on the gearbox.
3 Wipe clean the contact surfaces from any
remaining contamination.
4 Wipe clean the o-ring groove in the gearbox Grease, Shell Gadus S2: 3HAC042536-
and apply some grease to the groove. 001.
5 Wipe a new o-ring clean, apply some grease O-ring: 3HAB3772-160.
to it and replace the old one between base Grease, Shell Gadus S2: 3HAC042536-
and frame with a new. 001.
Install the new o-ring in the groove.
Note
xx1700000336
Action Note
6 Apply flange sealant in two strings according Flange sealant, Loctite 574: -.
to the figure.
xx1700000415
xx1700000329
Action Note
1
CAUTION
2 Make sure that all lifting accessories still is See Attachment points of lifting accessory
fitted correctly on the arm system. on page 217.
Action Note
3 Attach the upper arm lifting accessory (chain) Lifting accessory (chain): 3HAC15556-1
to an overhead crane (or similar) and then to
the lifting eye in the arm house and to the
lifting eye in the wrist.
xx1400002108
Note
CAUTION
Action Note
11
Note
xx1700000320
xx1700000321
Action Note
15 Refit the radial sealing.
Replace if damaged.
16 Refit the sealing ring. Make sure the o-ring
is placed in its groove on the sealing ring.
Replace if damaged.
xx1700000569
A Sealing ring
B Radial sealing with dust lip
17 Refit the back plate.
xx1400002171
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION
Action Note
5 Release the brakes of the axis-1 motor with Brake release tool: 3HAC081310-001
the brake release tool. User instructions are enclosed with the
1 Turn off the brake release tool. tool.
2 Connect the tool to the R2.MP1
connector.
3 Release the brakes by turning on the
brake release tool and pressing the
brake release button on the tool.
DANGER
Note
6
CAUTION
xx1200001072
Action Note
8 Secure the motor with its attachment Bits extender: 3HAC12342-1
screws and washers. Tightening torque: 50 Nm.
Use a bits extender to reach the screws. Screws: M10x30 Steel 12.9 Gle
603+Geo500 (4 pcs)
xx1200001071
9 Perform a leak-down test (if not already See Performing a leak-down test on
done). page 202.
10 Disconnect the brake release tool / 24 VDC
power supply.
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Action Note
1 Refill oil in the gearbox. See Changing oil, axis-1 gearbox
on page 162.
Action Note
1 Run the cables through the protection tube
in this order:
• R1.MP
• R1.SMB
If necessary, lubricate the cables with
grease to make them run more smoothly.
xx1300000732
xx1300000736
xx1300000591
Action Note
5 Connect the earth cable. Screw dimension: M6x16.
Washer dimension: 6.4x17x3.
xx1400000354
xx1400000078
xx1200000052
Action Note
10 Refit the base cover.
xx1300000561
Action Note
1 Foundry Plus:
Apply Mercasol on the surfaces shown in the
figure, on stop pin and in the hole as shown
in the figure.
xx1400000378
xx1400002179
Action Note
3 Secure the cable harness inside the frame
hole with a cable strap.
xx1200001237
xx1200001246
Concluding procedure
Action Note
1 Re-calibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 813.
General calibration information is included
in section Calibration on page 799.
2
DANGER
4.8.3 Replacing the axis-2 gearbox (IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
-200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60,
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Note
This section describes how to replace the gearbox on variants IRB 6700-235/2.65,
-220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID.
How to replace the gearbox on variants IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID see Replacing the axis-2 gearbox (IRB 6700-300/2.70,
-270/2.70 LID, -245/3.00, -220/3.00 LID) on page 709.
DANGER
The base shall be fitted to the foundation when performing this procedure! Valid
in both examples described below.
xx1300002303
Example 1: Position with space for pallets in front of the robot. Axis-1 in calibration
position.
If needed, run axis-1 into a position that gives the required space. The figure shows
an example.
xx1300002304
Note
Using this method to replace the gearbox with cable harness and DressPack
fitted, is only a recommendation. If it is not possible to put the arm system close
enough to the robot and keep the cable harness partly fitted, it may by necessary
to remove the cable harness and DressPack in base and frame first.
xx1200001276
Spare parts
Consumables
Required documents
Follow the order of the procedures according to the order they are presented.
CAUTION
When performing these procedures, the cable harness will still be fitted or partly
fitted to the robot. Use extreme caution not to cause any damage to the cable
harness.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2
DANGER
Unloading the balancing device springs with the robot and locking position with the Distance tool
Use this procedure to unload the balancing device with the help of the robot, and
lock the balancing device springs in a compressed position, using the Distance
tool (3HAC030662-001).
Action Note
1
DANGER
Action Note
3
DANGER
DANGER
xx1300000554
xx0800000480
Action Note
9
DANGER
Action Note
1
CAUTION
xx1300000661
3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.
Action Note
1 Remove the protection plug or VK cover at It is possible to drive a screwdriver (or
the link ear (depends on shaft version). similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.
xx1200001278
xx1900002311
xx1900002146
Action Note
3 Unscrew the attachment screw and washer.
xx1200001279
xx0900000813
DANGER
xx1200001283
xx1200001281
Robot position
Use this procedure to jog the robot into position.
Valid for variants IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID,
-175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID.
Action Note
1
Note
xx1200001250
3
DANGER
Valid for variants IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID,
-175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID.
Action Note
1
CAUTION
xx1200001133
3 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1
xx1200001234
xx1200001251
Action Note
5 Run a roundsling around the lower arm, beneath Roundsling, 1.5 m: Length: 1.5 m.
the securing screw. Lifting capacity: 2,000 kg.
If DressPack cable package is installed: place the
roundsling beneath the ball joint housing on the
outside of the lower arm instead.
xx1200001252
xx1200001253
Note
9
DANGER
Action Note
10 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer: Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.
xx1400002196
xx1200001134
xx1400000355
xx1200001254
Action Note
15 To release the brake, connect the 24 VDC power
supply.
Connect to connector R2.MP2, axis-2 motor:
• + = pin 2
• - = pin 5
xx1200001135
xx1200001070
Action Note
4 Disconnect the motor cables.
xx1200001066
Tip
xx1200001067
Action Note
1 Before removing the motor, make sure that
the axis-2 gearbox is completely drained.
2
DANGER
Action Note
4 Remove the attachment screws. Bits extender: 3HAC12342-1
Use a bits extender in order to reach the
screws.
xx1200001117
6
CAUTION
7 If required, press the motor out of its posi- Removal tool kit M12 and M14:
tion by using the removal tool in opposite 3HAC057339-002
holes of the motor. Removal tool kit M12 and M14:
3HAC057339-002
Depending on motor type A or B, see
Identifying the motor by article number on
page 839
Always use removal tools in pairs.
8 Disconnect the 24 VDC power supply.
9
CAUTION
Action Note
12 Remove the motor by sliding it out on the Make sure the pinion is not damaged.
guide pins and lift it off.
xx1200001118
xx1400000195
Action Note
2 Unscrew the attachment screws that secure
the axis-2 lower arm metal clamp and the
axis-3 lower arm metal clamp located on
the inside of the lower arm by removing the
attachment screws.
Note
xx1300000540
Removing and lifting away the lower and upper arms un-separated (Step 1)
Use this procedure for the first step of removing and lifting away the lower and
upper arm un-separated.
Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Tip
xx1300000788
Action Note
2 Remove all but one of the remaining attach-
ment screws that secure the lower arm to
the axis-2 gearbox.
xx1300000789
Removing and lifting away the lower and upper arms un-separated (Step 2)
Use this procedure for the second step to remove and lift the lower and upper arm
un-separated.
Action Note
1 Put two pallets on the floor, in front of the
position of the mechanical stop.
Note
2
CAUTION
Action Note
3 Use caution and remove the remaining
screw and slowly lift away the lower and
upper arm together.
Let the cabling run in the lower arm. Make
sure not to stretch any cabling!
CAUTION
xx1300000790
xx1300002249
Action Note
4 Remove the remaining screw left in the
gearbox.
5 Use two fully threaded attachment screws
(M12) as removal tools to press the gear-
box out of position.
6 Attach the lifting accessory to the gearbox. Lifting accessory, gearbox: 3HAC046112-
001
7 Use caution and let the gearbox slide out
on the guide pins.
8 Remove the gearbox.
CAUTION
When performing these 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!
2 Apply the lifting accessory to the gearbox. Lifting accessory, gearbox: 3HAC046112-
001
3 Use caution and lift the gearbox so that it
rests on its side.
4 Remove the o-ring and wipe it clean.
Note
Note
Action Note
6 Check the condition of the o-ring. O-ring: 3HAB3772-144 (D=309.3x3.1) /
Replace if damaged. 3HAB3772-48 (D=319.3x5.7)
Located between the gearbox and the
frame.
Size depends on gearbox model. Measure
the groove to see dimension of the o-ring.
7 Lubricate the o-ring with some grease, for
a better fitting in the groove.
8 Fit the o-ring in the groove.
9 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply rust preventive to the gearbox sur- casol 3110 Waxcoat. Recommended drying
faces shown in the figures. time is 24h.)
xx1400000374
10 Fit two guide pins in opposite holes (M12). Guide pin, M12x150: 3HAC13056-2
Guide pin, M12x200: 3HAC13056-3
Tip Always use guide pins in pairs.
xx1700000445
Action Note
13 Fit the attachment screws and washers
now accessible.
xx1400002188
xx1200001019
Action Note
4 Make sure the o-ring is seated in the groove.
Tip
xx1200001020
xx1200001135
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
Action Note
2
CAUTION
xx1200001120
Action Note
12 Remove the guide pins and replace with
the remaining attachment screws.
13 Secure the motor with its attachment Bits extender: 3HAC12342-1
screws and washers. Tightening torque: 50 Nm.
Use a bits extender in order to reach the Screw dimension: M10x30 Steel 12.9 Gle
screws. 603+Geo500 (4 pcs)
xx1200001117
Tip
xx1400000360
Action Note
4
CAUTION
xx1300000819
Action Note
12 Fit all now accessible attachment screws Screws: M16x50 quality steel 12.9 Gleitmo
and washers.
xx1300000789
13 Remove the two guide pins and replace Screws: M16x50 quality steel 12.9 Gleitmo
with the remaining attachment screws and
washers.
14 Secure the lower arm to the axis-2 gearbox Tightening torque M16: 300 Nm
with its attachment screws.
15 Disconnect the 24 VDC power supply.
16 Remove the lifting accessories.
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Action Note
2 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
xx1200001282
xx1200001283
xx1400000195
4 Apply the lifting accessory to the balancing device Lifting shackle: SA-10-8-NA1
(if not already done). Lifting accessory (chain):
3HAC15556-1
5 Remove all residue of Loctite in the screw hole of
the shaft.
6 Wipe all contact surfaces inside the recess clean
from contamination.
7 Align the balancing device link ear with the hole
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
Apply Mercasol on the surfaces on the shaft and
front ear.
A
A
C
xx1400000368
Action Note
9 Lubricate the shaft and place it to the front ear.
Note
Foundry Plus:
Do not lubricate surfaces where Mercasol is ap-
plied.
xx1200001280
10 Press in the shaft using the dismantle and Dismantle and mounting tool:
mounting tool, according to user instructions en- 3HAC028920-001
closed with the equipment. User instructions are enclosed with
the tool.
xx0900000813
DANGER
xx1300000782
12 Secure the shaft with screw and washer. Tightening torque: 180 Nm
xx1200001279
Action Note
13 Fit the protection plug or a new VK-cover (de-
pends on shaft version).
xx1200001278
xx1900002311
14 Unscrew both screws in link ear and fill the bear- Grease: 3HAA1001-294
ing with grease from the upper hole until the
grease appears in the lower hole.
xx1300000783
15 Refit the two screws and wipe clean from residual Tightening torque:
grease. 10 Nm
xx1900002146
Action Note
1 Remove the lifting accessory from the bal-
ancing device.
Action Note
2 Refit the cable bracket (if not already refit-
ted).
xx1200001283
3
DANGER
Action Note
6 Remove the distance tool.
xx0800000480
xx1300000554
Concluding procedure
Action Note
1 If the robot is equipped with DressPack,
refit the brackets of the ball joint housings
on the wrist.
2 Refill oil to the axis-2 gearbox. See Filling oil into the axis-2 gearbox on
page 171.
3 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
Action Note
4
DANGER
4.8.4 Replacing the axis-2 gearbox (IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID)
Note
This section describes how to replace the gearbox on variants IRB 6700-300/2.70,
-270/2.70 LID, -245/3.00, -220/3.00 LID.
How to replace the gearbox on variants IRB 6700-235/2.65, -220/2.65 LID,
-205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID, IRB
6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID see Replacing the axis-2
gearbox (IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05,
-155/3.05 LID, -150/3.20, -145/3.20 LID, IRB 6700-200/2.60, -175/2.60 LID,
-155/2.85, -140/2.85 LID) on page 671.
DANGER
The base shall be fitted to the foundation when performing this procedure! Valid
in both examples described below!
Note
Using this method to replace the gearbox with cable harness and DressPack
fitted, is only a recommendation. If it is not possible to put the arm system close
enough to the robot and keep the cable harness partly fitted, it is necessary to
remove the cable harness and DressPack in base and frame first.
xx1200001276
Spare parts
DANGER
Consumables
Required documents
Action Note
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 814.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
CAUTION
When performing these 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!
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2
DANGER
Unloading the balancing device springs with the robot and locking position with the Distance tool
Use this procedure to unload the balancing device with the help of the robot, and
lock the balancing device springs in a compressed position, using the Distance
tool (3HAC030662-001).
Action Note
1
DANGER
DANGER
xx1300000554
Action Note
5 Fit the Distance tool on the back of the Tightening torque: 45 Nm
balancing device using the four screws. Attachment screws: M10 quality 12.9 (4
pcs)
DANGER
xx0800000480
Action Note
1
CAUTION
xx1300000661
3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.
Action Note
1 Remove the protection plug or VK cover at It is possible to drive a screwdriver (or
the link ear (depends on shaft version). similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.
xx1200001278
xx1900002311
xx1900002146
Action Note
3 Unscrew the attachment screw and washer.
xx1200001279
xx0900000813
DANGER
xx1200001283
xx1200001281
Robot position
Action Note
1
Note
xx1200001250
3
DANGER
Action Note
2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1
xx1400002106
4 Run a roundsling around the lower arm, place it Roundsling, 2.5 m: Length: 2.5 m.
accordingly: Lifting capacity: 2,000 kg.
• With no DressPack cable package installed:
Place the roundsling beneath the securing
screw.
• With DressPack cable package installed:
Place the roundsling beneath the ball joint
housing on the outside of the lower arm.
xx1400002105
xx1400000729
Action Note
7 Stretch the roundsling between the upper and the
lower arm by slowly jogging the axis-3.
Note
8
DANGER
9 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer: Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.
xx1400002196
xx1200001134
xx1400002104
Action Note
11 Raise the overhead crane to stretch the chains
and roundslings.
Verify that the roundsling between the wrist and
the lower arm is stretched.
12 To release the brake, connect the 24 VDC power
supply.
Connect to connector R2.MP2, axis-2 motor:
• + = pin 2
• - = pin 5
xx1400000195
Action Note
2 Unscrew the attachment screws that secure
the axis-2 lower arm metal clamp and the
axis-3 lower arm metal clamp located on
the inside of the lower arm by removing the
attachment screws.
Note
xx1300000540
xx1200001283
xx1400002181
Action Note
2 Remove all but one of the remaining attach-
ment screws that secure the lower arm to
the axis-2 gearbox.
xx1400002182
Removing and lifting away the lower and upper arms un-separated
Use this procedure to remove and lift away the lower and upper arm un-separated.
Action Note
1 Put two pallets on the floor, in front of the
position of the mechanical stop.
Note
2
CAUTION
Note
xx1700000442
Action Note
4 Use a piece of wood or similar as a support
under the arm house when the arm system
is put down on the pallets.
This is done in order not to damage any
parts of the cable harness and DressPack.
xx1200001135
xx1200001070
Action Note
4 Disconnect the motor cables.
xx1200001066
Tip
xx1200001067
Action Note
1 Before removing the motor, make sure that
the axis-2 gearbox is completely drained.
2
DANGER
Action Note
4 Remove the attachment screws. Bits extender: 3HAC12342-1
Use a bits extender in order to reach the
screws.
xx1200001117
6
CAUTION
7 If required, press the motor out of its posi- Removal tool kit M12 and M14:
tion by using the removal tool in opposite 3HAC057339-002
holes of the motor. Removal tool kit M12 and M14:
3HAC057339-002
Depending on motor type A or B, see
Identifying the motor by article number on
page 839
Always use removal tools in pairs.
8 Disconnect the 24 VDC power supply.
9
CAUTION
Action Note
12 Remove the motor by sliding it out on the Make sure the pinion is not damaged.
guide pins and lift it off.
xx1200001118
xx1700000443
Action Note
2 Leave one of the upper attachment screws
and remove the rest. The remaining screw
is used to prevent the gearbox from falling
down.
xx1700000444
3
CAUTION
xx1400002185
Action Note
8 Remove the gearbox.
xx1400002186
CAUTION
When performing these procedures, the cable harness will still be fitted or partly
fitted to the robot. Use the utmost caution not to cause any damage to the cable
harness!
2 Apply the lifting accessory to the gearbox. Lifting accessory, gearbox: 3HAC046112-
001
3 Use caution and lift the gearbox so that it
rests on its side.
4 Remove the o-ring and wipe it clean.
Note
Action Note
5 Wipe clean the contact surfaces from any
contamination.
Note
xx1400000374
10 Fit two guide pins in opposite holes (M12). Guide pin, M12x150: 3HAC13056-2
Guide pin, M12x200: 3HAC13056-3
Tip Always use guide pins in pairs.
xx1700000445
Action Note
13 Fit the attachment screws now accessible.
xx1400002188
xx1500002118
Action Note
2 Remove any old paint residues or other contam-
ination from the contact surfaces on both the
motor and the mating parts.
Wipe clean the contact surfaces and the o-ring
groove.
3 Fit a new o-ring.
xx1200001019
Tip
xx1200001020
xx1200001135
Action Note
6 Protection type Foundry Plus Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 20 Nm ±10%
If the motor is a new spare part, the evacuation Tightening torque, protection filter:
hole protection filter must be replaced with a 10 Nm ±10%
transparent plug/sight glass (enclosed with the
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
On the axis-6 motor there are two protection filters
that must be replaced with transparent plugs/sight
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION
xx1200001120
Action Note
7 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
8 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP2, axis-2 mo-
tor:
• + = pin 2
• - = pin 5
9
CAUTION
xx1200001117
Action Note
2 Fit the rotation tool, if not already fitted. Rotation tool: 3HAB7887-1
3 Fit two guide pins in opposite holes in the Guide pin, M16x150: 3HAC13120-2
axis-2 gearbox. Always use guide pins in pairs.
Tip
xx1400002189
4
CAUTION
Tip
xx1700000692
Action Note
8 Rotate the gear to match the hole pattern Rotation tool: 3HAB7887-1
in the lower arm, using the rotation tool.
Note
xx1300000819
xx1400002190
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738
Note
xx1200001067
xx1200001066
Action Note
4 Inspect the o-ring. O-ring, axis-1: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
Note file)
O-ring, axis-2: 3HAB3772-111 (circular
Replace if damaged. profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)
xx1200001070
Tip
7
CAUTION
Action Note
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Note
xx1200001282
xx1200001283
Action Note
4 If robot is equipped with DressPack. How to refit the DressPack is described in
• Place the cabling in the two ball joint the product manual "IRB 6700 DressPack".
housings on the lower arm and close For article number see References on
the ball joint housings. page 10.
xx1400000195
4 Apply the lifting accessory to the balancing device Lifting shackle: SA-10-8-NA1
(if not already done). Lifting accessory (chain):
3HAC15556-1
5 Remove all residue of Loctite in the screw hole of
the shaft.
6 Wipe all contact surfaces inside the recess clean
from contamination.
Action Note
7 Align the balancing device link ear with the hole
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
Apply Mercasol on the surfaces on the shaft and
front ear.
A
A
C
xx1400000368
Note
Foundry Plus:
Do not lubricate surfaces where Mercasol is ap-
plied.
xx1200001280
Action Note
10 Press in the shaft using the dismantle and Dismantle and mounting tool:
mounting tool, according to user instructions en- 3HAC028920-001
closed with the equipment. User instructions are enclosed with
the tool.
xx0900000813
DANGER
xx1300000782
12 Secure the shaft with screw and washer. Tightening torque: 180 Nm
xx1200001279
Action Note
13 Fit the protection plug or a new VK-cover (de-
pends on shaft version).
xx1200001278
xx1900002311
14 Unscrew both screws in link ear and fill the bear- Grease: 3HAA1001-294
ing with grease from the upper hole until the
grease appears in the lower hole.
xx1300000783
15 Refit the two screws and wipe clean from residual Tightening torque:
grease. 10 Nm
xx1900002146
Action Note
1 Remove the lifting accessory from the bal-
ancing device.
Action Note
2 Refit the cable bracket (if not already refit-
ted).
xx1200001283
3
DANGER
Action Note
6 Remove the distance tool.
xx0800000480
xx1300000554
Concluding procedure
Action Note
1 If the robot is equipped with DressPack,
refit the brackets of the ball joint housings
on the wrist.
2 Refill oil to the axis-2 gearbox. See Filling oil into the axis-2 gearbox on
page 171.
3 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
Action Note
4
DANGER
DANGER
Do not unscrew the attachment screws that secure the robot to the foundation!
If unscrewed, the robot will be unstable.
xx1300000515
xx1300000553
When removing the upper arm, the cable harness can be kept fitted or partly
fitted to the robot. Use caution not to cause any damage to the cable harness.
2 Replace the axis-3 gearbox.
Spare parts
Consumables
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
Action Note
2 Jog the robot to: If needed, run the axis-1 into a position that
• Axis 1 = No significance (as long as gives the required space (space to place
the robot is secured to the founda- two pallets in a row) at the right-hand side
tion). of the balancing device, as seen from be-
• Axis 2 = -65° hind.
• Axis 3 = maximum + position, upper
arm resting against the mechanical
stop (approximately +70°).
• Axis 4 = 0°
• Axis 5 = -90°
• Axis 6 = 0°
xx1800000029
3
DANGER
Action Note
7 Unscrew the uppermost attachment screw
that holds the bracket of the DressPack
cable package (if one is fitted), and let it
"fall down" . See figure!
Note
xx1200001331
xx1200001332
Note
xx1200001135
xx1200001070
xx1200001066
Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.
Tip
xx1200001067
xx1200001126
Action Note
5 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
Tip
6
CAUTION
7 If required, press the motor out of position Removal tool kit M12 and M14:
by using the removal tool in the remaining 3HAC057339-002
holes for the motor. Removal tool kit M12 and M14:
3HAC057339-002
Depending on motor type A or B, see
Identifying the motor by article number on
page 839
Always use removal tools in pairs.
8 Use caution and lift the motor out on the
guide pins, in order to get the pinion away
from the gear, and let the motor rest on
the guide pins.
9
CAUTION
10 Fasten the lifting accessory to the motor. Lifting accessory, motor: 3HAC15534-1
Attach the lifting chain to the accessory Lifting accessory (chain): 3HAC15556-1
and an overhead crane.
11 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.
CAUTION
Action Note
13 Remove the motor by lifting it straight out. Make sure the pinion is not damaged.
xx1200001131
Note
xx1800000042
Action Note
2 Unscrew the attachment screws that hold
the cable bracket on top of the arm house.
xx1300000541
xx1300000543
Note
xx1300001973
xx1300000544
Action Note
5 In order not to damage the cable harness
later, it shall be moved over to the other
side of the arm house and be placed on the
right side (as seen from behind) of the back
lifting eye.
See figure!
xx1300000534
6 If the robot is equipped with DressPack: How to remove the DressPack is described
• Open the two ball joint housings on in more detail in the product manual "IRB
the lower arm and lift away the cable 6700 DressPack". For article number see
harness from the ball joint housings. References on page 10.
xx1400000195
xx1200001133
3 Fit a lifting eye in the arm house, with a Lifting eye: 3HAC16131-1
fender washer underneath. Fender washer: Outer diameter: minimum
26 mm, maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.
xx1400002196
xx1200001134
Action Note
4 Attach the upper arm lifting accessory Lifting accessory (chain): 3HAC15556-1
(chain) to an overhead crane (or similar)
and then to the lifting eye in the arm house
and in the wrist.
xx1200001308
xx1400002197
Preparations before removing the upper arm - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80
LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID
Action Note
1 Remove two attachment screws (M12) in Guide pin, M12x150: 3HAC13056-2
opposite holes and replace them with guide Guide pin, M12x200: 3HAC13056-3
pins.
Always use guide pins in pairs.
Note
Tip
xx1300000659
Action Note
2 Leave one of the remaining attachment
screws fitted, remove the other screws.
xx1300000747
Preparations before removing the upper arm - IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-3
Always use guide pins in pairs.
Note
Tip
xx1300002245
xx1300002246
Preparations before removing the upper arm - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Note
Tip
xx1400002563
xx1400002564
Action Note
1
Note
xx1400002197
Action Note
2 Remove the remaining attachment screw IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
and let the upper arm slide out from the -200/2.80 LID, -175/3.05, -155/3.05 LID, -
lower arm with support from the guide pins. 150/3.20, -145/3.20 LID
xx1300001610
xx1700000059
CAUTION
Action Note
4 This step is only valid when the upper arm
is removed due to replacement of the axis-
3 gearbox:
Place pieces of wood (or similar) under arm
house and wrist. Lower the upper arm, and
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 axis-3 gearbox,
if applicable. xx1300000553
xx1300001969
xx1700000370
Action Note
2 Remove all but one of the remaining attach- IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
ment screws. -200/2.80 LID, -175/3.05, -155/3.05 LID, -
150/3.20, -145/3.20 LID
xx1300001970
xx1700000371
3 Fit two fully threaded screws and use them Removal tool motor M10: Used to push out
as removal tools. the motor, if necessary.
4 Remove the remaining attachment screw.
5 Loosen the gearbox from its fitting position
with the help of the removal tools, but only
pull it out on the guide pins a little.
DANGER
Action Note
6
CAUTION
Action Note
1
DANGER
Action Note
2
CAUTION
Note
Securing the axis-3 gearbox - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05,
-155/3.05 LID, -150/3.20, -145/3.20 LID
Action Note
1 Secure the gearbox with 29 of the 31 attach- Screws: M12x70
ment screws and washers. Tightening torque: 120 Nm
xx1300001970
xx1300001969
Securing the axis-3 gearbox - IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1 Secure the gearbox with 13 of the 15 attach- Tightening torque: 120 Nm
ment screws. M12x70.
xx1300001970
xx1300001969
Securing the axis-3 gearbox - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1 Secure the gearbox with 28 of the 30 attach- Tightening torque: 120 Nm
ment screws. M12x70.
xx1400002193
Action Note
2 Remove the guide pins and replace with
the remaining attachment screws.
xx1400002194
Action Note
1 Wipe clean all contact surfaces.
2 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply Mercasol on the surface on the lower casol 3110 Waxcoat. Recommended drying
arm as shown in the figure. time is 24h.)
CAUTION
xx1700001880
Action Note
3 IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, Guide pin, M12x150: 3HAC13056-2
-200/2.80 LID, -175/3.05, -155/3.05 LID, - Guide pin, M12x200: 3HAC13056-3
150/3.20, -145/3.20 LID
Always use guide pins in pairs.
Fit two guide pins in opposite M12 holes
in the axis-3 gearbox.
Tip
xx1700000058
Tip
xx1400000361
Tip
xx1700000056
Securing the upper arm - IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and put it on the guide
pins.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
In order to release the brakes, connect the
24 VDC power supply.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1400000359
Action Note
7 Remove the guide pins and fit the two re-
maining M12 screws.
xx1300000659
8 Secure the upper arm by tightening the at- Tightening torque depends on screw dimen-
tachment screws. sion.
Tightening torque, M16: 300 Nm
Tightening torque, M12: 120 Nm
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Securing the upper arm - IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and put it on the guide
pins.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
In order to release the brakes, connect the
24 VDC power supply.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
Action Note
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1300002246
xx1300002245
8 Secure the upper arm by tightening the at- M12, tightening torque: 120 Nm
tachment screws.
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Securing the upper arm - IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Action Note
1
CAUTION
2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 235.
3 Lift the upper arm and bring it towards the
lower arm.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
Connect the 24 VDC power supply, to re-
lease the brakes.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
Disconnect and remove the 24 VDC power
supply after finding the position.
5 If the axis-3 motor is not installed to the Pinion:
upper arm: 3HAC067546-001 i
Use the pinion to rotate the axis-3 gearbox 3HAC067547-001 ii
to find the correct position for the guide
pins in the lower arm. 3HAC067545-001 iii
xx1700000057
Action Note
7 Remove the guide pins and fit the two re-
maining screws.
8 Secure the upper arm by tightening the at- M16, tightening torque: 300 Nm
tachment screws.
i IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, -200/2.80 LID, -175/3.05, -155/3.05 LID, -150/3.20,
-145/3.20 LID
ii IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
iii IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
xx1200001019
Tip
xx1200001020
Action Note
5 If the motor is a new spare part, remove the cover.
xx1200001135
xx1600000576
xx1800000101
xx2200002188
Protection filter
Transparent plug (Standard).
(Foundry Plus).
Action Note
3 Apply the lifting accessories to the motor. Lifting accessory, motor: 3HAC15534-1
Note
xx1700000273
xx1200001131
Action Note
9 Use caution and push the motor in position
while at the same time the motor pinion is
slightly rotated.
Pay attention to following points:
• Mate the motor pinion properly to the
gear of the gearbox.
• Do not damage the motor pinion.
10 Fit two of the attachment screws and wash- Screws: M10x30 quality 12.9 Gleitmo
ers.
11 Remove the guide pins.
12 Fit the remaining attachment screws and Screws: M10x30 quality 12.9 Gleitmo
washers.
13 Tighten the screws. Tightening torque: 50 Nm
14 Remove the rotation tool.
15 Perform a leak-down test. See Performing a leak-down test on
page 202.
16 Disconnect the 24 VDC power supply.
Note
xx1800000042
Action Note
4 Fasten the cable bracket on top of the arm
house.
xx1300000541
xx1300000543
Note
xx1300001973
xx1300000544
Action Note
7 Refit the DressPack cable package into the
ball joint housings on the lower arm and
close them.
xx1400000195
xx1300000738
Action Note
2 Refit the cable gland cover.
Note
xx1200001067
xx1200001066
xx1200001070
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
7
CAUTION
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Note
xx1200001135
Action Note
1 Remove the lifting accessory.
Action Note
2 Fit the bracket of the DressPack cable
package (if one is fitted) under the arm
house with its screws.
xx1200001332
Note
xx1200001331
A Removed screw.
B Screw unscrewed but not removed.
Concluding procedures
Action Note
1 Refill oil in the gearbox. See Filling oil into the axis-3 gearbox on
page 177.
2 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 813.
General calibration information is included
in section Calibration on page 799.
Action Note
3
DANGER
xx1300000824
Spare parts
Consumables
Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2
DANGER
Action Note
5 If installed, remove the DressPack axis-6
support.
xx1400000208
xx1400000223
Action Note
8 Remove the synchronization plate axis-6.
xx1300000825
Action Note
1 - IRB 6700-235/2.65, -220/2.65 LID, -
205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
LID, -150/3.20, -145/3.20 LID
Remove the screws and washers, that se-
cure the turning disc.
xx1300000492
xx1300002302
xx1400002195
Action Note
4 Remove the turning disc.
xx1300000493
Action Note
1 Unscrew the attachment screws that secure • M8x40 quality 12.9 Gleitmo, 16 pcs
the axis-6 gearbox. (IRB 6700-235/2.65, -220/2.65 LID, -
205/2.80, -200/2.80 LID, -175/3.05, -
155/3.05 LID, -150/3.20, -145/3.20
LID)
• M6x30 quality 12.9 Gleitmo, 24 pcs
(IRB 6700-200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID)
• M8x50 quality 12.9 Gleitmo, 16 pcs
(IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
xx1700001600
2
CAUTION
Action Note
3 Remove the gearbox.
If required fit two attachment screws and
press out the gearbox.
xx1700001601
Action Note
1
DANGER
xx1300000828
Action Note
3 Foundry Plus:
Apply Loctite 574 on the surface shown in
the figure.
xx1400000717
Action Note
1
CAUTION
CAUTION
xx1700001601
Action Note
3 Secure the gearbox with its attachment Screws:
screws. • M8x40 quality 12.9 Gleitmo, 16 pcs
(IRB 6700-235/2.65, -220/2.65 LID, -
205/2.80, -200/2.80 LID, -175/3.05, -
155/3.05 LID, -150/3.20, -145/3.20
LID)
• M6x30 quality 12.9 Gleitmo, 24 pcs
(IRB 6700-200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID)
• M8x50 quality 12.9 Gleitmo, 16 pcs
(IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
Tightening torque:
• 35 Nm (IRB 6700-235/2.65, -220/2.65
LID, -205/2.80, -200/2.80 LID, -
175/3.05, -155/3.05 LID, -150/3.20, -
145/3.20 LID, IRB 6700-300/2.70, -
270/2.70 LID, -245/3.00, -220/3.00
LID)
• 14 Nm (IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID)
xx1700001600
Action Note
1 If new turning disc spare part is installed: See Replacing the synchronization mark
verify that the correct synchronization mark plate on page 374.
plate for axis-6 is installed on the wrist.
2 Wipe clean the contact surfaces.
Action Note
3 Foundry Plus: A B
Apply Mercasol on the surfaces on turning
disc and axis-6 gearbox as shown in the
figure.
xx1400000385
xx1300000492
xx1300002302
Action Note
6 IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, Tightening torque: 70 Nm
-220/3.00 LID Attachment screws: M10x25, Steel 12.9
Secure the turning disc with its attachment Gleitmo 603, (21 pcs)
screws and washers. Washers: Steel 11x17x25 (21 pcs)
xx1400002195
Concluding procedure
Action Note
1 Refit the synchronization plate axis-6.
xx1300000825
5 Calibration
5.1 Introduction to calibration
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 813.
Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.
Calibration terminology
Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
xx0400001197
References
Article numbers for the calibration tools are listed in the section Special tools on
page 849.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
When to calibrate
The system must be calibrated if any of the following situations occur.
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Axis 1 Axis 2
xx1300000868
xx1300000869
Axis 3 Axis 4
xx1300000870 xx1300000871
Axis 5 Axis 6
Two variants of synchronization mark plates.
xx1300000872
xx1300000873
xx1500000845
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.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
xx0200000089
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).
xx1500000942
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
Action
3 This step is valid for RobotWare 6.02 and later.
Calibration method used at factory for each axis is shown, as well as calibration
method used during last field calibration.
Tap Manual Method (Advanced).
xx1500000944
en0400000771
Action
5 Tap Update Revolution Counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
6 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
7 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
8
CAUTION
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
2 During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.
3 The axis position is stored in RobotWare with an active choice from the
operator.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
Note
When using reference calibration with some tools, typically large or flexible tools,
oscillations in the robot can cause issues leading to failure of the calibration.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
Axis to calibrate
Required Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
position of
axis
Axis 1 - * * * * *
Axis 2 0 - 0 * * *
Axis 3 0 0 - * * *
Axis 4 * * * - * *
Axis 5 * * * * - *
Axis 6 * * * * * -
- Axis to be calibrated
* Unrestricted. Axis is allowed to be jogged to other position than 0 degrees.
0 Axis must be put in position 0 degrees.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration bushings may cause severe damage to
the robot and/or personnel.
WARNING
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring
xx1500000951
A Outer diameter
Note
Action Note
1 It is possible to use any RFID solution, with the
correct dimensions. ABB has verifed function on
some suppliers fulfilling the requirements of NFC
compatible devices (13.56 Mhz) according to ISO
14443 or ISO 15693.
Note
xx1500000890
Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new.
Spare part Article number Note
Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration holes may cause severe damage to the
robot and/or personnel.
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
Note
3 Check if the standard calibration data for axes 4 If the data is optimized, the calibra-
or 5 are updated with wrist optimization. tion routine Wrist Optimization
This is shown in the calibration overview/summary must be re-run after standard calib-
window on the FlexPendant. ration.
See Calibrating with Wrist Optimiza-
tion method on page 826.
Note
3 The calibration method used at ABB factory for The FlexPendant will give all inform-
each axis is shown, as well as calibration method ation needed to proceed with Axis
used for the robot during last field calibration. Calibration.
Action Note
4 Valid for RobotWare 6
Tap Call Calibration Method. The software will
automatically call for the procedure for the valid
calibration method. If not, tap Call Routine and
then tap Axis calibration.
5 Valid for RobotWare 7
Tap Calibration Methods on the right pane and
then tap Calibration. The software will automatic-
ally call for the procedure for the valid calibration
method.
6 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 819.
CAUTION
After calibration
Action Note
1 Check the o-ring on the fixed calibration pin.
Replace if damaged or missing.
2 Reinstall the protective cover on the fixed calibra-
tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.
xx1600002102
xx1500000952
Tip
Select positions with large reorientations around the TCP. For best results,
make sure that axis 4 and 5 have large movements.
a Jog the robot to an appropriate position,
A, for the first approach point.
Use small increments to accurately posi-
tion the tool tip as close to the reference
point as possible.
b Tap Modify Position to define the point.
c Repeat for each approach point to be
defined, positions B, C, and D.
Jog away from the fixed world point to
achieve the best result. Just changing the
tool orientation will not give as good a
result.
en0400000906
5 The robot moves to the optimized positions for the wrist axes and
automatically overwrites previous calibration data.
WARNING
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Introduction
Check the synchronization position of the robot 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 the Jog window on
the FlexPendant.
6 Decommissioning
6.1 Introduction to decommissioning
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
Note
Transportation
Prepare the robot or parts before transport, this to avoid hazards.
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Note
DANGER
General
There is much energy stored in the balancing device. Therefore a special procedure
is required to disassemble it. The coil springs inside the balancing device exert a
potentially lethal force unless disassembled properly.
The device must be disassembled by a decommissioning company.
Required equipment
DANGER
Do not, under any circumstances, deal with the balancing device in any other
way than that detailed in the product documentation! For example, attempting
to open the balancing device is potentially lethal!
4 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft.
figure. The measurements shown below are maxim-
um values!
20
0
mm
m
m
0
40
xx0700000391
5 Cut the coils of the springs inside the Use a cutting torch with a long shaft.
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!
Action Note
6 Double-check the number of coils cut and
make sure all the tension in the springs is
removed.
Double-check the number of coils cut and
make sure all the tension in the springs is
removed.
7 Robot description
7.1 Type A vs type B motors
xx1500001058 xx1500001057
Note
The article numbers in the table can not be used for ordering spare parts. The
numbers are only used for identification of installed motors.
See Product manual, spare parts - IRB 6700/IRB 6700Inv for spare part numbers.
Robot Article number Article number Reach Reach Reach Reach Reach Reach Reach Reach
axis Type A motor Type B motor /2.65 /2.80 /3.05 /3.20 /2.60 /2.85 /2.70 /3.00
1 3HAC045060-001 3HAC055433-001 X X X X X X
3HAC051321-001 3HAC055442-001 X X
2 3HAC045061-001 3HAC055434-001 X X X X X X
3HAC051323-001 3HAC055443-001 X X
Robot Article number Article number Reach Reach Reach Reach Reach Reach Reach Reach
axis Type A motor Type B motor /2.65 /2.80 /3.05 /3.20 /2.60 /2.85 /2.70 /3.00
3 3HAC045063-001 3HAC055435-001 X X X X X X
3HAC051323-001 3HAC055443-001 X X
4 3HAC045064-001 3HAC055436-001 X X X X X X
3HAC045762-001 3HAC055449-001 X X
5 3HAC045064-001 3HAC055436-001 X X X X X X X X
6 3HAC045066-001 3HAC055445-001 X X X X X X
3HAC045067-001 3HAC055438-001 X X
Interchangeable parts
Use the table to see if type A and type B motors are interchangeable on each robot
axis.
Robot axis Motor replacement from Requirements/notes for replacing type A motor
type A to type B with type B motor
1 Fully interchangeable.
2 Fully interchangeable.
3 Fully interchangeable.
4 Fully interchangeable.
5 Partly interchangeable. Replacement to type B requires replacement of
the heat protection plates that are fitted to the
motor.
6 Interchangeable in a wrist A type B motor does not fit a wrist that is manu-
that is manufactured in and factured before October 2015.
after October 2015.
8 Reference information
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
General
The product is compliant with ISO 10218-1:2011, Robots for industrial environments
- Safety requirements - Part 1 Robots, and applicable parts in the normative
references, as referred to from ISO 10218-1:2011. In case of deviation from ISO
10218-1:2011, these are listed in the declaration of incorporation. The declaration
of incorporation is part of the delivery.
Robot standards
Standard Description
ISO 9283 Manipulating industrial robots – Performance criteria and re-
lated test methods
ISO 9787 Robots and robotic devices – Coordinate systems and motion
nomenclatures
ISO 9946 Manipulating industrial robots – Presentation of characteristics
Standard Description
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements, normative reference from ISO 10218-
1
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design, normative reference
from ISO 10218-1
Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
ments
EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus-
trial robots — Part 1: Robots
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal
General
This section describes how to tighten the various types of screw joints on ABB
robots.
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 screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• 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%!
Tightening torque for oil-lubricated screws with slotted or cross-recess head screws
The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
Note
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M24 680 960 1150
Tightening torque for lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws
The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note
Note
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
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
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 standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
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 848, and of special tools, listed directly in the instructions
and also gathered in this section.
Special tools
Balancing device
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 6 gearbox
Cable harness
Axis 1 motor
Axis 2 motor
Axis 3 motor
Axis 4 motor
Axis 5 motor
Axis 6 motor
Turning disc
Lower arm
Upper arm
(link ear)
device)
Wrist
SMB
Tools and equipment with spare part number:
(These tools can be ordered from ABB)
Guide pins
3HAC15520-1 Guide pin, M8x100 2
3HAC15521-2 Guide pin, M10x150 2i 2i 2i 2 2 2 2
3HAC13056-2 Guide pin, M12x150 x x 2 2 i 2 i 2 i x x
3HAC13056-3 Guide pin, M12x200 x x x x x
3HAC13120-2 Guide pin, M16x150 x x x
3HAC13120-3 Guide pin, M16x200 x x x
Lifting accessories
xx1200001241
Lifting eye
3HAC16131-1 2 2 2 2 2
M12
xx1200001242
Lifting eye
3HAC14457-4 2 x
M16
xx1200001242
Lifting shackle
- x x x x x
SA-10-8-NA1
xx1200001243
Balancing device
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 6 gearbox
Cable harness
Axis 1 motor
Axis 2 motor
Axis 3 motor
Axis 4 motor
Axis 5 motor
Axis 6 motor
Turning disc
Lower arm
Upper arm
(link ear)
device)
Wrist
SMB
Tools and equipment with spare part number:
(These tools can be ordered from ABB)
Fender washer
- Outer diameter: minimum 26 mm, x x x x x
maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.
Roundsling, 1.5 m
- Length: 1.5 m. Lifting capacity: x x x
2,000 kg.
Roundsling, 1 m
- Length: 1 m, lifting capacity: 1,000 x x x x x x x x x x
kg.
3HAC047054-003 Fork lift accessory set x x x x x
Press, puller and unloading tools
3HAC12475-6 AdapterM20-M16 x x x
3HAC028920-001 Dismantle and mounting tool x x x x x
xx1400000726
xx1300000672
Balancing device
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 6 gearbox
Cable harness
Axis 1 motor
Axis 2 motor
Axis 3 motor
Axis 4 motor
Axis 5 motor
Axis 6 motor
Turning disc
Lower arm
Upper arm
(link ear)
device)
Wrist
SMB
Tools and equipment with spare part number:
(These tools can be ordered from ABB)
Removal tools
- Screws M8x75, fully threaded 3
3HAC057339-002 Removal tool kit M12 and M14 xi xi xi x x x
3HAC057339-002 Removal tool kit M12 and M14 x i x i x i x x
Other tools
- 24 VDC power supply x x x x x x x x x x x x x
xx1700001659
xx1700002195
- Leak-down tester x x x x x x x x x x
- Lock screw, M16x120 x x x x
- Oil collecting vessel x x x x x x
- Oil dispenser x x x x x x
Balancing device
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 6 gearbox
Cable harness
Axis 1 motor
Axis 2 motor
Axis 3 motor
Axis 4 motor
Axis 5 motor
Axis 6 motor
Turning disc
Lower arm
Upper arm
(link ear)
device)
Wrist
SMB
Tools and equipment with spare part number:
(These tools can be ordered from ABB)
3HAC067546-001 viii
3HAC067547-001 ix Pinion x
3HAC067545-001 x
xx1800001147
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 delivered with each piece of lifting accessories.
The instructions delivered with the lifting accessories should be stored for later
reference.
9 Spare parts
9.1 Spare part lists and illustrations
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document for registered users on myABB Business Portal,
www.abb.com/myABB.
Tip
10 Circuit diagrams
10.1 Circuit diagrams
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.abb.com/myABB.
See the article numbers in the tables below.
Controllers
Manipulators
Index battery
replacing, 193
battery shutdown
A service routine, 193
Absolute Accuracy, calibration, 802
bearing
additional mechanical stop location, 154
balancing device front eye, 196
allergenic material, 30
brake release, 84
aluminum
brake release unit
disposal, 832
replacing, 298
ambient humidity
brakes
operation, 46
testing function, 38
storage, 45
BRU
ambient temperature
replacing, 298
operation, 46
buttons for brake release, 84
storage, 45
assembly instructions, 41 C
assessment of hazards and risks, 30 cabinet lock, 31
axis-6 cable harness
gearbox replacing, 238, 262
replacing, 787 cable harness attachments, 146
axis-1 gearbox cabling, robot, 104
replacing, 709 cabling between robot and controller, 104
axis 1 calibrating
gearbox robot, 813
replacing, 590 roughly, 807, 811
mechanical stop calibrating robot, 813, 825–826
replacing, 502 calibration
motor Absolute Accuracy type, 800
replacing, 506 rough, 807, 811
axis 2 standard type, 800
gearbox verification, 828
replacing, 671 when to calibrate, 803
motor calibration, Absolute Accuracy, 802
replacing, 520 calibration manuals, 802
axis 3 calibration marks, 804
gearbox Calibration Pendulum
replacing, 748 overview of method, 825
motor calibration position
replacing, 534 jogging to, 829–830
axis 4 scales, 804
motor calibration scales, 804
replacing, 547 CalibWare, 800
axis 5 carbon dioxide extinguisher, 31
motor cast iron
replacing, 558 disposal, 832
axis 6 changing oil
motor axis 1, 162
replacing, 575 axis 2, 169
Axis Calibration, 813 axis 3, 174
calibration tool axis 4, 180
article number, 816, 819 axis 5, 184
examining, 816 axis 6, 188
installation position, 818 cleaning, 198
overview of method, 813 climbing on robot, 34
procedure on FlexPendant, 819, 826 Cold environments, 115
protective cover and protection plug, 818–819 connecting the robot and controller, cabling, 104
cooling fan, 109
B copper
balancing device
disposal, 832
inspection, 142
lubrication of front eye bearing, 196 D
replacing, 471 damage to additional mechanical stop, 154
base plate damage to mechanical stop, 152
guide pins, 66 dampers
securing, 66 inspection, 156
batteries direction of axes, 806
disposal, 832
E I
environmental information, 832 information labels location, 148
EPS, 99 inspecting
equipment, on robot, 87 additional mechanical stop, 154
ESD cable harness, 146
damage elimination, 57 dampers, 156
sensitive equipment, 57 information labels, 148
expected life, 121 mechanical stop, 152
extended working range, 99 motor seal, 122
extended working range, axis 1, 99 inspecting balancing device, 142
inspecting oil levels
F axis 1, 124
fan, 109 axis 2, 129
fire extinguishing, 31 axis 3, 132
fitting equipment to robot, 87 axis 4, 135
FlexPendant axis 5, 137
jogging to calibration position, 829–830 axis 6, 139
MoveAbsJ instruction, 829–830 installation
updating revolution counters, 808, 812 mechanical stop axis 1, 102
foundation installation on track motion carriage, 82
requirements, 45 installation procedure, 64
securing robot, 81 installing
motor cooling fan, 109
G instructions for assembly, 41
gearbox integrator responsibility, 30
axis-6 intervals for maintenance, 119
replacing, 787
axis 1 L
replacing, 590 labels
axis 2 robot, 23
replacing, 671 leak-down test, 202
axis 3 lifting
replacing, 748 complete arm system, 211
inspecting oil level axis 1, 124 lower and upper arm together, 222, 229
inspecting oil level axis 2, 129 robot, 72, 75
inspecting oil level axis 3, 132 upper arm, 235
inspecting oil level axis 4, 135 lifting accessory, 847
inspecting oil level axis 5, 137 lifting accessory, robot, 73
inspecting oil level axis 6, 139 lifting robot
oil change axis 1, 162 with lifting accessory, 73
oil change axis 2, 169 limitation of liability, 19
oil change axis 3, 174 Lithium
oil change axis 4, 180 disposal, 832
oil change axis 5, 184 loads on foundation, 44
oil change axis 6, 188 lock and tag, 31
gearbox axis-1 lower arm
replacing, 631 replacing, 385
gearboxes lubricants, 34
location of, 160 lubricating
grease, 34 spherical roller bearing, 196
disposal, 832 lubrication
guide pins, base plate, 66 amount in gearboxes, 160
type of lubrication, 160
H
hanging M
installed hanging, 30 magnesium
hazard levels, 21 disposal, 832
hazardous material, 832 maintenance intervals, 119
height maintenance schedule, 119
installed at a height, 30 manually releasing brakes, 84
holes for equipment, 87 mechanical stop
hot surfaces, 34 axis 1, 102
HRA, 30 replacing, 502
humidity mechanical stop location, 152
operation, 46 motor
storage, 45 axis 1
replacing, 506
ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC044266-001, Rev AB, en