3HAC044266 PM IRB 6700-En

ROBOTICS
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
Document ID: 3HAC044266-001

Revision: AB
© Copyright 2013 - 2023 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

Table of contents
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
2 Installation and commissioning 41

2.1 Introduction to installation and commissioning ....................................................... 41
2.2 Unpacking ....................................................................................................... 42
2.2.1 Pre-installation procedure ......................................................................... 42
2.2.2 Technical data ........................................................................................ 43
2.2.3 Working range ........................................................................................ 47
2.2.4 Risk of tipping/stability ............................................................................. 53
2.2.5 Main dimensions ..................................................................................... 55
2.2.6 The unit is sensitive to ESD ....................................................................... 57
2.3 On-site transportation ........................................................................................ 58
2.3.1 Robot transportation precautions ............................................................... 58
2.3.2 Securing the robot with a transport support ................................................. 62
2.4 On-site installation ............................................................................................ 64
2.4.1 Brief installation procedure ....................................................................... 64
2.4.2 Lifting the base plate ................................................................................ 65
2.4.3 Securing the base plate ............................................................................ 66
2.4.4 Lifting the robot ...................................................................................... 72
2.4.4.1 Lifting the robot with fork lift .......................................................... 72
2.4.4.2 Lifting robot with lifting accessory (recommended lifting method) ......... 73
2.4.4.3 Lifting the robot with roundslings .................................................... 75
2.4.5 Orienting and securing the robot ................................................................ 79
2.4.6 Manually releasing the brakes ................................................................... 84
2.4.7 Loads fitted to the robot, stopping time and braking distances ......................... 86
2.4.8 Fitting equipment to the robot ................................................................... 87
2.4.9 Extended working range, axis 1 (option) ..................................................... 99
2.5 Restricting the working range .............................................................................. 101
2.5.1 Axes with restricted working range ............................................................. 101
2.5.2 Mechanically restricting the working range of axis 1 ...................................... 102
2.6 Electrical connections ........................................................................................ 104
2.6.1 Robot cabling and connection points .......................................................... 104
2.7 Installation of options ......................................................................................... 108
2.7.1 Safety lamp (option for IRC5) ..................................................................... 108
2.7.2 Installing the motor cooling fan (option) ...................................................... 109
2.8 Start of robot in cold environments ...................................................................... 115
2.9 Test run after installation, maintenance, or repair .................................................... 116
Product manual - IRB 6700 5

3HAC044266-001 Revision: AB
Table of contents
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
3.3.8 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
3.4.8 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
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
6 Product manual - IRB 6700

Table of contents
4.4.2 Refitting the cable harness ....................................................................... 262

4.4.3 Replacing the SMB ................................................................................. 292
4.4.4 Replacing the brake release unit ............................................................... 298
4.5 Upper and lower arms ........................................................................................ 303
4.5.1 Replacing the upper arm .......................................................................... 303
4.5.2 Replacing the wrist ................................................................................. 347
4.5.3 Replacing the turning disc ........................................................................ 372
4.5.4 Replacing the process turning disc ............................................................. 378
4.5.5 Replacing the lower arm .......................................................................... 385
4.6 Frame and base ................................................................................................ 453
4.6.1 Replacing spherical roller bearing, link ear ................................................... 453
4.6.2 Replacing the balancing device ................................................................. 471
4.6.3 Replacing the rear bearings on the balancing device ..................................... 490
4.6.4 Replacing the stop pin ............................................................................. 502
4.7 Motors ............................................................................................................ 506
4.7.1 Replacing the axis-1 motor ....................................................................... 506
4.8 Gearboxes ....................................................................................................... 590
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) ..................................................................... 590
LID) ...................................................................................................... 631
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) ..................................................................... 671
LID) ...................................................................................................... 709
4.8.5 Replacing the axis-3 gearbox .................................................................... 748
4.8.6 Replacing the axis-6 gearbox .................................................................... 787
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

Table of contents
6.2 Environmental information .................................................................................. 832

6.3 Scrapping of robot ............................................................................................. 834
6.4 Decommissioning of balancing device ................................................................... 835
7 Robot description 839

7.1 Type A vs type B motors .................................................................................... 839
8 Reference information 841

8.1 Introduction ...................................................................................................... 841
8.2 Applicable standards ......................................................................................... 842
8.3 Unit conversion ................................................................................................. 843
8.4 Screw joints .................................................................................................... 844
8.5 Weight specifications ......................................................................................... 847
8.6 Standard toolkit ................................................................................................ 848
8.7 Special tools .................................................................................................... 849
8.8 Lifting accessories and lifting instructions .............................................................. 854
9 Spare parts 855

9.1 Spare part lists and illustrations ........................................................................... 855
10 Circuit diagrams 857

10.1 Circuit diagrams ................................................................................................ 857
Index 859

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 6700
• maintenance of the IRB 6700
• mechanical and electrical repair of the IRB 6700
The robot described in this manual has the following protection types:
• Standard
• Foundry Plus
This manual describes the manipulator using either the IRC5 or the OmniCore
controller.
Product manual scope

The manual covers all variants and designs of the IRB 6700. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
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
It is the responsibility of the integrator to conduct a risk assessment of the final

application.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
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.
Continues on next page

Continued
References
Documentation referred to in the manual, is listed below.
General
Document name Document ID

Product manual, spare parts - IRB 6700/IRB 6700Inv 3HAC044268-001
Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Directions for use - Fork lift accessory set 3HAC047054-001 3HAC048484-002
Product manual - DressPack/SpotPack IRB 6700 3HAC044270-001
Safety manual for robot - Manipulator and IRC5 or OmniCore con- 3HAC031045-001
troller i
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
For OmniCore robots

Product specification - IRB 6700 3HAC080365-001
Product manual - OmniCore V250XT Type A 3HAC084692-001
Product manual - OmniCore V250XT 3HAC073447-001
Operating manual - OmniCore 3HAC065036-001
Technical reference manual - System parameters 3HAC065041-001
For IRC5 robots

Product specification - IRB 6700 3HAC044265-001
Product manual - IRC5 3HAC047136-001
For IRC5 robots, with main computer DSQC1000.
Product manual - IRC5 3HAC021313-001
For IRC5 robots, with main computer DSQC 639.
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Calibration Pendulum 3HAC16578-1
Technical reference manual - System parameters 3HAC050948-001
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.
Continued
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.

Continued
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.

Continued
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.

Continued
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.

Continued
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
All documents can be found via myABB Business Portal, www.abb.com/myABB.
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.
Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
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.

Continued
• Examples of 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.

How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
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
1.1.1 Limitation of liability
1 Safety
1.1 Safety information
1.1.1 Limitation of liability
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.
Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved for their intended use. The installation and/or use of non-original spare
parts and equipment can negatively affect the safety, function, performance, and
structural properties of the robot. ABB is not liable for damages caused by the use
of non-original spare parts and equipment.

1 Safety
1.1.2 Requirements on personnel
1.1.2 Requirements on personnel
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.
Personal protective equipment

Use personal protective equipment, as stated in the instructions.

1 Safety
1.2.1 Safety signals in the manual
1.2 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
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.
WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.
ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.
CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.
ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.
NOTE Signal word used to indicate important facts and

conditions.

1 Safety
Continued
Symbol Designation Significance

TIP Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.

1 Safety
1.2.2 Safety symbols on manipulator labels
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.
Symbols on safety labels
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

1 Safety
Continued
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
Before disassembly, see product manual
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

1 Safety
Continued
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

1 Safety
Continued
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

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Adjustable chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
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
Shut off with handle

Use the power switch on the controller.
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648

1 Safety
1.3 Robot stopping functions
1.3 Robot stopping functions
Protective stop and emergency stop

The protective stops and emergency stops are described in the product manual
for the controller.
For more information see:
• Product manual - OmniCore V250XT
• Product manual - OmniCore V250XT Type A
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller

1 Safety
1.4 Safety during installation and commissioning
National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform a risk assessment.
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.
Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
respective product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.

1 Safety
Continued
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.

1 Safety
Continued
Pneumatic or hydraulic related hazards
Note
The pressure in the complete pneumatic or hydraulic systems must be released

before service and maintenance.
All components in the robot system that remain pressurized after switching off
the power to the robot must be marked with clearly visible drain facilities and a
warning sign that indicates the hazard of stored energy.
Loss of pressure in the robot system may cause parts or objects to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Verify the safety functions

Before the robot system is put into operation, verify that the safety functions are
working as intended and that any remaining hazards identified in the risk
assessment are mitigated to an acceptable level.

1 Safety
1.5 Safety during operation
1.5 Safety during operation
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
Unexpected movement of robot arm
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
WARNING
equipment.

1 Safety
1.6.1 Safety during maintenance and repair
1.6 Safety during maintenance and repair
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
Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
Gearbox lubricants (oil or grease)

When handling oil, grease, or other chemical substances the safety information of
the respective manufacturer must be observed.
Note
Take special care when handling hot lubricants.

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease

1 Safety
Continued

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
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.
Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume

1 Safety
Continued

For lifetime reasons always drain
as much oil as possible from the
gearbox. The magnetic oil plugs
will gather residual metal chips.
Contaminated oil in
gearboxes
Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads
to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions, robot on page 46.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation and operation.

1 Safety
1.6.2 Emergency release of the robot axes
1.6.2 Emergency release of the robot axes
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.

1 Safety
1.6.3 Brake testing
1.6.3 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be 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
It is recommended to run the service routine BrakeCheck as part of the regular

maintenance, see the operating manual for the robot controller.
For robots with the option SafeMove, the Cyclic Brake Check routine is
recommended. See the manual for SafeMove in References on page 10.

1 Safety
1.7 Safety during troubleshooting
1.7 Safety during troubleshooting
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
Troubleshooting on the controller while powered on must be performed by

personnel trained by ABB or by ABB field engineers.
CAUTION
Risk of hot surfaces that can cause burns.

A risk assessment must be done to address both robot and robot system specific
hazards.
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.

1 Safety
1.8 Safety during decommissioning
1.8 Safety during decommissioning
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
WARNING
equipment.

2 Installation and commissioning
2.1 Introduction to installation and commissioning

2.1 Introduction to installation and commissioning
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.
• Product manual - OmniCore V250XT Type A

2.2.1 Pre-installation procedure
2.2 Unpacking
2.2.1 Pre-installation procedure
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Prerequisites for installation personnel

Installation personnel working with an ABB product must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/maintenance/repair work
• conform to all national and local codes.
Checking the pre-requisites for installation
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
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 43
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 45
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 46
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 44
• Protection classes, robot on page 46
• Requirements, foundation on page 45
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 53
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 64
11 Install required equipment, if any.
• Safety lamp (option for IRC5) on page 108

2.2.2 Technical data
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.

Continued
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
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
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±7.4 kN i / ±8.7 kN ii ±19.8 kN i / ±21.8 kN ii
Force z 14.6 ±4.5 kN i / 18.0 ±5.4 kN ii 14.6 ±15.7 kN i / 18.0 ±17.4 kN ii
Torque xy ±21.0 kNm i / ±24.9 kNm ii ±37.1 kNm i / ±45.3 kNm ii

Continued
Force Endurance load (in operation) Max. load (emergency stop)

Torque z ±5.0 kNm i / ±6.5 kNm ii ±11.4 kNm i / ±15.5 kNm ii
i Valid for IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID, 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 Valid for IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID.
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.
Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25°C (-13°F)
Maximum ambient temperature +55°C (+131°F)
Maximum ambient temperature (less than 24 hrs) +70°C (+158°F)
Maximum ambient humidity Maximum 95% at constant temper-
ature.

Continued
Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5°C i (41°F)
Maximum ambient temperature +50°C (122°F)
Maximum ambient humidity Maximum 95% at constant temper-
ature.
i At low environmental temperature (below 10° C) a warm-up phase is recommended to be run with
the robot. Otherwise there is a risk that the robot stops or runs with lower performance due to
temperature dependent oil and grease viscosity.
Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class i
Manipulator, protection type Standard IP67
Manipulator, protection type Foundry Plus IP67
i According to IEC 60529.

2.2.3 Working range
2.2.3 Working range
Working range
Axis Type of motion Working range Note

Axis 1 Rotation motion ±170° or ±220° (op-
tion)
Axis 2 Arm motion -65°/+85° i
Axis 3 Arm motion -180°/+70°
Axis 4 Wrist motion ±300° Default value.
Axis 5 Bend motion ±130° ii
Axis 6 Turn motion ±360° iii Default value.
±93.7 revolutions Maximum value.
The default working range for axis
6 can be extended by changing
parameter values in the software.
i Working range for variants IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID:
+85° to -65° when axis 3 is within +70° to -45°
+85° to -58° when axis 3 is within +70° to -180°
ii Working range +120° to -120° for robots with LeanID (LID).
iii Working range +220° to -220° for robots with LeanID (LID).
Working range axis 5 and axis 6 for LeanID (LID)

Allowed working area for axis 6 related to axis 5 position is shown in the figure
below.
xx1300001587

2.2.3 Working range
Continued
Illustration, working range IRB 6700-235/2.65

This illustration shows the unrestricted working range of the robot.
3114
320
1187 920
1908 2650
xx1300000281
Robot type Handling capacity Reach

IRB 6700 235 kg 2.65 m

3259
308
1281 958
2039 2794
xx1300000282

IRB 6700 205 kg 2.80 m

2.2.3 Working range
Continued

3520
726
1527 1109
2314 3056
xx1300000283

IRB 6700 175 kg 3.05 m

3665
713
1604 1067
2445 3200
xx1300000284

IRB 6700 150 kg 3.20 m

2.2.3 Working range
Continued

3065
282
1150 911
1859 2601
xx1300000341

IRB 6700 200 kg 2.60 m

3312
529
1352 994
2106 2848
xx1300000340

IRB 6700 155 kg 2.85 m

2.2.3 Working range
Continued

3154
349
1187 957
1850 2720
xx1400001137

IRB 6700 300 kg 2.70 m

3399
596
1518 1057
2097 2967
xx1400001138

IRB 6700 245 kg 3.00 m

2.2.3 Working range
Continued
Turning radius axis 1

170°
R1
170°
xx1300001082
Robot variant R1 (mm)

IRB 6700-235/2.65 2650
IRB 6700-205/2.80 2794
IRB 6700-175/3.05 3056
IRB 6700-150/3.20 3200
IRB 6700-200/2.60 2601
IRB 6700-155/2.85 2848
IRB 6700-300/2.70 2720
IRB 6700-245/3.00 2967

2.2.4 Risk of tipping/stability
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
Axis number Angle of axis

Axis 1 0°

Continued
Axis number Angle of axis

Axis 2 -34 to -39°
Axis 3 +70°
Axis 4 0°
Axis 5 0°
Axis 6 0°
Note
The robot might be positioned in a different position at delivery, due to actual

configurations and options (for example DressPack).
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.

2.2.5 Main dimensions
Illustration
F
G
A
200
E
D
780
377
1009
B 745 C
360
J
1009
H
360
xx1300000241
Dimensions for different robot variants
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

Continued
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

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

2.3.1 Robot transportation precautions
2.3 On-site transportation
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.
Method 1 - recommended method

Transportation according to method 1 is strongly recommended by ABB.
xx0800000030
Always follow these instructions when transporting an ABB robot according to

method 1:
• Always remove the tool before transportation of the robot.
• Always place the robot in the ABB recommended transport position, described
in section Risk of tipping/stability on page 53.
• Always read and follow the instructions in section Pre-installation procedure
on page 42

Continued
Method 2 - transportation with a tool mounted to the robot

Transportation according to method 2 is approved by ABB, only if use of method
1 is not possible.
Always follow these instructions when transporting an ABB robot according to
method 2:
• Always read and follow the instructions in section Securing the robot with a
transport support on page 62
• Always place the robot in the ABB recommended transport position for robot
with tool, described in sub section Transport position with a transport support
on page 60.
• Always use the recommended transport support described in sub section
Recommended transport support on page 61.
IRB 6700
C
D
xx0800000037
A Transport Support
B Hexagon socket head cap screw M16x140
C Threaded bar M10x200
D Nut M10

Continued
Transport position with a transport support

All transportation of the robot with tool must follow these instructions.
IRB 6700
xx0800000040

Continued
Recommended transport support

Always use the recommended transport support when transporting a robot with
tool.
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
Variant IRB IRB IRB IRB IRB IRB IRB IRB

6700- 6700- 6700- 6700- 6700- 6700- 6700- 6700-
235/2.65 205/2.80 175/3.05 150/3.20 200/2.60 155/2.85 300/2.70 245/3.00
Lower 1135 1280 1135 1280 1125 1125 1145 1145
arm L
A 1000 1160 630 860 1004 817 1000 817
B 21 21 21 21 21 21 6 6

2.3.2 Securing the robot with a transport support
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.
Fitting the transport support

Illustration for fitting the transport support
xx0800000062

Continued
Fitting the transport support
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.
5 Use the brake release for axis 5 and 6 to

reach the final resting position for the tool,
see the section Manually releasing the brakes
on page 84

2.4.1 Brief installation procedure
2.4 On-site installation
2.4.1 Brief installation procedure
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 Pan-
el Mounted Controller
• Product manual - OmniCore
V250XT
V250XT Type A
5 Configure the safety settings. See
V250XT
V250XT Type A
6 How to start and run the robot is described in the See
product manual for the controller. • Product manual - IRC5
V250XT
V250XT Type A
7 Install required equipment, if any.
• Safety lamp (option for IRC5) on page 108
8
DANGER
Make sure all safety requirements are met when

performing the first test run. See Test run after
installation, maintenance, or repair on page 116.

2.4.2 Lifting the base plate
2.4.2 Lifting the base plate
Required equipment
Equipment Article number Note

Lifting eye, M16 3HAC14457-4 3 pcs
Lifting slings Length: approx. 2 m
Hole configuration
xx0200000096
A Attachment holes for lifting eyes (x3)
Lifting, base plate
Action Note
1
CAUTION
The base plate weighs 353 kg. All lifting accessories

used must be sized accordingly.
2 Fit lifting eyes in specified holes. Shown in figure Hole configur-

ation on page 65.
3 Fit lifting slings to the eyes and to the lifting accessory.
CAUTION
Lift and move the base plate very slowly. If the base
plate starts to swing it is a risk for injuries or damage.

2.4.3 Securing the base plate
Base plate drawing

The following figure shows the option base plate (dimensions in mm).
540
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
0,2 Common Zone E, F, G, H

M
5
±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)

Continued
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

Continued
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
A Color: RAL 9005

Thickness: 80-100 µm
Weight: 360 kg

Continued
Guide pins
25g6
(A)
15
18
12k6
XX1500000248
Pos Description
A Cylindrical guide pin (x2)
Assembly of guide pins

(A)
800
(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.

Continued
Base plate, orienting grooves and leveling bolts

The illustration below shows the orienting grooves and attachment holes for leveling
bolts in the base plate.
B A
B
B
A
xx1500000312
A Orienting grooves (3 pcs)

B Levelling bolts, attachment holes (4 pcs)
Required equipment

Base plate 3HAC051821- Includes
001 • guide pins
• levelling screws, 9ADA120-79
• attachment screws and washers
for securing the robot to the
base plate.
Standard toolkit - Content is defined in section Standard
toolkit on page 848.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.

Continued
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
The base plate weighs 353 kg! All lifting

equipment used must be sized accordingly!
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
All screws and pins are delivered in a plastic

bag together with the base plate. (A)
(B)
B-B
B B
xx1500000250
A Cylindrical guide pin

B M5 x 40. Tightening torque 6 Nm.
(x2)

2.4.4.1 Lifting the robot with fork lift
2.4.4 Lifting the robot
2.4.4.1 Lifting the robot with fork lift
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 tools and equipment

Fork lift accessory set 3HAC047054-003 Contains fork lift pockets and all
required hardware for installation.
User instructions are enclosed
with the tool, see Directions for
use - Fork lift accessory for IRB
6700.
Required documents
Document Document number

Directions for use - Fork lift accessory for IRB 6700 3HAC048484-002
Lifting the robot
Action Note
1 Lift the robot according to the user instructions
enclosed with the fork lift accessory.

2.4.4.2 Lifting robot with lifting accessory (recommended lifting method)
General
This section contains a general overview of how to lift the complete robot using
special lifting accessory.
Illustration, lifting accessory

The following figure shows the principle for how to use and lift the entire robot with
lifting accessory. For a more detailed instruction, see the user instructions enclosed
with the accessory.
Note
The user manual may be out of date. The latest revision is available for download
via myABB Business Portal, www.abb.com/myABB.
xx0200000153
Required equipment

Lifting accessory, robot 3HAC15607-1 Includes user instructions 3HAC15971-2

Continued
Slings attached directly onto robot

This section details how to lift and move the robot using lifting slings when these
are attached directly onto the robot.
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
Handling the tool incorrectly will cause serious

injury.
Read and follow enclosed user instructions
for the tool.
4
CAUTION
The IRB 6700 robot weighs 1300 kg.

All lifting accessories used must be sized ac-
cordingly!
5
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
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.

2.4.4.3 Lifting the robot with roundslings
Roundslings used for lifting and transporting

The robot can be lifted and transported using roundslings according to this section.
Attaching the roundslings
C
B
Variant Length A (1 pc) Length B (1 pc)

Do not strain! Do not strain!
IRB 6700-235/2.65 Roundsling, 2 m Roundsling, 2 m
IRB 6700-220/2.65 LID Roundsling, 2 m Roundsling, 2 m
IRB 6700-175/3.05 Roundsling, 2.5 m Roundsling, 2 m
IRB 6700-155/3.05 LID Roundsling, 2.5 m Roundsling, 2 m

Continued
Variant Length A (1 pc) Length B (1 pc)

Do not strain! Do not strain!
IRB 6700-300/2.70 Roundsling, 2 m Roundsling, 2.5 m
IRB 6700-270/2.70 LID Roundsling, 2 m Roundsling, 2.5 m
IRB 6700-245/3.00 Roundsling, 2.5 m Roundsling, 2.5 m
IRB 6700-220/3.00 LID Roundsling, 2.5 m Roundsling, 2.5 m
C Roundsling, 2.5 m (4 pcs)

D Lifting eye, M20 (4 pcs)
Required equipment
See quantity of roundslings in figure Attaching the roundslings on page 75.
Equipment, etc. Article number Note

Overhead crane -
Lifting eye, M20 - Working load limit: 2,000 kg.
Roundsling, 2 m - Length: 2 m. Lifting capacity: 2,000 kg.
Roundsling, 2.5 m - Length: 2.5 m. Lifting capacity: 2,000 kg.
Lifting the robot with roundslings

Use this procedure to lift the robot with roundslings.
Jogging the robot to lifting position
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
The robot is likely to be mechanically un-

stable if not secured to the foundation.
913 65
(645 CL)
670 65
xx1300000356

Continued
Lifting the robot with roundslings
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
If the lifting eyes have sharp edges that

might damage the roundslings, lifting
shackles must be used to attach the
roundslings to the lifting eyes.
xx1300001572

Continued
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
The securing sling must not be strained at

lifting. It only secures for tipping.
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
The securing sling must not be strained at

lifting. It only secures for tipping.
xx1300001574
5
CAUTION
The IRB 6700 robot weighs 1300 kg.

All lifting accessories used must be sized
accordingly!
6
WARNING
Personnel must not, under any circum-

stances, be present under the suspended
load!
7 Raise the overhead crane to lift the robot.
CAUTION
Make sure that the roundsling running from

the front, left corner is positioned on the
correct side of the brake release unit plate
when stretching the roundslings with the
crane.

2.4.5 Orienting and securing the robot
General
This section details how to orient and secure the robot to the base plate in order
to run the robot safely.
It also contains information about securing the robot to a track motion.
Hole configuration, base

The figure shows the hole configuration used when positioning and securing the
robot.
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)

Continued
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)

Continued
Securing the robot to the base plate/foundation

Use this procedure to secure robot to base plate after fitting plate to the foundation.
The same procedure is also used to secure the robot to a track motion carriage.
See specific pictures for this in figure Securing the robot to a track motion on
page 82.
Action Note
(A)
1 Fit two guide pins to the guide pin holes in the 800
base plate.
Note
All screws and pins are delivered in a plastic (A)

bag together with the base plate. (B)
B-B
B B
xx1500000250
A Cylindrical guide pin (2 pcs)

B M5 x 40. Tightening torque 6
Nm. (x2)
2 Lift the robot. See Lifting the robot with roundslings
on page 75.
3 Move robot close to its installation location.
4 Guide the robot gently using two M24 screws Make sure the robot base is correctly
while lowering it into its mounting position. fitted onto the guide sleeves!
5 Fit the bolts and washers in the base attachment Specified in Attachment screws on
holes. page 80.
Note
Lightly lubricate screws before as-

sembly.
6 Tighten bolts in a crosswise pattern to ensure

that the base is not distorted.

Continued
Securing the robot to a track motion

Fitting manipulator to a standard carriage
xx1500000319
Pos Description
Note
There are versions with a flattened cylindrical guide pin in left rear of the base.

Continued
Fitting manipulator to a carriage plate

The figure below shows the carriage plate that is used as a second added carriage
for a double track or as a single carriage as mirrored, for track motions IRBT
6004/7004.
There are adapters fitted to the guide pin holes in each corner of the plate, to allow
the robot to be installed in-line, turned 90° or 180°.
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.

2.4.6 Manually releasing the brakes
Introduction to manually releasing the brakes

This section describes how to release the holding brakes for the motors of each
axis.
Location of brake release unit

The internal brake release unit is located as shown in the figure.
xx1200000964
Releasing the brakes

This procedure details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action Note
1 The internal brake release unit is equipped with Buttons are shown in figure Loca-
buttons for controlling the axes brakes. The buttons tion of brake release unit on
are numbered according to the numbers of the page 84.
axes.
If the robot is not connected to the controller, power
must be supplied to the connector R1.MP according
to the section Supplying power to connector R1.MP
on page 85.
2
DANGER
When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways.
Make sure no personnel is near or beneath the ro-
bot.

Continued
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.
Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector
R1.MP on the robot, in order to enable the brake release buttons.
Action Note
1
DANGER
Incorrect connections, such as supplying

power to the wrong pin, may cause all
brakes to be released simultaneously!
2 Supply 0V on pin 12 and 24V on pin 11.
xx0600002937

2.4.7 Loads fitted to the robot, stopping time and braking distances
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
Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached
to the robot. For more information, see product specification listed in References
on page 10.

2.4.8 Fitting equipment to the robot
General
Extra loads can be fitted on the upper arm housing, the lower arm, and on the
frame. Definitions of distances and masses are shown in the following figures. The
robot is supplied with holes for fitting extra equipment (see figure in Holes for fitting
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.
Frame (hip load)

Extra load can be fitted on the frame.
Description
Permitted extra load on frame JH = 100 kgm 2
Recommended position (see the fol- JH = JH0 + M4 x R 2
lowing figure) where:
• JH0 is the moment of inertia of the equipment
• R is the radius (m) from the center of axis 1
• M4 is the total mass (kg) of the equipment
including bracket and harness (≤ 250 kg)

Continued
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

Continued
(A)
400
200
xx1300000866
A Center of gravity 50 kg

Continued
Holes for fitting extra equipment

The holes are placed the same regardless of the controller. To simplify reading
the tables, the variants are presented first for IRC5, then for OmniCore.
Position of attachment holes - drawing 1, IRC5

E G H
H J
A K
(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

Continued
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.

Continued
Position of attachment holes - drawing 2, IRC5

B
C C
CL 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
(4x M10 20) CL Axis 1

456
50 J
25
377
K F G
(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

Continued
Position of attachment holes - drawing 1, OmniCore

E G H
H J
A K
(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.

Continued
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

Continued
Position of attachment holes - drawing 2, OmniCore

B
C C
CL 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
(4x M10 20) CL Axis 1

456
50 J
25
377
K F G
(2x M8)
(2x M8)
C-C
A 190 M
90
D
328
80
40
2x M8 12
CL Axis 5
100
xx1300000264
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

Continued
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
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

Continued
Tool flange, standard

Below is the standard tool flange. The guide pin hole is, in calibration position,
pointing upwards in Z-direction.
1,6
+0,018
12 H7 0
B
0,04 A
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
A Thread length: 18 mm.
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.

Continued
Tool flange, LeanID, LID variants

Below is the tool flange for option/variant LeanID (LID). The guide pin hole is, in
calibration position, pointing upwards in Z-direction.
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
A Thread length: 18 mm.
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.

2.4.9 Extended working range, axis 1 (option)
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.
Extending the working range
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
A Mechanical stop pin

3 In RobotWare, redefine the working range With the option Extended working range,
limitations in the system parameters, topic the maximum value for the system paramet-
Motion. The Arm parameters Upper Joint ers Upper Joint Bound and Lower Joint
Bound and Lower Joint Bound can be Bound is 3.84 respectively -3.84. The val-
changed to the values corresponding to ues are in radians, that is 3.84 radians =
the actual installation. 220 degrees.

Continued
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).

2.5.1 Axes with restricted working range
2.5 Restricting the working range
2.5.1 Axes with restricted working range
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
Adjustments must also be made in the robot configuration software (system

parameters). References to relevant manuals are included in the installation
procedures.

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

The illustration shows the mounting position of the stop pin and one of the additional
mechanical stops available for axis 1.
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

Continued
Required equipment

Movable mechanical stop set, axis 1 3HAC055744-001 IRB 6700-235/2.65, -220/2.65
(15°). 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
Includes attachment screws and
an assembly drawing.
Movable mechanical stop set, axis 1 3HAC048533-003 IRB 6700-300/2.70, -270/2.70
(15°). LID, -245/3.00, -220/3.00 LID
Includes attachment screws and
an assembly drawing.
Standard toolkit -
Technical reference manual - System - Article number is specified in
parameters section References on page 10.
Installation, mechanical stops axis 1

Use this procedure to fit the additional mechanical stops to axis 1 of the robot. An
assembly drawing is also enclosed with the product.
Action Note
1
DANGER
Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Fit the additional mechanical stop to the Tightening torque: 60 Nm.

frame according to the figure Mechanical
stops, axis 1 on page 102.
3 Adjust the software working range limitations The system parameters that must be
(system parameter configuration) to corres- changed (Upper joint bound and Lower
pond to the mechanical limitations. joint bound) are described in Technical
reference manual - System parameters.
4
WARNING
If the mechanical stop pin is deformed after

a hard collision, it must be replaced!
Deformed movable stops and/or additional
stops as well as deformed attachment
screws must also be replaced after a hard
collision.

2.6.1 Robot cabling and connection points
2.6 Electrical connections
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
Turn off the main power before connecting any cables.
CAUTION
Verify that the serial number is according to the number(s) in the Declaration of
Incorporation (DoI).
Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the serial measurement board.
Fan cables (option) Handles supply to and feedback from any cooling fan on
the robot.
Specified in the table Fan cables (option) on page 106.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
The customer cables also handle databus communication.
See the product manual for the controller, see document
number in References on page 10.
DressPack cables (option) Handles signals, process media and power feeding for
customer use, regarding material handling or spot welding.
See the Product manual - DressPack/SpotPack IRB 6700,
see document number in References on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
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.

Continued
Robot cable, power
Power cable length Article number

7m 3HAC026787-001
15 m 3HAC026787-002
22 m 3HAC026787-003
30 m 3HAC026787-004
Robot cable, signals
Signal cable length Article number

7m 3HAC068917-001
15 m 3HAC068918-001
22 m 3HAC068919-001
30 m 3HAC068920-001
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10

Continued
Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.
xx1500001600
Note
How to ground DressPack/SpotPack cables is detailed in the Product

manual - DressPack/SpotPack IRB 6700, see the document number in References
on page 10.
Fan cables (option)

These cables are not included in the standard delivery, but are included in the
delivery if the fan option is ordered. The cables are completely pre-manufactured
and ready to plug in.
Cabling to be installed on the robot is specified in section Installing the motor
cooling fan (option) on page 109.
Cabling between robot base and control cabinet, cooling fans

The cables specified below are specific for the IRC5 controller and used when the
robot is equipped with cooling fans. The cabling for the cooling fans runs all the
way from the robot base to the inside of the cabinet. Fans can also be ordered
without cables.
If equipping the robot with cooling fans, use the cabling specified below. The cables
for cooling fans listed below are used together with a distributing cable, also
specified below.
Cable Art. no. Connection point
Harness - cooling, 7 m 3HAC022723-001 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11

Continued
Cable Art. no. Connection point


2.7.1 Safety lamp (option for IRC5)
2.7 Installation of options
2.7.1 Safety lamp (option for IRC5)
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.

2.7.2 Installing the motor cooling fan (option)
Location of the axis-1 motor cooling fan

A cooling fan can be installed on the axis-1 motor as an option. The fan is not
possible to install on a robot with protection type Foundry Plus.
xx1800000156
Required spare parts
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 6700 via myABB Business Portal,
www.abb.com/myABB.
Spare part Article number Note

Fan unit set 3HAC051149-001 Only available for the axis-1 motor.
Can not be used together with protec-
tion type Foundry Plus.
Includes fan unit, fan cable harness,
customer connection plate and re-
quired fasteners.

Standard toolkit - Content is defined in section Stand-
ard toolkit on page 848.

Continued
Required consumables
Consumable Article number Note

Cable straps -
Installing the cooling fan

Use these procedures to install the cooling fan.
Installing the fan
Action Note
1 Move the robot to its synchronization position.
2
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the safeguarded
space.
3 Remove the metal sheet frame from the fan unit

assembly by loosening the six screws.
xx1800000157
4 Loosen the two tightening screws so they don´t

damage the motor surface during installation.
xx1800000159

Continued
Action Note
5 Fit the fan unit sheets around the motor and fasten
them to each other by tightening the six screws.
xx1800000158
6 Lift the box so that it does not rest directly on the

robot and secure the box against the motor with
the two tightening screws.
Tighten them properly so that the box is firmly
attached to the motor.
xx1800000160
Connecting the fan cabling
Action Note
1 Remove the rear cover plate.
xx1800000161
2 Fit the customer connection plate.
xx1800000162

Continued
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
6 Secure the cable bracket inside the frame with

the two enclosed nuts.
xx1800000166

Continued
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
A Fan cable connector

B Cable straps
9 Refit the frame cable clamp with the screws.
xx1300000542
10 Connect the connector R1.SW2/3 to the base of

the robot.
Make sure that the cabling, run through the frame
and base, is not twisted and runs freely from the
robot cabling.
xx1800000167
11 Refit the rear cover plate to the robot base.
xx1800000161

Continued
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.

2.8 Start of robot in cold environments
2.8 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
reference manual - System parameters.
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.
Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.
Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
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.

2.9 Test run after installation, maintenance, or repair
2.9 Test run after installation, maintenance, or repair
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
3 Maintenance
3.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
6700.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 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.
• Robot cabling and connection points on page 104.

3 Maintenance
3.2.1 Specification of maintenance intervals
3.2 Maintenance schedule and expected component life
3.2.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 6700:
• Calendar time: specified in 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.

3 Maintenance
3.2.2 Maintenance schedule
Scheduled and non-predictable maintenance

The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!
Life of each component

The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 121
Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals:
Every 20,000 hours i


Every 12 months
Every 18 months
Every 24 months
Every 36 months
Every 6 months
Regularly
Maintenance activities Reference
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

3 Maintenance
Continued


Every 12 months
Every 18 months
Every 24 months
Every 36 months
Every 6 months
Regularly
Maintenance activities Reference
Inspecting the axis-1

Inspecting the mechanical stop x mechanical stop pin on
page 152
Replacement/changing activities
Changing oil, axis-1
Changing the oil in axis-1 gearbox x
gearbox on page 162
gearbox on page 169
gearbox on page 174
gearbox on page 180
gearbox on page 184
gearbox on page 188
Replacing the SMB
Replacing the SMB battery pack x iv
battery on page 193
Lubrication activities
Lubricating the spherical
Lubricating the balancing device
xv roller bearing, balancing
bearings
device on page 196
Overhaul
Overhaul of complete robot x
i Operating hours counted by the DTC = Duty time counter.
ii Only valid for robots that are equipped with Type B motors.
Type B motors include evacuation on the motor flange to indicate failure of primary sealing between
the gearbox and the motor. Robots with protection type Foundry Plus have a sight glass installed
in the evacuation holes.
See Type A vs type B motors on page 839.
iii Replace when damage or cracks is detected or life limit is approaching that specified in section
Expected component life on page 121.
iv The battery is to be replaced at given maintenance interval or at battery low alert.
v Always lubricate the front eye bearing after refitting the shaft of the balancing device.

3 Maintenance
3.2.3 Expected component life
3.2.3 Expected component life
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Expected component life - protection type Standard
Component Expected life Note

Cable harness 40,000 hours ii Not including:
Normal usage i • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Cable harness 20,000 hours ii Not including:
Extreme usage iii • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Balancing device 40,000 hours iv
Gearboxes v 40,000 hours
i Examples of "normal usage" in regard to movement: most material handling applications.
ii Severe chemical or thermal environments, or similar environments, can result in shortened life
expectancy.
iii Examples of "extreme usage" in regard to movement: press tending, very severe palletizing
applications, major use of axis 1 movement.
iv The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from
the initial position and goes to maximum extension, and back. Deviations from this cycle will result
in differences in expected life!
v The SIS for an IRC5 system is described in the Operating manual - Service Information System.

3 Maintenance
3.3.1 Inspecting the motor seal
3.3 Inspection activities
Purpose of evacuation holes

This section is only valid for robots that are equipped with Type B motors.
The motors include evacuation on the motor flange to indicate failure of primary
sealing between the gearbox and the motor.
More information is found in Type A vs type B motors on page 839.
Location of evacuation hole on motor

The evacuation hole is located on each motor flange. The figure shows axis-1
motor as an example.
xx1500001057
Plug in the evacuation hole

New motors have a transparent plug/sight glass installed in the evacuation hole.
Remove the plug or drill a drainage hole with diameter 3 mm, if an open evacuation
hole is required instead.
xx2200002188

3 Maintenance
Continued
Inspecting the evacuation hole
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot working
area.
2
WARNING
Handling gearbox oil involves several safety risks,

see Gearbox lubricants (oil or grease) on page 34.
3 Do a leakage check of the sight glass/evacuation

hole of each motor.
If any oil is available on the sight glass or if any
oil has been spilled out from the evacuation hole,
replacement of the motor is recommended.
Note
If oil is present in the evacuation it is an indication

that the primary seal of the motor is leaking. A
secondary seal after the evacuation is keeping
the oil out from the motor, but it is still recommen-
ded to replace the motor at a suitable timing if oil xx1500001057
is present in the evacuation.
Replacing of motors is described
in the repair chapter Motors on
page 506.

3 Maintenance
3.3.2 Inspecting the oil level in axis-1 gearbox
Location of oil plug

The oil plug through which the oil level is inspected is located as shown in the
figure.
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

3 Maintenance
Continued
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
xx1500001655
Required tools

Required consumables and wear parts
Consumables Article number Note

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.
O-ring, G 1/2" 3HAC061327-059 Used on oil plug. Always replace when
refitting oil plug.
Required documents
Document name Document number


3 Maintenance
Continued
Inspecting the oil level in axis-1 gearbox

Use this procedure to inspect the oil level in the gearbox.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot
working area.
2
WARNING
Handling gearbox oil involves several

safety risks, see Gearbox lubricants (oil or
grease) on page 34.
3 Make sure that the oil temperature is +25°C

± 10°C.

3 Maintenance
Continued
Action Note
4 Open the oil plug.
xx1200000950
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
xx1500001655
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,

-220/3.00 LID
5 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
Check the oil level.
Required oil level is: 58 mm ± 5 mm below
the sealing surface of the oil plug.
xx1300000692

3 Maintenance
Continued
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
Make sure all safety requirements are met

when performing the first test run. See Test
run after installation, maintenance, or repair
on page 116.

3 Maintenance
Location of the oil plug

The oil plug for inspection is located as shown in the figure.
xx1200000952
Tightening torque: 24 Nm


tion in gearboxes.
refitting oil plug.
Required documents


3 Maintenance
Continued

Action Note
1
DANGER
Turn off all:

area.
2
WARNING
Handling gearbox oil involves several safety

risks, see Gearbox lubricants (oil or grease)
on page 34.
3 Make sure that the oil temperature is +25°C ±

10°C.
xx1200000952
5 Check the oil level.

Required oil level is: 0-15 mm below the oil
plug hole.
6 Add or drain oil, if required. Type of oil and total amount is detailed
in Technical reference manual - Lubric-
ation in gearboxes.
Further information about how to drain
or fill with oil is found in section Chan-
ging oil, axis-2 gearbox on page 169.

3 Maintenance
Continued
Action Note
8
DANGER

on page 116.

3 Maintenance

The gearbox has a level plug that is located as shown in the figure.
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
xx1200000955
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
xx1500001645

3 Maintenance
Continued
Required tools


tion in gearboxes.
refitting oil plug.
Required documents


Action Note
1 Run the robot to calibration position.
2
DANGER
Turn off all:

working area.

± 10°C.
4
WARNING

grease) on page 34.

3 Maintenance
Continued
Action Note
xx1200000955
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
xx1500001645
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,

-220/3.00 LID
oil plug hole.
in gearboxes.
9
DANGER

on page 116.

3 Maintenance

xx1200000957
Required tools


tion in gearboxes.
refitting oil plug.
Required documents


Action Note

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

working area.

± 10°C.
4
WARNING

grease) on page 34.
xx1200000957

oil plug hole.
in gearboxes.
9
DANGER

on page 116.

3 Maintenance

xx1200000959
Required tools


tion in gearboxes.
refitting oil plug.
Required documents


Action Note

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

working area.

± 10°C.
4
WARNING

grease) on page 34.
xx1200000959

oil plug hole.
in gearboxes.
9
DANGER

on page 116.

3 Maintenance

The oil plug through which the oil level is inspected is located as shown in the
figure.
xx1600002049
Required tools


tion in gearboxes.
refitting oil plug.
Required documents


3 Maintenance
Continued

The procedure includes two alternative positions for axis 5, where one of the
positions makes it possible to use the filling plug as a level plug.
Action Note
2
DANGER
Turn off all:

working area.

± 10°C.
4
WARNING

grease) on page 34.
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
• IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID
xx1300000693

3 Maintenance
Continued
Action Note
7 Method 2
Rotate axis 5 +77°.
oil plug hole.
in gearboxes.
10
DANGER

on page 116.

3 Maintenance
3.3.8 Inspecting the balancing device
General
Several points are to be checked on the balancing device during the inspection.
This section describes how to perform the inspection regarding:
• dissonance
• damage
• leakage
• contamination / lack of free space.
Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure.
The figure also shows the inspection points, further described in the instructions.
xx1300000413
A Piston rod (inside balancing device)

B Link ear
C Rear attachments of the balancing device (rear bearing)
Required tools
Visual inspection, no tools are required.

3 Maintenance
Continued
Required material
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.
Check for dissonance

The check points are shown in the figure Inspection points, balancing device on
page 142.
Check points Action

1 Check for dissonance from If dissonance is detected, perform maintenance accord-
the bearing at the link ear ing to maintenance kits and instructions in section Re-
and the bearings at the rear placing spherical roller bearing, link ear on page 453 and
attachments. on page ?.
2 Check for dissonance from If dissonance is detected, replace the balancing device
the balancing device (a tap- or consult ABB Service.
ping sound, caused by the How to replace the device is detailed in section Repla-
springs inside the cylinder). cing the balancing device on page 471. This section also
specifies the spare part number.
3 Check for dissonance from If dissonance is detected, wipe clean the piston rod.
the piston rod (squeaking If dissonance continues after the piston rod is cleaned,
may indicate worn plain perform maintenance according to given instructions in
bearings, internal contamin- Maintenance kit, complete.
ation or insufficient lubrica-
tion).
Check for damage

Check for damage, such as scratches, general wear, uneven surfaces or incorrect
positions.
The check points are shown in the figure Inspection points, balancing device on
page 142.
Check points Action

1 Check for damage on the part of the pis- If damage is detected, perform mainten-
ton rod that is visible at the front of the ance according to given instructions in
balancing device. Maintenance kit, complete.

3 Maintenance
Continued
Check for leakage

Leaks at o-rings, radial sealings etc. are not acceptable and must be attended to
immediately to avoid damage to the bearing.
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
Turn off all:

4 Check the area around the o-ring and radial

sealings at the front ear, for leakage.
5 Replace o-ring and radial sealings if leaks are The o-ring and radial sealings are in-
detected. cluded in the Maintenance kit, bear-
ings and seals already assembled with
sealing spacers and sealing rings.
Article number for the kit is specified
in Required material on page 143.
Replacement of the complete bearing
is described in section Replacing the
balancing device on page 471.

3 Maintenance
Continued
Check for contamination / lack of free space
Action Note
1
DANGER
Turn off all:

2 Check that there are no obstacles inside the frame, that

could prevent the balancing device from moving freely.
Keep the areas around the balancing device clean and free
from objects, such as service tools.
xx1300000423

3 Maintenance
3.3.9 Inspecting the cable harness
Location of cable harness

The cable harness is located as shown in the figure.
xx1300001096
Required tools
Visual inspection, no tools are needed.
Inspecting the cable harness

Use this procedure to inspect cable harness of axes 1-6.
Action Note
1
DANGER
Turn off all:

working area.

3 Maintenance
Continued
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
3 Check that all visible cable brackets and

attachments are properly secured, by fol-
lowing the cable harness from the base to
the wrist.
4 Check that all visible velcro straps are
properly secured.
Note
Replace if damaged.
5 Check the motor cables visually for any

damage.
6 Check the connectors at the base visually
for any damage.
7 Check the cabling going through the protec-
tion tube, to detect possible cable chafing,
by using your hands inside the tube to feel
the cables. Ensure that the cables are un-
damaged.
Remove any objects that may cause pos-
sible cable chafing.
Replace damaged cabling, if any.
xx1300001094
8 Replace the cable harness if wear, cracks See Removing the cable harness on
or damage is detected. page 238.

3 Maintenance
3.3.10 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on manipulator labels on page 23.
Illustration 1
E E
K M B
N E
J
E
F
F
F
xx1300001093

3 Maintenance
Continued
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
IRB 6700, m = 1160 - 1600 kg / 2557 - 3527 lbs
45°
65°
! !
20°
°
70 4x
890 50
570 55
1x, 2000 kg, 2 m/2,5 m !

1x, 2000 kg, 2 m
4x, 2000kg, 2,5 m
3HAC 046732-001 / 00
xx1300001084

3 Maintenance
Continued
D Instruction label
3HAC 8225-1/xx
Brake release 3
4
5
6
Moving robot
Brake release buttons
! 1
2
xx1300001083
E Oil specification label

F Grease specification label
G Complete oil specification
H Warning label
Do not dismantle
Stored energy !
3HAC 9526-1/04
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

3 Maintenance
Continued
L Warning label
4 6
5
Moving robot 3
Shut off with handle ! 1

2
Before dismantling see product manual 0
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
Turn off all:

to the robot, before entering the safeguarded space.
2 Inspect the labels, located as shown in the figures.

3 Replace any missing or damaged labels. Article numbers for the labels and
plate set is specified in Spare
parts on page 855.

3 Maintenance
3.3.11 Inspecting the axis-1 mechanical stop pin
WARNING
Mechanical stop pin can not be fitted onto robot if the option 561-1 Extended
working range is used for axis 1.
Location of mechanical stop pin

The axis-1 mechanical stop is located as shown in the figure.
xx1200001073
Required equipment

3 Maintenance
Continued
Inspecting, mechanical stop pin

Use this procedure to inspect the axis-1 mechanical stop pin.
Action Note
1
DANGER
Turn off all:

space.
2 Inspect the axis-1 mechanical stop pin.

If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
The expected life of gearboxes can be reduced

after collision with the mechanical stop.

3 Maintenance
3.3.12 Inspecting the additional mechanical stops
Location of mechanical stops

The figure shows the location of additional mechanical stops.
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

3 Maintenance
Continued
Required equipment
Equipment etc. Article number Note

Movable mechanical stop 3HAC055744-001 IRB 6700-235/2.65, -220/2.65 LID, -
axis 1 205/2.80, -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
Limits the robot working range by 15°.
Includes attachment screws and an as-
sembly drawing.
• Mechanical stop
• Attachment screws M12x70 quality
12.9 Gleitmo 603 and washers
• Document for mechanical stop
Movable mechanical stop 3HAC048533-003 IRB 6700-300/2.70, -270/2.70 LID, -
axis 1 245/3.00, -220/3.00 LID
Limits the robot working range by 15°.
Includes attachment screws and an as-
sembly drawing.
• Mechanical stop
• Attachment screws M12x70 stain-
less steel and washers stainless
steel
• Document for mechanical stop
Inspecting, mechanical stops

Use this procedure to inspect the additional mechanical stops.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot working area.
2 Make sure no additional stops are damaged. Shown in figure Location of

mechanical stops on page 154.
3 Make sure the stops are properly attached.
Correct tightening torque, additional mechanical
stops:
• Axis 1 = 60 Nm.
4 If any damage is detected, the mechanical stops must Article number is specified in
be replaced. Required equipment on page 155.
Correct attachment screws:
• M12x70 quality 12.9 Gleitmo 603 (2 pcs per
additional mechanical stop)

3 Maintenance
3.3.13 Inspecting the dampers
Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx1300000414
A Axis-2 damper, 2 pcs

B Axis-3 damper, 2 pcs
Required equipment
Inspecting, dampers
The procedure below details how to inspect the dampers.
Note
A damaged damper must be replaced.

3 Maintenance
Continued
Action Note
1
DANGER
Turn off all:

2 Check all dampers for damage, cracks or exist-

ing impressions larger than 1 mm.
3 Check attachment screws for deformation.
xx1300000414
A Axis-2 damper, 2 pcs

B Axis-3 damper, 2 pcs
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.

3 Maintenance
3.3.14 Inspecting the signal lamp (option)
Location of signal lamp

The signal lamp is located as shown in this figure.
xx1600002089

Signal lamp kit See Spare parts on To be replaced if damage is detected.
page 855.
Standard toolkit - Content is defined in section Stand-
ard toolkit on page 848.
Inspecting, signal lamp

Use this procedure to inspect the function of the signal lamp.
Action Note
1 Inspect that signal lamp is lit when motors are put in
operation ("MOTORS ON").

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

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.

3 Maintenance
3.4.1 Type of lubrication in gearboxes
3.4 Replacement/changing activities
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.
Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB.
Location of gearboxes
The figure shows the location of the gearboxes.
xx1400000189
A Gearbox, axis 1

3 Maintenance
Continued
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

3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Usage of oil dispenser

The oil change procedure in this section describes usage of an oil dispenser.
Location of oil plugs

The oil plugs of the gearbox are located as shown in the figure.
xx1500001654 xx1500001644
A Oil hole with nipple (Used for both Oil plug.

draining and filling with an oil dis-
penser). Used for both ventilation and level measure-
ment on manipulator types:
B Level plug (IRB 6700-300/2.70, - • IRB 6700-235/2.65, -220/2.65 LID, -
270/2.70 LID, -245/3.00, -220/3.00 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
Used for ventilation on manipulator types:
• IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID
Tightening torque: 24 Nm. Tightening torque: 24 Nm.

tion in gearboxes.
refitting oil plug.

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.

3 Maintenance
Continued

Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 160.
Required documents
Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes
Draining the axis-1 gearbox

Use this procedure to drain the gearbox.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the safe-
guarded space.
2
WARNING

grease) on page 34.
3
CAUTION
The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let the excess
pressure out.

3 Maintenance
Continued
Action Note
4 Remove the protective cap from the nipple
of the oil hole and connect the oil dis-
penser.
xx1200000948
5 Remove the plug from the vent hole.
WARNING
Open the vent hole while using the dis-

penser, to avoid damaging vital parts in the
gear.
xx1200000950
6 Suck out the oil with the oil dispenser.
Note
There will be some oil left in the gear after

draining.
7
WARNING
Used oil is hazardous material and must

be disposed of in a safe way. See section
Decommissioning on page 831 for more in-
formation.
8 Remove the oil dispenser.

Refit the protective cap on the nipple.
9 Refit the vent hole oil plug with a new o- O-ring, G 1/2": 3HAC061327-059
ring. Tightening torque: 24 Nm.

3 Maintenance
Continued
Filling oil into the axis-1 gearbox

Use this procedure to refill the gearbox with oil.
Action Note
1
DANGER
Turn off all:

guarded space.
2
WARNING

grease) on page 34.

penser.
xx1200000948
Note
The vent hole is opened to let out air during

the filling process.
xx1200000950

3 Maintenance
Continued
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
The amount of oil to be filled depends on

the amount previously being drained.

3 Maintenance
Continued
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
Required oil level: 58 mm ± 5 mm below

the sealing surface of the oil plug.
xx1300000692
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,

-220/3.00 LID

3 Maintenance
Continued
Action Note
xx1500001655
Required oil level: 0 - 10 mm below the oil

plug hole.
7 Remove the oil dispenser and refit the
protective cap to the nipple.
9
Note
After all repair and maintenance work in-

volving oil, always wipe the robot clean
from all surplus oil. The robot color can
otherwise be discolored.
10
DANGER

on page 116.

3 Maintenance


xx1200000951 xx1200000952
Oil hole with nipple Vent hole plug/level plug

Used for both draining and filling with an oil
dispenser.
Tightening torque: N/A. Tightening torque: 24 Nm.

of oil.

tion in gearboxes.
refitting oil plug.

3 Maintenance
Continued
Required documents


Action Note
1
DANGER
Turn off all:

guarded space.
2
WARNING

grease) on page 34.
3
CAUTION
The gearbox can contain an excess pres-

sure that can be hazardous. Open the oil
plug carefully in order to let the excess
pressure out.

penser.
xx1200000951

3 Maintenance
Continued
Action Note
WARNING

gear.
xx1200000952
Note

draining.
7
WARNING

formation.
8 Refill oil or: O-ring, G 1/2": 3HAC061327-059

1 Remove the oil dispenser Vent hole plug, tightening torque: 24 Nm.
2 Refit the protective cap on the
nipple.
3 Refit the vent hole oil plug with a
new o-ring.

Action Note
1
DANGER
Turn off all:

guarded space.

3 Maintenance
Continued
Action Note
2
WARNING

grease) on page 34.

penser.
xx1200000951
Note
The vent hole is opened to let air out during

xx1200000952
5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Note in gearboxes.


3 Maintenance
Continued
Action Note
6 Inspect the oil level at the vent hole (level
plug).
xx1200000952
Required oil level is: 0-15 mm below the oil

plug hole.
More information is found in Inspecting the
oil level in axis-2 gearbox on page 130.
9
DANGER

on page 116.

3 Maintenance


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
xx1200000954
xx1200000955
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,

-220/3.00 LID
xx1500001645
Oil hole with nipple Level/vent plug

Used for both draining and filling with an oil
dispenser.

of oil.

3 Maintenance
Continued

tion in gearboxes.
refitting oil plug.
Required documents


Action Note
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.
4
CAUTION

pressure out.

3 Maintenance
Continued
Action Note
penser.
xx1200000954
WARNING

gear.
xx1200000955
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
xx1500001645
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,

-220/3.00 LID
Note

draining.

3 Maintenance
Continued
Action Note
8
WARNING

be disposed of in a safe way. SeeDecom-
missioning on page 831 for more informa-
tion.


Action Note
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.

penser.
xx1200000954

3 Maintenance
Continued
Action Note
Note
The vent hole is opened to let air out during

xx1200000955
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
xx1500001645
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,

-220/3.00 LID
Note in gearboxes.


3 Maintenance
Continued
Action Note
7 Inspect the oil level at the vent hole (level
plug).
xx1200000955
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
xx1500001645
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,

-220/3.00 LID
oil plug hole.
10
DANGER

on page 116.

3 Maintenance

xx1200000957
xx1200000956
Oil drain plug Oil fill plug/level plug


of oil.

tion in gearboxes.
refitting oil plug.
Required documents


3 Maintenance
Continued

Action Note
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.
4
CAUTION

pressure out.
5 Place the oil collecting vessel underneath

the oil drain plug.
6 Remove the oil plug from the drain hole
and let the oil run into the vessel.
xx1200000956

3 Maintenance
Continued
Action Note
7 Remove the oil plug from the fill/level hole.
Note
The level hole is opened to speed up the

drainage.
xx1200000957
8
WARNING

be disposed of in a safe way. See Decom-
missioning on page 831 for more informa-
tion.
9 Refill oil or refit the oil plugs with new o- O-ring, G 1/2": 3HAC061327-059
rings. Tightening torque: 24 Nm.

Action Note
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.

3 Maintenance
Continued
Action Note
4 Open the fill/level plug.
xx1200000957
Note in gearboxes.

6 Inspect the oil level. The level is measured at the fill hole.
xx1200000957

oil plug hole.
See Inspecting the oil level in axis-4 gear-
box on page 135.
8
DANGER

on page 116.

3 Maintenance

xx1200000958 xx1200000959
Oil drain plug Oil fill plug/level plug


of oil.

tion in gearboxes.
refitting oil plug.
Required documents


Action Note

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.
4
CAUTION

pressure out.

xx1200000958

the oil drain plug.
7 Remove the oil plug from the fill/level hole.
Note
The fill hole is opened to speed up the

drainage.
xx1200000959
8
WARNING

formation.

3 Maintenance
Continued
Action Note
9 Refill oil or refit the oil plug with a new o- O-ring, G 1/2": 3HAC061327-059

Action Note
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.
4 Open the fill/level plug.
xx1200000959
Note in gearboxes.


3 Maintenance
Continued
Action Note
6 Inspect the oil level at the oil fill/level hole
(level plug).
xx1200000959

oil plug hole.
8
DANGER

on page 116.

3 Maintenance

xx1200000963
xx1200000962
Oil drain plug Oil fill plug


of oil.

tion in gearboxes.
refitting oil plug.
Required documents


3 Maintenance
Continued

Action Note
1 Jog the robot to calibration position.
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.
4
CAUTION

pressure out.

the oil drain plug.
xx1200000962
7 Remove the oil plug from the fill hole.
Note
The fill hole is opened to speed up the

drainage.
xx1200000963

3 Maintenance
Continued
Action Note
8
WARNING

formation.
9 Refill oil or refit the oil plugs with new o- O-ring, G 1/4": 3HAC061327-060
rings. Tightening torque: 24 Nm.

Action Note
1 Jog axis 5 to horizontal position.
2
DANGER
Turn off all:

guarded space.
3
WARNING

grease) on page 34.
4 Open the fill plug.
xx1200000963
Note in gearboxes.


3 Maintenance
Continued
Action Note
6 Check the oil level. Method 1:
Note
The level is measured at the fill hole.
xx1200000963
• 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
• IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID
xx1300000693

Method 2:
Rotate axis 5 +77°.
oil plug hole.

3 Maintenance
Continued
Action Note
8
DANGER

on page 116.

3 Maintenance
3.4.8 Replacing the SMB battery
Note
The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an un-synchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
WARNING
See Hazards related to batteries on page 36.
Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the frame as
shown in the figure below.
xx1200001069
Required tools


3 Maintenance
Continued
Required spare parts

Battery unit See Product manual, spare Battery includes protection
parts - IRB 6700/IRB 6700Inv circuits. Only replace with the
specified spare part or an
ABB-approved equivalent.
Removing the battery

Use this procedure to remove the SMB battery.
Action Note
1 Jog the robot to its calibration position. This is done in order to facilitate
updating of the revolution counter.
2
DANGER
Turn off all:

space.
3
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit read the safety information in section The unit
is sensitive to ESD on page 57.
4 Remove the SMB battery cover by unscrewing the

attachment screws.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Pull out the battery and disconnect the battery

cable. xx1200001069
6 Remove the SMB battery.

Battery includes protection circuits. Only replace
with a specified spare part or with an ABB- ap-
proved equivalent.

3 Maintenance
Continued
Refitting the battery

Use this procedure to refit the SMB battery.
Action Note
1
DANGER
Turn off all:

space.
2

unit read the safety information in section The unit
is sensitive to ESD on page 57.
3 Connect the battery cable and install the battery

pack into the SMB/battery recess.
4 Secure the SMB battery cover with its attachment
screws.
xx1200001069
5 Update the revolution counters. See Updating revolution counters

on IRC5 robots on page 807.
6
DANGER


3 Maintenance
3.5.1 Lubricating the spherical roller bearing, balancing device
3.5 Lubrication activities
Location of spherical roller bearing

The spherical roller bearing is located in the link ear of the balancing device.
xx1300000773
A Attachment screws M6x10 quality 8.8-A2F (2 pcs)

B End cover
C Radial sealing with dust lip, 50x68x8 (2 pcs)
D O-ring 85x3
E Spherical roller bearing
F Washer
Consumables

Grease 3HAA1001-294 Tribol GR 100-0 PD, 50 ml
Used for lubrication of the
spherical roller bearing.

3 Maintenance
Continued
Lubricating the spherical roller bearing

Use this procedure to lubricate the spherical roller bearing.
Action Note
1
DANGER
Turn off all:

guarded space.
2
CAUTION
Always cut the paint with a knife and grind

the paint edge when disassembling parts.
See Cut the paint or surface on the robot
before replacing parts on page 209.
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
4 Refit the two screws and wipe clean from

residual grease.

3 Maintenance
3.6.1 Cleaning the IRB 6700
3.6 Cleaning activities
DANGER
Turn off all:

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
Always verify the protection type of the robot before cleaning.
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.
Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.

3 Maintenance
Continued
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.
Cleaning with water and steam

Instructions for rinsing with water
ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80° C
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.

3 Maintenance
Continued
• 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
4 Repair
4.1 Introduction
Structure of this chapter

This chapter describes repair activities for the IRB 6700. Each procedure contains
the information required to perform the activity, for example spare parts numbers,
required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Report replaced units
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.

4 Repair
4.2.1 Performing a leak-down test
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test

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

Leak-down tester -
Leak detection spray -
Performing a leak-down test
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
The pressure must under no circumstance be higher

than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
4 Disconnect the compressed air supply.

5 Wait for approximately 8-10 minutes and make sure If the compressed air is signific-
that no pressure loss occurs. antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
6 If any pressure drop occurred, then localize the leak
as described in step 7.
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
7 Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
8 When the leak has been localized, take the necessary
measures to correct the leak.

4 Repair
4.2.2 Mounting instructions for bearings
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment

Grease 3HAC042536-001 Shell Gadus S2
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.
Action Note
1 To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
2 Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
3 Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action Note
1 Tension the bearing gradually until the recommended pre-tension is achieved.
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
This instruction is not valid for solid oil bearings.

4 Repair
Continued
The bearings must be greased after assembly according to the following

instructions:
• The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available
volume.
• Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as following description:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the
split condition.

4 Repair
4.2.3 Mounting instructions for sealings
General
This section describes how to mount different types of sealings.
Equipment

Rotating sealings
The following procedures describe how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:

• Protect the sealing during transport and mounting, especially the main lip
on radial sealings.
• Keep the sealing in its original wrappings or protect it well before actual
mounting.
• The fitting of sealings and gears must be carried out on clean workbenches.
• Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
• Do not lubricate a static side of a sealing with grease, since this may result
in movement of the sealing during operation.
The only exception for lubrication of static sides of a sealing, is to use P-80
rubber lubrication gel against certain aluminium surfaces. If usage of P-80
is relevant, it is stated in the repair procedures.
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

4 Repair
Continued
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
Ensure that no grease is ap-

plied to the red marked surface.

4 Repair
Continued
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
Flange sealings and static sealings

The following procedure describes how to fit flange sealings and static sealings.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface.
4 Tighten the screws evenly when fastening the flange joint.
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.

4 Repair
Continued
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 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
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
Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Standard/Foundry 3HAC067974-001 Graphite White
Plus
Touch up paint Standard/Foundry 3HAC037052-001 ABB Orange
Plus
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
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

4 Repair
4.2.5 The brake release buttons may be jammed after service work
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
If the power is turned on while a brake release button is jammed in depressed

position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.
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.

4 Repair
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)
4.3 Lifting associated procedures
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)
Validity of this section
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.
Definition of the complete arm system

The complete arm system consists of the following parts of the robot:
• upper arm
• wrist
• lower arm
• frame

4 Repair
-155/2.85, -140/2.85 LID)
Continued
Attachment points of lifting accessory
Required tools

Lifting eye 3HAC16131-1 M12
Fender washer - Outer diameter: minimum 26 mm,
maximum 30 mm, hole diameter: 13
mm, thickness: 3 mm.
Lifting shackle - SA-10-8-NA1
Roundsling, 1.5 m - Length: 1.5 m. Lifting capacity: 2,000
kg.
Roundsling, 1 m - Length: 1 m, lifting capacity: 1,000 kg.
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.

4 Repair
-155/2.85, -140/2.85 LID)
Continued
Attaching the lifting accessories
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
• Axis 1: no significance as long as the robot
is secured to the foundation.
• Axis 2: -40°
• Axis 3: +65° (approximately)
• Axis 5. +90°
xx1200001132
2
DANGER
Turn off all:

area.
Attaching lifting accessories to the arm system

Use this procedure to attach the lifting accessories.
-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
Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

4 Repair
-155/2.85, -140/2.85 LID)
Continued
Action Note
2
CAUTION
The complete arm system weigh (according to

variants) .
1100 kg (IRB 6700 -235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
1115 kg (IRB 6700 -220/2.65 LID, -200/2.80 LID, -
155/3.05 LID, -145/3.20 LID, -175/2.60 LID, -
140/2.85 LID)
All lifting accessories used must be sized accord-
ingly.
3 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1
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

4 Repair
-155/2.85, -140/2.85 LID)
Continued
Action Note
6 Attach the roundsling to the shackle on the wrist.
7 Jog axis-3 slowly until the roundsling is stretched
(approximately +58°), to carry the weight of the
lower arm and frame.
WARNING
Without the roundsling the weight of the lower

arm and frame is applied to the axis-3 gear during
lifting, which risks to damage the gear.
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
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

4 Repair
-220/3.00 LID)
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)
Note
6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 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.
Definition of the complete arm system

The complete arm system consists of the following parts of the robot:
• upper arm
• wrist
• lower arm
• frame, including the balancing device.

4 Repair
-220/3.00 LID)
Continued
xx1400002080
Required tools


4 Repair
-220/3.00 LID)
Continued

kg.
closed.

Robot position
Action Note
• 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°
2
DANGER
Turn off all:

area.
Attaching the lifting accessories to the arm system
Action Note
1
DANGER

off.
2
CAUTION
The complete arm system weighs .

1,300 kg (IRB 6700 -300/2.70, -245/3.00)
1,320 kg (IRB 6700 -270/2.70 LID, -220/3.00 LID)
ingly!

4 Repair
-220/3.00 LID)
Continued
Action Note
xx1200001133
4 Fit a lifting eye to the arm house, with a fender Lifting eye: 3HAC16131-1
3 mm.
xx1400002196
xx1200001134

4 Repair
-220/3.00 LID)
Continued
Attach the lifting chains

Use this procedure to attach the Lifting accessory (chain).
Action Note
1 Run a roundsling through the hole in the frame, Roundsling, 2.5 m: Length: 2.5 m.
continue up and over the upper arm. Lifting capacity: 2,000 kg.
Tip
When attaching the roundsling, make sure to

cross it over, creating a figure 8 of the roundsling.
This will prevent the roundsling from gliding.
xx1400002107
xx1400000728
A Upper arm
B Shackle
C Roundsling
D Hole in frame

4 Repair
-220/3.00 LID)
Continued
Action Note
2 Connect the roundsling with a shackle. Lifting shackle SA-10-8-NA1
xx1400000729
3 Use caution and jog axis-3 slowly to stretch the

roundsling.
Note
Make sure the roundsling is stretched, so it can

carry the weight of the frame.

in the arm house and to the lifting eye in the wrist.
xx1400002108

4 Repair
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)
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 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).
-245/3.00, -220/3.00 LID see section 4.3.4 Attaching lifting accessories to an
unseparated lower and upper arm.

4 Repair
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Continued
xx1200001254
Required tools

kg.
closed.

4 Repair
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Continued
Attaching lifting accessories to the lower and upper arm
Robot position
-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
When jogging the axis-2 into position check

that the balancing device ear and the ear
on the lower arm is not colliding!

• Axis-1: no significance as long as
the robot is secured to the founda-
tion
• Axis-2: -45°
• Axis-3: +65° (approximately)
• Axis-4: 0°
• Axis-5: 0°
• Axis-6: 0°.
xx1200001250
3
DANGER
Turn off all:

working area.


4 Repair
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Continued
-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
The lower and upper arms together weigh (accord-

ing to variants) .
510 kg (IRB 6700 -235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
525 kg (IRB 6700 -220/2.65 LID, -200/2.80 LID, -
155/3.05 LID, -145/3.20 LID, -175/2.60 LID, -
140/2.85 LID)
ingly!
xx1200001133
xx1200001234
4 Insert a M8x50 securing screw, not more than 10-

15 mm, into the screw hole shown in the figure.
This is done to secure the roundsling from gliding
when lifting.
If DressPack cable package is installed: use the
ball joint housing instead, in the same way.
xx1200001251

4 Repair
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Continued
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
6 Adjust the roundsling on the other side of the

lower arm, so that the roundsling runs on the left
side of the most lower of the four bosses.
xx1200001253
8 Stretch the roundsling between the wrist and the

lower arm by slowly jogging the axis-3.
Note
Make sure the roundsling is stretched, in order to

carry the weight of the lower arm.
9
DANGER
Turn off all:

area.

4 Repair
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Continued
Action Note
washer underneath. Fender washer: Outer diameter:
3 mm.
xx1400002196
xx1200001134
11 If the robot is equipped with DressPack, unscrew

the attachment screws of the bracket that holds
the ball joint housings on the wrist. The DressPack
can stay fitted in the ball joint housing.
xx1400000355
12 Move the DressPack cable package over to the

other side of where the lifting accessory will be
attached to the shackle on the arm house.
head crane (or similar), then to the lifting eye in 3HAC15556-1
the arm house and to a roundsling run through Roundsling, 1 m: Length: 1 m, lift-
xx1200001254
14 Raise the overhead crane to stretch the chains

and roundslings.
Verify that the roundsling between the wrist and
the lower arm is stretched.

4 Repair
-175/2.60 LID, -155/2.85, -140/2.85 LID)
Continued
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

4 Repair
LID, -245/3.00, -220/3.00 LID)
6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID)
Note
6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 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.

4 Repair
LID, -245/3.00, -220/3.00 LID)
Continued
xx1400002104
Required tools

kg.
closed.

4 Repair
LID, -245/3.00, -220/3.00 LID)
Continued


Robot position
Action Note
1
Note


• Axis 1: position the axis 1 to be able
to put down the arm system after
removal
• Axis 2: -60°
• Axis 4: +90°
• Axis 5: 0° (-90° if DressPack is in-
stalled)
• Axis 6: 0° (+90° if DressPack is in-
stalled)
xx1200001250
3
DANGER
Turn off all:

guarded space.

4 Repair
LID, -245/3.00, -220/3.00 LID)
Continued

Action Note
1
CAUTION

ing to variants) .
650 kg (IRB 6700 -300/2.70, -245/3.00)
670 kg (IRB 6700 -270/2.70 LID, -220/3.00 LID)
ingly!
xx1400002106
3 In order to secure the roundsling from gliding

when lifting:
• With no DressPack cable package installed:
Insert a M12x50 securing screw, not more
than 10-15 mm, into the screw hole shown
in the figure.
• With DressPack cable package installed:
Use the ball joint housing in the same way.
xx1200001251
4 Run a roundsling around the lower arm, place it Roundsling, 2.5 m: Length: 2.5 m.
accordingly: Lifting capacity: 2,000 kg.
Place the roundsling beneath the securing
screw.
Place the roundsling beneath the ball joint
housing on the outside of the lower arm.
xx1400002105
5 Run the roundsling up and over the upper arm.

4 Repair
LID, -245/3.00, -220/3.00 LID)
Continued
Action Note
6 Connect both ends of the roundsling with a
shackle.
xx1400000729
7 Stretch the roundsling between the upper and the

Note

8
DANGER
Turn off all:

area.
3 mm.
xx1400002196
xx1200001134

4 Repair
LID, -245/3.00, -220/3.00 LID)
Continued
Action Note
the arm house and to the lifting eye in the wrist.
xx1400002104

and roundslings.
supply.
• + = pin 2
• - = pin 5

4 Repair
4.3.5 Attaching lifting accessories to the upper arm
xx1200001308
Required equipment

closed.

4 Repair
Continued
Robot position
Action Note
1 Jog the robot to the position:
• Axis-1: no significance
• Axis-2: -65°
• Axis-3: +65°
• Axis-4: 0°
xx1200001255
Attaching lifting accessories

Attaching the lifting accessories to the upper arm
Use this procedure to attach the lifting accessories to the upper arm.
Action Note
1
CAUTION
The weight of the complete upper arm (in-

cluding the wrist) is
360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
xx1200001133

4 Repair
Continued
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
5 Raise the lifting accessories to take the

weight of the upper arm.
6 In case of necessary adjustments, use the
shortening loops on the lifting accessory
(chain) to find the level position.
xx1400002197

4 Repair
4.4.1 Removing the cable harness
4.4 Complete robot
Location of the cable harness

xx1300001096

Preparations before removing the cable harness
Note
Handle the cables carefully to avoid any scratches or damage that lead to leakage
when the system is pressurized.

4 Repair
Continued
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
The specified position is a recommended

position.
Axis-5 must be oriented as close as pos-
sible to +90° to be able to open the axis-6
motor cover and to remove the axis-6 motor xx1200001081
cables, and in order to avoid the spiral of
the cable harness in the carrier, being un-
wound or placed in the wrong position.
Depending on what tool is used, the other
axes may need to be jogged to another
position.
2
DANGER
Turn off all:

guarded space.
3
Note
If only the manipulator harness shall be

removed, the DressPack cable package
can stay fitted on the process turning disk.
xx1400000208

4 Repair
Continued
Removing the cable harness - upper arm and wrist

These procedures describe how to remove the cable harness in the upper arm and
wrist.
Retrieving access to the wrist cabling

Use this procedure to remove the wrist cover to retrieve access to the axis-5 and
axis-6 motor cables.
Action Note
1
DANGER
Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.
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
3 If used, open the ball joint housing on the

arm tube and remove the DressPack cable
package.
xx1400000206

4 Repair
Continued
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

4 Repair
Continued
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
Keep the heat protection plate until refitting.
Tip
If removing the plate only for replacing the

motor, the cabling does not need to be
loosened from the plate.
xx1500001029
xx1300000489
Disconnecting the axis-6 motor cables
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
2 Unscrew the attachment screws and re-
move the motor cover.
xx1200001080
3 Disconnect the motor cables.
xx1300000488
4 Unscrew the attachment screws that hold

the cable bracket.
xx1300000484

4 Repair
Continued
Action Note
5 Unscrew the M4 screw that holds the carri-
er.
Note
The screw is located at the bottom of the

carrier.
xx1300000485
6 Pull out the carrier from its position.
xx1300001113
7 Pull out the axis-6 motor cables by holding

the cables with one hand at the motor and
the other at the carrier.
xx1300000666
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.
xx1200001135
3 Make sure the o-ring is present.
xx1200001070
xx1200001066

4 Repair
Continued
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
Make a note in which direction the cable

exit hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.
xx1300000656
6 Use caution and pull out the motor cables.
Disconnecting the axis-3 and axis-4 motor cables
Action Note
1
DANGER

are turned off.

xx1200001135

4 Repair
Continued
Action Note
xx1200001070
xx1200001066
5 Remove the cable gland cover.

Make sure the gasket is not damaged.
Tip

gland hole is facing, if the motor will be re-
the same position.
xx1200001067

4 Repair
Continued
Removing the cable harness - wrist and upper arm
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
2 If the cabling is to be replaced by a new

cable harness, remove the cover insert to
use it on the new cabling.
xx1700001803
3 If used, loosen the insert.
xx1700000690

4 Repair
Continued
Action Note
4 If used, push the DressPack tube a little
backwards.
xx1400000720
5
Tip
Use tape and tie the axis-5 and axis-6

connectors and carrier into a bundle (if not
already done). This is done to facilitate the
removal and to avoid damaging the parts.
This will also make it easier to run the cable
harness through the inside of the upper
arm.
xx1300000668
6 Remove the side cover on the arm tube.
xx1300000557

4 Repair
Continued
Action Note
7 Unscrew the attachment screw that secures
the axis-4 metal clamp inside the arm tube.
Note
The screw is reached from outside the up-

per arm.
xx1700000340
xx1700000339
8 Remove the arm house metal clamp.
xx1300000543

4 Repair
Continued
Action Note
9 Cut the cable tie at the cable fixing bracket.
Note
If DressPack is fitted, the cable fixing

bracket is replaced by the cable guide.
xx1300001973
Cable guide.
xx1300000544
Cable fixing bracket.

10 Remove the metal clamp on top of the arm
house.
xx1300000541

4 Repair
Continued
Action Note
11 Remove the cable harness out from the Person 1, working at the side hole:
wrist.
Tip
This step is best performed by two persons

working together:
• Person 1: Put one hand inside the
side hole and take a hold of the
cable harness.
• Person 2: Take a hold on the cable
harness inside the wrist. xx1300000745
• Together: Move the cable harness Person 2, working at the wrist:

past the axis-5 motor and into the
arm tube.
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

working together:
cable harness.
harness at the back of the robot. xx1300000745
• Together: Move the cable harness Person 2, working at the back:

out of the arm tube.
Note
To be able to remove the cable harness

with the DressPack tube fitted, the tube
needs to be pulled out a little, then be
placed on the lower left side in the arm tube
and the bracket of the cable harness then
needs to be placed on the upper right hand
side.
(This is not needed on variants IRB 6700-
300/2.70, -270/2.70 LID, -245/3.00, -220/3.00
LID)
xx1400002561

4 Repair
Continued
Removing the cable harness - base, frame and lower arm

These procedures describes how to remove the cable harness from base, frame
and lower arm.
Preparations before removing the cable harness in the base
Action Note
1
DANGER

are turned off.
2 Remove the base cover.
xx1300000561
3 Disconnect connectors:
• R1.MP
• R1.SMB
xx1300000591
4 If used, disconnect the DressPack hoses

in the base.
xx1400000366

4 Repair
Continued
Action Note
5 Disconnect the earth cable. Screw dimension : M6x16
Washer dimension : 6.4x17x3
xx1400000354
6 If used, remove the attachment screws that

secure the bracket.
This is done to facilitate removal of the
DressPack hoses.
xx1400000078
7 If used, use caution and pull out the

DressPack hoses through the protection
tube in the base.
Note
There is no need to pull out the DressPack

cables at this point!
xx1400000088

4 Repair
Continued
Removing the axis-1 motor protection plates
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

are turned off.

4 Repair
Continued
Action Note
xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1200001067
Preparations before disconnecting the SMB unit
Action Note
1
DANGER
Make sure that all supplies for electrical power, hy-

draulic pressure, and air pressure are turned off.
2
The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 57
3 Open the small cover on the SMB cover, disconnect

the battery cable and remove the battery.
xx1300000829
4 Remove the SMB cover.
CAUTION

xx1300000669

4 Repair
Continued
Disconnecting the brake release unit
Action Note
1
DANGER

2

3 Take a picture or make notes of how the robot cabling

is positioned in regard to the brake release board.
4 Remove the connectors X8, X9 and X10 from the
brake release board.
xx1300000670
Removing the cable harness in the base
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
3 Place the cable harness over the balancing

device.

4 Repair
Continued
Removing the cable harness in the frame
Action Note
the metal clamp frame.
xx1300000542
2 Cut the cable tie inside the frame recess.
xx1200001237
3 Disconnect connectors on the SMB unit.
xx1300001114

4 Repair
Continued
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

the SMB/BU cover from inside the SMB
recess.
xx1300000655
6 Use caution and pull out the cable harness

from the SMB recess.
Note
The parts are sealed with Sikaflex. Remove

the part carefully.
xx1300000560

4 Repair
Continued
Action Note
7 Use caution and pull out the cable harness
through the hole in the frame.
Tip
Keep a hand on the cable protection while

pulling out the cable harness from the
base, so it does not come loose.
xx1700001587
Removing the cable harness in the lower arm
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
The screws are reached from the outside

of the lower arm.
xx1300000540
2 Use caution and pull the cable harness out.
xx1300000733

4 Repair
4.4.2 Refitting the cable harness
Location of the cable harness

xx1300001096
Spare part
Spare part Spare part number Note

Cable harness See Product manual, spare
parts - IRB 6700/IRB 6700Inv
Cover insert 3HAC048520-001 Replace if damaged.
Cable protection, PU rubber 3HAC055411-001 Replace if damaged.

Consumables

Shell Gadus S2
Grease 3HAC042536-001
Used to lubricate o-rings.
O-ring D=84.5x3
21522012-429
Used on the SMB/BU cover.

4 Repair
Continued

O-ring i 3HAB3772-111 (circular pro- /
file) / 3HAC054692-002
(hexagon profile) Used on axis-1 motor cover.
3HAB3772-111 (circular pro- D=169.5x3

file) / 3HAC054692-002

file) / 3HAC054692-002
(hexagon profile) Used on axis-3 motor cover
3HAB3772-110 (circular pro- D=119x3

file) / 3HAC054692-001

file) / 3HAC054692-001
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.
Refitting the cable harness - base, frame and lower arm

These procedures describes how to refit the cable harness in base, frame and
lower arm.
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
Turn off all:

guarded space.

4 Repair
Continued
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.
harness through the inside of the robot.
xx1300000668
3 Run the cable harness through the lower

arm.
xx1300000733
4 Secure the axis-2 lower arm cable bracket.
Note
Do not secure the axis-3 lower arm cable

bracket at this point.
Note
Screws are reached from the outside of the

lower arm.
xx1300000734
5 Run the cable harness into the hole in the

frame in this order:
• R1.MP
• R1.SMB
• R2.MP2
• R2.MP1
xx1300000735

4 Repair
Continued
Refitting the cable harness in the base
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
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
3 Make sure that the markings on the cables

are facing the base cover, when connected.
4 Connect connectors R1.MP and R1.SMB. Tightening torque for R1.SMB: 10 Nm.
xx1300000591

4 Repair
Continued
Action Note
5 Connect the earth cable. Screw dimension: M6x16.
Washer dimension: 6.4x17x3.
xx1400000354
6 If used, run the DressPack cables through

the protection tube in the base.
7 If used, run the DressPack hoses through
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
9 If used, connect the DressPack cable

package on the base plate.
xx1200000052

4 Repair
Continued
Action Note
10 Refit the base cover.
xx1300000561
Refitting the cable harness in the frame
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
The figure shows the position of the o-ring.

2 Check the o-ring and replace if damaged.
3 Wipe clean the contact surfaces and apply Sealant (grey): 3HAC026759-001 (Sikaflex
new sealant on top of the new o-ring after 521FC)
positioning it in the groove.
4 Run the SMB/BU cables into the SMB re-
cess.
xx1300000560

4 Repair
Continued
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
Do not tighten the screws fully! It must still

be possible to adjust the position of the
cable harness by rotating the SMB/BU
cover in its hole a little.
xx1300000655
6 Adjust the cables running through the hole

in the frame by carefully moving the
SMB/BU cover on its screws, while at the
same time checking the position of the
cable harness through the hole.
Note
The cables must be placed so that they

don't rub against any part of the robot.
xx1300000593
7 Secure the SMB/BU cover with its three

attachment screws from inside the SMB/BU
recess.
xx1300000655

4 Repair
Continued
Action Note
8 Secure the cable harness to the bracket
inside the frame hole, with a cable tie.
xx1200001237
9 Refit the frame metal clamp.
xx1300000542
Refitting and reconnecting the SMB and BU units
Action Note
1
DANGER

off.
2

unit please read the safety information in the
section The unit is sensitive to ESD on page 57

4 Repair
Continued
Action Note
3 Connect the battery cable to the SMB unit.
Make sure the lock snaps into place during refit-
ting.
xx1300000729
4 Connect all connectors to the SMB board:

• R1.SMB1-3, R1.SMB4-6 and R2.SMB
xx1300000728
5 Push the SMB unit carefully into position and fit

the bracket that secures the SMB unit.
xx1300000730
6 If disconnected, reconnect the connectors X8,

X9 and X10 to the brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
X9
are snapped down properly.
xx1700000978

4 Repair
Continued
Action Note
7 Pull out the battery cable through the recess for
the battery.
xx1300000834
8 Secure the SMB cover with the attachment

screws.
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
xx1300000669
Reconnecting the axis-1 and axis-2 motor cables
Action Note
1 Push the motor cables through the cable
gland opening.
xx1300000738

4 Repair
Continued
Action Note
2 Refit the cable gland cover.
Note
Replace the gasket if damaged.
xx1200001067
3 Connect the motor cables.

Connect in accordance with the markings
on the connectors.
xx1200001066
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)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
5 Wipe clean o-ring and o-ring groove.
6 Refit the o-ring.
Tip
Lubricate the o-ring with some grease for

a better fitting in the groove.
7
CAUTION
When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.
8 Refit the motor cover with it's attachment Attachment screws: M5x12 8.8 (7 pcs)
screws.
Note
Do not reuse the self-threading attachment

screws. Replace with standard attachment
screws or the threads will be damaged.
Note
Make sure the o-ring is undamaged and

properly fitted.
xx1200001135
9 Make sure that the covers are tightly

sealed.
Refitting the cable harness - lower arm
Action Note
1
Tip

procedure and to avoid damaging the parts
during the procedure.
xx1300000668

4 Repair
Continued
Action Note
2 Run the upper end of the cable harness up
through the lower arm.
xx1300000733
3 Refit the axis-2 lower arm metal clamp

located on the inside of the lower arm.
Note

of the lower arm.
xx1300000734
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

4 Repair
Continued
Action Note
Note

of the lower arm.
xx1300000558
Refitting the cable harness - upper arm and wrist

These procedures describes how to refit the cable harness in upper arm and wrist.
Refitting the cable harness - upper arm
Action Note
1 Refit the metal clamp on top of the arm
house.
xx1300000541
2 Refit the arm house metal clamp.
xx1300000543
3 Arrange the cables between the cable

clamps in the upper arm.

4 Repair
Continued
Action Note
4
Tip

xx1300000668
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

4 Repair
Continued
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

working together:
side hole of the arm tube and take
a hold of the cable harness.
• Person 2: Take a hold on the cable xx1300000745
harness at the back of the robot.
Person 2, working at the back:
• Together: Use caution and move the
cable harness into the arm tube.
Note
The cable harness is best placed at the

upper right hand side of the DressPack
tube, if used, through the arm tube.
Do not run the cable harness into the
DressPack tube!
Note

DressPack tube, if one is fitted!
xx1400000356
xx1300000820

4 Repair
Continued
Action Note
7 Use caution and push the cable harness Person 1, working at the side hole:
into the wrist.
Tip

working together:
side cover hole and take a hold of
the cable harness.
• Person 2: Take a hold of the cable
harness from inside the wrist. xx1300000745

wrist.
xx1300000746
8 Refit the metal clamp axis-4, inside the arm

tube.
Note
The screws are reached from outside the

upper arm.
xx1700000340
xx1700000339

4 Repair
Continued
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
10 If used, refit the insert that guides the

DressPack cable package through the hole
in the upper arm.
xx1700000690
11 If used, refit the tube containing the

DressPack into the insert.
xx1400000092

4 Repair
Continued
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
13 DressPack or Foundry Plus:

Refit the cover with the tube guiding ring
fitted.
Note
Foundry Plus:
rectly
stainless steel to fit the cover.
xx1200000045

4 Repair
Continued
Action Note
14 Secure the cable harness to the cable fixing
bracket with a cable tie.
Note

xx1300001973
xx1300000544
Connecting the axis-3 and axis-4 motor cables
Action Note
gland opening.
xx1300000738
Note
xx1200001067

4 Repair
Continued
Action Note
on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

6 Refit the o-ring.
Tip

7
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Connecting the axis-5 motor cables
Action Note
1 Push the motor cables in through the cable
gland opening.
xx1300000738
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

4 Repair
Continued
Action Note
3 Connect the connectors.
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

aged.

4 Repair
Continued
Action Note
6 Refit the motor cover with its attachment Screws: M5x12.
screws.
Note
Do not refit the screws that will hold the

heat protection plate at this point.
Note

screws, it will damage the threads. Replace
with standard attachment screws.
Note
Make sure the o-ring is undamaged and xx1200001013

properly fitted.
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.
If replacing a type A motor with a type B

motor, the heat protection plate must be
replaced with plates suited for the type B
motor. See Type A vs type B motors on
page 839.
xx1500001029
xx1300000489

4 Repair
Continued
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

4 Repair
Continued
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
Cable layout in the wrist with Type A mo-

tors.
2
Note
Axis 5 must be in position +90° (or as close

as possible) for a correct installation of the
cable harness in the wrist. If not, connect
the 24 VDC power supply, release the
brakes and move axis 5 manually to +90°.
xx1200001081
3 Push the cable harness into the wrist re-

cess and up into the axis-6 motor.
xx1300000667

4 Repair
Continued
Action Note
4 Push the carrier carefully into position.
xx1300001113
5 Secure the carrier with the M4 screw.
Note

carrier.
Tip
The attachment screw securing the carrier

may be difficult to fit. Make sure the carrier
is level and completely pressed against the
bottom.
xx1300000485
6 Secure the cable bracket with its attach-

ment screws.
xx1300000484

4 Repair
Continued
Action Note
7 Reconnect the connectors to the axis-6
motor.
Note
Place the resolver cable under the motor

cable.
xx1300000488
8 Make sure the gasket is undamaged. Gasket, 3HAC033489-001/ 3HAC044252-

Replace if damaged. 001
xx1200001095
9
CAUTION

aged.
10 Refit the motor cover.
xx1200001080

4 Repair
Continued
Concluding procedure
Action Note
the wrist cover is fitted.
xx1600002061
xx1300000596

tors.
2 Foundry Plus:
Inspect the gasket. Replace if damaged.
Put washers in the holes of the gasket.
xx1400000383
A Protection plugs (2 on wrist cover

and 2 on cover axis-5 gearbox)
B Washers (10 pcs) in gasket holes

4 Repair
Continued
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.
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

on page 116.

4 Repair
4.4.3 Replacing the SMB
Location of SMB unit

The SMB (serial measurement board) unit is located inside the SMB/BU recess,
as shown in the figure.
xx1300000740
Spare part

SMB unit (DSQC633C) See Product manual, spare
Battery pack See Product manual, spare


4 Repair
Continued
Removing the SMB unit

Use these procedures to disconnect and remove the SMB unit.
Preparations before disconnecting the SMB unit
Action Note
1
DANGER

2

3 Open the small cover on the SMB cover, disconnect

the battery cable and remove the battery.
xx1300000829
CAUTION

xx1300000669
Disconnecting and removing the SMB unit
Action Note
1
DANGER

2


4 Repair
Continued
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:
• 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
5 Pull out the SMB unit and put it in an ESD bag.
xx1300000731
Refitting the SMB unit

Refitting the SMB unit
Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
2

3 Connect the battery cable to the SMB unit.

Make sure the lock snaps into place during refit-
ting.
xx1300000729
4 Connect all connectors to the SMB board:

xx1300000728
5 Push the SMB unit carefully into position and fit

the bracket that secures the SMB unit.
xx1300000730
6 If disconnected, reconnect the connectors X8,

X9 and X10 to the brake release board.
Make sure the connector and its locking arms X8
X10
X9
are snapped down properly.
xx1700000978

4 Repair
Continued
Action Note
7 Pull out the battery cable through the recess for
the battery.
xx1300000834
8 Secure the SMB cover with the attachment

screws.
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
xx1300000669
Refitting the SMB battery
Action Note
1

2 Reconnect the battery cable.

3 Place the battery in the recess.
xx1300000829
4 Refit the battery cover with its attachment

screws.

4 Repair
Continued
Concluding procedures
Action Note
1 Update the revolution counters. See Updating revolution counters on
IRC5 robots on page 807.
2
DANGER


4 Repair
4.4.4 Replacing the brake release unit
Location of brake release unit

The brake release unit (BU) is located inside SMB/BU recess, as shown in the
figure.
xx1300000741
Spare part

Brake release unit See Product manual, spare
Battery pack See Product manual, spare


4 Repair
Continued
Removing the brake release unit

Preparations before removing the brake release unit
Action Note
1
DANGER
Turn off all:

2

3 Remove the push button guard from the SMB cover.

The push button guard must be removed to ensure
a correct refitting of the brake release unit.
xx1300000743
xx1300000742
5 The battery can stay connected, to avoid the need of

synchronizing the robot.
CAUTION
If the battery stays connected, put (or hold) the SMB

cover in a safe position. The battery cable connectors
can otherwise be damaged.

4 Repair
Continued
Disconnecting the brake release unit
Action Note
1
DANGER

2

3 Take a picture or make notes of how the robot cabling

is positioned in regard to the brake release board.
4 Remove the connectors X8, X9 and X10 from the
xx1300000670
Removing the brake release unit
Action Note
1 Unscrew the attachment screws that secure the brake
release unit bracket.
xx1300000744
2 Remove the bracket with the brake release unit fitted.

3 Remove the brake release unit from the bracket.

4 Repair
Continued
Refitting the brake release unit

Use this procedure to refit the brake release unit.
Action Note
1

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
4 Reconnect the connectors X8, X9 and X10 to the

brake release unit.
X8
X10
Make sure the connector and its locking arms are X9
snapped down properly.
xx1700000978
5 Verify that the robot cabling is positioned correctly,

according to previously taken picture/notes.
WARNING
Screened cables must not get in contact with the

brake release board after installation. Eliminate all
risks of contact between screened cables and the
6 Refit the SMB cover with its attachment screws.
Note
Do not refit the push button guard at this point!
xx1300000742

4 Repair
Continued
Action Note
7
WARNING
Before continuing any service work, follow the safety

procedure in section The brake release buttons may
be jammed after service work on page 210!
8 Refit the push button guard to the SMB cover.
xx1300000743
9 Press the push buttons 1 to 6, one at a time, to make

sure that the buttons are moving freely and do not
stay in any locked position.
10 Reconnect the battery, if it has been disconnected.
11 Update the revolution counters if the battery has been See Updating revolution counters
disconnected. on IRC5 robots on page 807.
12
DANGER

performing the first test run. See Test run after install-
ation, maintenance, or repair on page 116.

4 Repair
4.5.1 Replacing the upper arm
4.5 Upper and lower arms
Location of the upper arm

The upper arm is located as shown in the figure. These sections describe how to
replace the complete upper arm, which includes the wrist unit.
xx1300000483
Spare part

Upper arm See Product manual, spare
Consumables
Parts needed to be replaced after removal.

4 Repair
Continued

file) / 3HAC054692-002 Used on axis-3 motor cover.
(hexagon profile)
O-ring file) / 3HAC054692-001 Used on axis-4 motor cover.
(hexagon profile)
(hexagon profile)
Gasket 3HAC033489-001/ Used on axis-6 motor cover.
3HAC044252-001
Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat. Re-
commended drying time is
24h.
Used on Foundry Plus.

closed.
Pallet Used for putting down removed parts
from robot.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
24 VDC power supply - Used to release the motor brakes.
Calibration Pendulum toolkit 3HAC15716-1 Required if Calibration Pendulum is the
valid calibration method for the robot.
Calibration tool box, Axis 3HAC055412-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot.

4 Repair
Continued
Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
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.
Removing the upper arm

Use these procedures to remove the upper arm.
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.
Preparations before removing the upper arm
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.

4 Repair
Continued
Action Note
3
DANGER
Turn off all:

guarded space.
4 Remove tools and other equipment fitted

to wrist and upper arm.
5 Prepare an area where to put the upper
arm, after removal. On pallets, as a sugges-
tion.
Position of the robot in the continued process
Action Note
• Axis 1: No significance (as long as
tion)
• Axis 2: -60°
• Axis 3: +60°
• Axis 4: +90°
• Axis 5: +90°
• Axis 6: No significance
2
DANGER
Turn off all:

guarded space.

Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1400000355

package.
xx1400000206
xx1300002247

4 Repair
Continued
Action Note
plate.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
Note
Tip

xx1500001029
xx1300000489
Removing the DressPack cable package

Remove the DressPack cable package from the upper arm, if used. How to remove
the DressPack cable package is described in more detail in the product manual
"IRB 6700 DressPack". For article number see References on page 10.
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1300000656
Action Note
1
DANGER

are turned off.

xx1200001080

4 Repair
Continued
Action Note
xx1300000488

the cable bracket.
xx1300000484

er.
Note

carrier.
xx1300000485

4 Repair
Continued
Action Note
xx1300001113

xx1300000666
Action Note
1
DANGER

are turned off.

xx1200001135

4 Repair
Continued
Action Note
xx1200001070
xx1200001066

Tip

the same position.
xx1200001067

4 Repair
Continued
Action Note
1 Remove the cover.
Note
Foundry Plus:
cover.
xx1200000045

xx1700001803
xx1700000690

4 Repair
Continued
Action Note
backwards.
xx1400000720
5
Tip

arm.
xx1300000668
xx1300000557

4 Repair
Continued
Action Note
Note

per arm.
xx1700000340
xx1700000339
xx1300000543

4 Repair
Continued
Action Note
Note

xx1300001973
Cable guide.
xx1300000544

house.
xx1300000541

4 Repair
Continued
Action Note
wrist.
Tip

working together:
cable harness.

arm tube.
xx1300000746
Tip

working together:
cable harness.

Note

side.
300/2.70, -270/2.70 LID, -245/3.00, -220/3.00
LID)
xx1400002561

4 Repair
Continued

Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
xx1200001133
xx1400002196
xx1200001134

4 Repair
Continued
Action Note
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
Make sure that it is the screws that hold

the lower arm to the axis-3 gearbox that
are removed!
Tip
Lubricate the guide pins with some grease

to make the upper arm slide better.
xx1300000659

4 Repair
Continued
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
Note

are removed!
Tip

xx1300002245

xx1300002246

4 Repair
Continued
Action Note
Note

are removed!
Tip

xx1400002563

xx1400002564
Action Note
1
Note
Make sure the lift is done completely

leveled! In case of necessary adjustments,
use the shortening loops on the lifting ac-
cessory (chain), and make sure to place
the chain the right way through the loops.
xx1400002197

4 Repair
Continued
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
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,

-140/2.85 LID
TBD
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID
xx1700000059
3 Lift the upper arm and place it on the pre-

pared area.
CAUTION
Only valid when the upper arm is removed

due to replacement of the axis-3 gearbox:
If the cable harness is still fitted or partly
fitted, use caution when lifting the upper
arm over to the other side of the robot, in
order not to cause any damage to the cable
harness.

4 Repair
Continued
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
Refitting the upper arm

Use these procedures to refit the upper arm.
Preparations before refitting the upper 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
Keep the sealing surfaces clean from Mer-

casol.
xx1700001880
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
Fit two guide pins in opposite M12 holes
in the axis-3 gearbox.
Tip

xx1700000058

4 Repair
Continued
Action Note
-140/2.85 LID Guide pin, M12x200: 3HAC13056-3
Fit two guide pins in opposite M12 holes Always use guide pins in pairs.
Tip

xx1400000361

Tip

xx1700000056

4 Repair
Continued
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

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
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
6 Insert all nine M16 screws and 25 of the 27 Screws:

M12 screws. M16 (9 pcs)
M12 (25 of 27 pcs)
xx1400000359

4 Repair
Continued
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
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

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
pins.
arm: Rotation tool
• + = pin 2
• - = pin 5

4 Repair
Continued
Action Note
6 Insert 22 of the 24 M12 screws and wash-

ers.
xx1300002246

maining screws and washers.
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

4 Repair
Continued
Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
3 Lift the upper arm and bring it towards the
lower arm.
arm: Rotation tool
Connect the 24 VDC power supply, to re-
lease the brakes.
• + = pin 2
• - = pin 5
Disconnect and remove the 24 VDC power
supply after finding the position.
6 Insert and tighten 20 of the 22 M16 screws.
xx1700000057

4 Repair
Continued
Action Note
maining screws.
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
house.
xx1300000541
xx1300000543

4
Tip

xx1300000668

4 Repair
Continued
Action Note
A B C D
5 Foundry Plus:
aged.
fitted.
xx1400000382
A Gasket
B Cable guide
C Washer
D Cover
arm tube.
Tip

working together:
Note

DressPack tube!
Note

xx1400000356
xx1300000820

4 Repair
Continued
Action Note
into the wrist.
Tip

working together:
the cable harness.

wrist.
xx1300000746

tube.
Note

upper arm.
xx1700000340
xx1700000339

4 Repair
Continued
Action Note
Note
Foundry Plus:
xx1300000557

in the upper arm.
xx1700000690

xx1400000092

4 Repair
Continued
Action Note
xx1700001803
xx1700001804

fitted.
Note
Foundry Plus:
rectly
xx1200000045

4 Repair
Continued
Action Note
Note

xx1300001973
xx1300000544
Refitting the DressPack cable package

If used, refit the DressPack cable package. How to refit the DressPack cable
package is described in more detail in the product manual "IRB 6700 DressPack".
For article number see References on page 10.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
Note
xx1200001067

on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
6 Refit the o-ring.
Tip

7
CAUTION

aged.
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
inner screw.
Note
xx1200001016

on the connectors.
xx1200001015
xx1200001021
5
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

Note

properly fitted.

page 839.
xx1500001029
xx1300000489

4 Repair
Continued
Action Note
Screws: M5x12.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
xx1600002061
xx1300000596

tors.
2
Note

xx1200001081

xx1300000667

4 Repair
Continued
Action Note
xx1300001113
Note

carrier.
Tip

bottom.
xx1300000485

ment screws.
xx1300000484

4 Repair
Continued
Action Note
motor.
Note

cable.
xx1300000488

xx1200001095
9
CAUTION

aged.
xx1200001080

4 Repair
Continued
Refitting the wrist cover
Action Note
1 Foundry Plus:
xx1400000383

1 Hold the cover angled. See figure!
2 Catch any part of the cable harness
hanging down.
3 Lift the cover, still held in an angle.
position.
5 Secure the cover with its attachment
screws. xx1300000772

3 Remove the lifting accessories.
Action Note

4 Repair
Continued
Action Note
2
DANGER

on page 116.

4 Repair
4.5.2 Replacing the wrist
Strictly forbidden to open the cover on the axis-5 gearbox
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
Location of the wrist

The wrist is located as shown in the figure.
xx1300000597

4 Repair
Continued
Spare part

Wrist See Product manual, spare
Consumables

Cable tie -
O-ring 3HAB3772-110 (circular pro- D=119x3
(hexagon profile)
3HAC044252-001
24h.

from robot.
Cardboard Used for protection.

4 Repair
Continued

Action Note
calibration:
Removing the wrist

These procedures describes how to remove the wrist.
Preparations before removing the wrist
Action Note
2 Remove tools and other equipment fitted
to the wrist.

4 Repair
Continued
Action Note
3 If used, open the DressPack axis-6 cable
support and remove the DressPack cable
package from the process turning disk.
Note
Use caution not to lose the two clamp jaws

on either side of the DressPack cable
package.
xx1400000208
xx1400000223
Clamp jaw
• Axis 1: no significance (as long as
tion)
• Axis 2: -60°
• Axis 3: +60°
• Axis 4: +90°
• Axis 5: +90°
5
DANGER
Turn off all:

guarded space.
6 Prepare a pallet with cardboard in front of

the robot or where it is possible, to be used
for putting down the wrist unit on.

Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1400000355

package.
xx1400000206
xx1300002247

4 Repair
Continued
Action Note
plate.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
Note
Tip

xx1500001029
xx1300000489
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1200001080
xx1300000488

the cable bracket.
xx1300000484

4 Repair
Continued
Action Note
er.
Note

carrier.
xx1300000485
xx1300001113

xx1300000666
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1300000656
Attaching the lifting accessories to the wrist
Action Note
1
CAUTION
The weight of the complete wrist is

125 kg (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)
140 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
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
It is very important that the roundsling is

placed as shown in the figure, to keep the
wrist balanced when it is removed. Placed
at a different position, there is a risk of
sudden change in the balance, which can
cause damage or injury.
Do not attach the roundsling around the
axis-5 gearbox!
xx1300000673

4 Repair
Continued
Action Note
3
Note
Make sure the roundsling is stretched, so

it can carry the weight of the wrist.
Removing the wrist
Action Note
1 If used, remove the bracket with the part
of the ball joint housing still fitted.
xx1700000691

holes and replace them with guide pins. Always use guide pins in pairs.
Tip

to make the wrist slide better.
xx1300000748
3 Remove the remaining attachment screws.
xx1300000749

4 Repair
Continued
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
Make sure that the cabling does not get

damaged.
xx1300000750
5 Use caution and pull out the cabling from

the wrist unit.
xx1300000769
6 Slide the wrist off the guide pins and put it

on a pallet or similar.
xx1300000770
Refitting the wrist

These procedures describes how to refit the wrist.
Preparations before refitting the wrist
Action Note
1
DANGER

are turned off.

4 Repair
Continued
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

to make the wrist slide better.
xx1700001595
5 If axis-5 is not already in position +90°, 24 VDC power supply

connect the 24 VDC power supply, release
the brakes and move the axis manually into
that position.
• + = pin 2
• - = pin 5
Attaching the lifting accessories to the wrist
Action Note
1
CAUTION
The weight of the complete wrist is

125 kg (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)
140 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.

4 Repair
Continued
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
It is very important that the roundsling is

placed as shown in the figure, to keep the
wrist balanced when it is removed. Placed
at a different position, there is a risk of
sudden change in the balance, which can
cause damage or injury.
Do not attach the roundsling around the
axis-5 gearbox!
xx1300000673
3
Note
Make sure the roundsling is stretched, so

it can carry the weight of the wrist.
Refitting the wrist
Action Note
1 Lift the wrist and insert the guide pins into
the holes of the arm tube.
Tip
Leave a small opening between wrist and

arm tube. This will make it easier to run the
cable harness back into the wrist.
xx1300000770
2 Run the cabling into the wrist unit.

Be careful not to damage any part of the
cable harness.
xx1300000769

4 Repair
Continued
Action Note
3 Mount the four sealing plate nuts on the
tube shaft.
4 Slide the wrist into fitting position.
xx1300000771
5 Fit 10 of the 12 attachment screws and Screws: M12x50.

washers.
xx1300000749
6 Remove the guide pins and replace them

with the remaining attachment screws and
washers.
xx1300000748
7 Tighten the attachment screws. Tightening torque: 120 Nm.

4 Repair
Continued
Action Note
gland opening.
xx1300000738

inner screw.
Note
xx1200001016

on the connectors.
xx1200001015

4 Repair
Continued
Action Note
xx1200001021
5
CAUTION

aged.

screws.
Note

Note

Note

properly fitted.

4 Repair
Continued
Action Note

page 839.
xx1500001029
xx1300000489

4 Repair
Continued
Action Note
Screws: M5x12.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
xx1600002061
xx1300000596

tors.
2
Note

xx1200001081

xx1300000667

4 Repair
Continued
Action Note
xx1300001113
Note

carrier.
Tip

bottom.
xx1300000485

ment screws.
xx1300000484

4 Repair
Continued
Action Note
motor.
Note

cable.
xx1300000488

xx1200001095
9
CAUTION

aged.
xx1200001080

4 Repair
Continued
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

tors.
2 Foundry Plus:
xx1400000383


4 Repair
Continued
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.
position.
screws.
xx1300000772

4 Foundry Plus:
on the wrist.
7
DANGER

on page 116.

4 Repair
4.5.3 Replacing the turning disc
Location of the turning disc

The turning disc is located in the front of the wrist housing as shown in the figure.
xx1300000491
Spare part

Turning disc See Product manual, spare
Consumables

24h.

Removing the turning disc

Use these procedures to remove the turning disc.
Preparations before removing the turning disc
Action Note
1 Run the robot to a position most comfort-
able for the removal of the turning disc.

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

guarded space.
3 Remove any equipment fitted to the turning

disc.
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
2 - IRB 6700-200/2.60, -175/2.60 LID, -

155/2.85, -140/2.85 LID
xx1300002302
3 - IRB 6700-300/2.70, -270/2.70 LID, -

245/3.00, -220/3.00 LID
xx1400002195

4 Repair
Continued
Action Note
4 Remove the turning disc.
xx1300000493
Replacing the synchronization mark plate

The design of the turning disc spare part might require replacement of the axis-6
synchronization mark plate if the existing plate is not compatible with the new
turning disc.
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
Incompatible synchronization mark plate is Compatible synchronization mark plate is in-

installed. stalled.
Replace the plate. No action required.

4 Repair
Continued
Fitting the axis-6 synchronization mark plate

There are different attachment holes on the plate used for different robot variants.
See table below.
IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-200/2.80 LID, -175/3.05, -155/3.05 LID, - -220/3.00 LID
150/3.20, -145/3.20 LID, IRB 6700-200/2.60,
-175/2.60 LID, -155/2.85, -140/2.85 LID
xx1500000877 xx1500000878
Use the holes closest to the synchronization Use the holes at the back end of the synchron-
mark. ization plate.
Refitting the turning disc

Use this procedure to refit the turning disc.
Screw joint for refitting turning disc
Variant Screw dimen- Number of Number of Tightening

sion screws washers torque
IRB 6700-235/2.65 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-220/2.65 LID M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-205/2.80 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-175/3.05 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-150/3.20 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-200/2.60 M10x25 9 pcs 3 pcs 70 Nm
IRB 6700-155/2.85 M10x25 9 pcs 3 pcs 70 Nm
IRB 6700-300/2.70 M10x25 21 pcs 21 pcs 70 Nm
IRB 6700-245/3.00 M10x25 21 pcs 21 pcs 70 Nm

4 Repair
Continued
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
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 turning disc with its attachment Washers: Steel 8.4x13x1.5 (24 pcs)
screws and washers.
xx1300000492
5 IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, Tightening torque: 70 Nm

-140/2.85 LID Attachment screws: M10x25, Steel 12.9
Secure the turning disc with its attachment Gleitmo 603, (9 pcs)
screws and washers. Washers: (3 pcs)
xx1300002302

4 Repair
Continued
Action Note
screws and washers. Washers: Steel 11x17x25 (21 pcs)
xx1400002195
Action Note
1
DANGER

on page 116.

4 Repair
4.5.4 Replacing the process turning disc
Location of the process turning disc

The process turning disc is located in the front of the wrist housing as shown in
the figure.
xx1400001391

Consumables

Rust preventive - Mercasol, used on Foundry
Plus
Removing the process turning disc

Use these procedures to remove the process turning disc.
Preparations before removing the process turning disc
Action Note
1 Run the robot to a position most comfort-
able for the removal of the process turning
disc.

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

guarded space.
3 Remove any equipment fitted to the pro-

cess turning disc.
Removing the process turning disc
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
2 IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,

-140/2.85 LID
Remove the nine M10 screws and three
washers, that secure the process turning
disc.
xx1400001394

4 Repair
Continued
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
4 Remove the process turning disc.
xx1400001393
Replacing the synchronization mark plate

The images below shows a wrist with standard turning disc, but is also valid for
the process turning disc.
The design of the turning disc spare part might require replacement of the axis-6
synchronization mark plate if the existing plate is not compatible with the new
turning disc.

4 Repair
Continued
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
Incompatible synchronization mark plate is Compatible synchronization mark plate is in-

installed. stalled.
Replace the plate. No action required.
Fitting the axis-6 synchronization mark plate

There are different attachment holes on the plate used for different robot variants.
See table below.
IRB 6700-235/2.65, -220/2.65 LID, -205/2.80, IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-200/2.80 LID, -175/3.05, -155/3.05 LID, - -220/3.00 LID
150/3.20, -145/3.20 LID, IRB 6700-200/2.60,
-175/2.60 LID, -155/2.85, -140/2.85 LID
xx1500000877 xx1500000878
Use the holes closest to the synchronization Use the holes at the back end of the synchron-
mark. ization plate.

4 Repair
Continued
Refitting the process turning disc

Use this procedure to refit the process turning disc.
Screw joint for refitting process turning disc
Variant Screw dimen- Number of Number of Tightening

sion screws washers torque
IRB 6700-235/2.65 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-205/2.80 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-175/3.05 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-150/3.20 M8x25 24 pcs 24 pcs 35 Nm
IRB 6700-200/2.60 M10x25 9 pcs 3 pcs 70 Nm
IRB 6700-155/2.85 M10x25 9 pcs 3 pcs 70 Nm
IRB 6700-300/2.70 M10x25 21 pcs 21 pcs 70 Nm
IRB 6700-245/3.00 M10x25 21 pcs 21 pcs 70 Nm
Refitting the process turning disc
Action Note
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
The figure show standard turning disc.

Surfaces to apply Mercasol on are the
same with process turning disc.

4 Repair
Continued
Action Note
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

Secure the process turning disc with its Gleitmo 603, (9 pcs)
attachment screws and washers. Washers: (3 pcs)
xx1400001394

4 Repair
Continued
Action Note
Secure the process turning disc with its Gleitmo 603, (21 pcs)
attachment screws and washers. Washers: Steel 11x17x25 (21 pcs)
xx1400001395
Action Note
1
DANGER

on page 116.

4 Repair
4.5.5 Replacing the lower arm
Location of the lower arm

The lower arm is located as shown in the figure.
xx1300000786
Summary of the replacement procedure

This is a brief summary of the replacement procedure, containing the major actions
to be performed.
1 Unload the balancing device.
2 Remove the shaft in the balancing device front link ear
3 Remove the cabling from the upper and lower arm.
4 Remove the upper arm.
5 Replace the lower arm.
Spare part

Lower arm See Product manual, spare
Consumables

For lubrication of the front
bearing of the balancing
device.

4 Repair
Continued

O-ring 3HAB3772-111 (circular pro- D=169.5x3
(hexagon profile)
(hexagon profile)
(hexagon profile)
3HAC044252-001
24h.

Distance tool 3HAC030662-001 Only used to keep the balancing device
in a locked position, after the balancing
device springs has been unloaded with
the help of the robot itself.
DANGER
Never use this tool to unload or restore

a balancing device!

closed.
Dismantle and mounting tool 3HAC028920-001 Used for removing and fitting shaft and
bearings.
User instructions are enclosed with the
tool.
Hydraulic pump 80 MPa 3HAC13086-1 To be used with the press and puller
tools.
See technical specifications in the user
instructions for the press equipment.
Hydraulic cylinder 3HAC11731-1 To be used with the press and puller
tools.
closed.

4 Repair
Continued

from robot.
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
Anvil 3HAC047273-001 Included in the tool kit Dismantle and
mounting tool (3HAC028920-001).

Action Note
calibration:

4 Repair
Continued
Removing the lower arm

Use these procedures to remove the lower arm.
Preparations before removing the lower arm
Action Note
2
DANGER
Turn off all:

guarded space.
3 Remove all equipment fitted to upper and

lower arms.
Position of the robot in the continued process
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°.
• + = pin 2
• - = pin 5
xx1200001081
3
DANGER
Turn off all:

guarded space.

4 Repair
Continued
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
Do not use the Distance tool (3HAC030662-

001) to unload or restore the pressure of
the balancing device springs! This tool is
only used to lock the spring unit in a com-
pressed position, after axis-2 has been
jogged to -30° or +30°. Fitting and removal
of the tool shall only be done with axis-2 in
this position!
To unload or restore a new balancing
device or if the spring unit of the balancing
device cannot be compressed by jogging
the robot, only use the Hydraulic press
equipment, balancing device
(3HAC074411-001).
2 Jog axis-2 to: This is done in order to compress the bal-

• -30° or +30° ancing device springs inside the balancing
device before fitting the Distance tool.
3
DANGER
Turn off all:

working area.
4 Remove the cover plate on the back of the

balancing device.
DANGER
DO NOT remove any other screws than the

rear cover attachment screws.
xx1300000554

4 Repair
Continued
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
Use caution when tightening the screws.

The threads in the cover can be damaged
if more tightening torque than 45 Nm is
used, risking that the Distance tool is not
properly fitted. A
xx0800000480
A Distance tool: 3HAC030662-001

6 Turn the power on temporary.
7 Jog axis-2 to the calibration position. This is done to compress the balancing
The balancing device is now unloaded. device springs, making it possible to re-
move the front shaft of the balancing
device.
8 Let the Distance tool stay fitted during the
continued procedure.
9
DANGER
Turn off all:

working area.
Preparations before removing the shaft in the link ear
Action Note
1 Jog axis-2 to the calibration position (if not
already in this position).

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

guarded space.
3 Remove any equipment, if fitted, on or

close to the balancing device.
4
CAUTION
The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700-235/2.65, -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)
185 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
5 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1
xx1300000661
6 Fit the lifting accessory (chain) to the Lifting accessory (chain): 3HAC15556-1
shackle and raise to unload the weight.

4 Repair
Continued
Removing the shaft in the front (link ear)
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
2 Remove the two screws.
xx1900002146

4 Repair
Continued
Action Note
3 Unscrew the attachment screw and washer.
xx1200001279
• M16x70 quality steel 8.8-A3F

4 Pull the shaft out using the dismantle and Dismantle and mounting tool:
mounting tool, according to user instruc- 3HAC028920-001
tions enclosed with the equipment. User instructions are enclosed with the
tool.
xx0900000813
Go to the user instructions enclosed with

the press tool.
DANGER
Handling the tool incorrectly will cause

serious injury.
for the tool.
5 Remove the attachment screws of the cable

bracket on the frame and let it hang loose.
xx1200001283
6 Put down the balancing device and let it

rest on the frame.
xx1200001281

4 Repair
Continued

Action Note
1
DANGER

are turned off.
xx1400000355

package.
xx1400000206
xx1300002247

4 Repair
Continued
Action Note
plate.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
Note
Tip

xx1500001029
xx1300000489
Removing cable brackets
Action Note
1 Unscrew the screws that hold the bracket
and let it hang free.
xx1200001184

4 Repair
Continued
Action Note
2 If used, open the ball joint housings on the
lower arm and remove the DressPack.
xx1400000195
3 If used, unscrew the screws that hold the

connection plate and let the DressPack
hang free.
xx1200001332
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1200001067
Action Note
1
DANGER

are turned off.

xx1200001135

4 Repair
Continued
Action Note
xx1200001070
xx1200001066

Tip

the same position.
xx1300000656

4 Repair
Continued
Action Note
1
DANGER

are turned off.

xx1200001080
xx1300000488

the cable bracket.
xx1300000484

4 Repair
Continued
Action Note
er.
Note

carrier.
xx1300000485
xx1300001113

xx1300000666

4 Repair
Continued
Action Note
1 Remove the cover.
Note
Foundry Plus:
cover.
xx1200000045

xx1700001803
xx1700000690

4 Repair
Continued
Action Note
backwards.
xx1400000720
5
Tip

arm.
xx1300000668
xx1300000557

4 Repair
Continued
Action Note
Note

per arm.
xx1700000340
xx1700000339
xx1300000543

4 Repair
Continued
Action Note
Note

xx1300001973
Cable guide.
xx1300000544

house.
xx1300000541

4 Repair
Continued
Action Note
wrist.
Tip

working together:
cable harness.

arm tube.
xx1300000746
Tip

working together:
cable harness.

Note

side.
300/2.70, -270/2.70 LID, -245/3.00, -220/3.00
LID)
xx1400002561

4 Repair
Continued

Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
xx1200001133
xx1400002196
xx1200001134

4 Repair
Continued
Action Note
and in the wrist.
xx1200001308

xx1400002197
LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID
Action Note
pins.
Note

are removed!
Tip

xx1300000659

4 Repair
Continued
Action Note
xx1300000747
Action Note
Note

are removed!
Tip

xx1300002245

xx1300002246

4 Repair
Continued
Action Note
Note

are removed!
Tip

xx1400002563

xx1400002564
Action Note
1
Note

xx1400002197

4 Repair
Continued
Action Note
xx1300001610
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,

-140/2.85 LID
TBD
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID
xx1700000059

pared area.
CAUTION

harness.

4 Repair
Continued
Action Note
3 gearbox:
ure.
Preparations before removing the lower arm
Action Note
1
DANGER

are turned off.
2 Open the ball joint housings on the lower

arm and remove the DressPack.
3 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

lower arm!
xx1300000540

4 Repair
Continued
Action Note
4 Remove the cable harness from inside the
lower arm.
xx1300000733
5
CAUTION
The lower arm weighs

145 kg (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)
160 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly!
6 Apply the lifting accessory to the lower arm.
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.
Tip

to make the lower arm slide better.
xx1300000788

4 Repair
Continued
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
4 Make sure the lifting accessory is holding

the weight of the arm system.
5 Remove the remaining screw, slide the
lower arm out on the guide pins and re-
move the lower arm.
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.
Tip

xx1400002181

4 Repair
Continued
Action Note
ment screws that secure the lower arm to
the axis-2 gearbox.
xx1400002182
4 Make sure the lifting accessory is holding

the weight of the arm system.
5 Remove the remaining screw, slide the
lower arm out on the guide pins and re-
move the lower arm.
Refitting the lower arm

Use these procedures to refit the lower arm.
Preparations before refitting the lower arm
Action Note
1
DANGER

are turned off.
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

casol.
xx1700001879

4 Repair
Continued
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
4 Valid for variants: IRB 6700-300/2.70, - Guide pin, M16x150: 3HAC13120-2

270/2.70 LID, -245/3.00, -220/3.00 LID. Always use guide pins in pairs.
Fit two guide pins in opposite holes in the
axis-2 gearbox.
Tip

xx1400002189
5
CAUTION
The lower arm weighs .

145 kg (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)
160 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
6 Attach the lifting accessory to the lower

arm.

4 Repair
Continued
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
The lower arm weighs .

145 kg (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)
160 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
2 Lift the lower arm onto the guide pins and

slide it into position.
3 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
4 Fit one attachment screw in one of the up-

per holes using it for security and lower the
lifting accessory a little.
xx1300000790

4 Repair
Continued
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
6 Disconnect the 24 VDC power supply (if

used).
with the remaining attachment screws.
xx1300000788
8 Secure the remaining attachment screws. Tightening torque M16: 300 Nm

9 Remove the lifting accessory from the
lower arm.
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.

4 Repair
Continued
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

4 Secure the lower arm by fitting and tighten- Tightening torque M16: 300 Nm
ing the accessible screws. Attachment screws: M16x50 quality steel
12.9 Gleitmo (21 pcs)
Washers: steel 17x25x3 (21 pcs)
xx1400002190
5 Disconnect the 24 VDC power supply (if

used).
with the remaining attachment screws.
xx1400002181
7 Secure the remaining attachment screws. Tightening torque M16: 300 Nm

4 Repair
Continued
Action Note
8 Remove the lifting accessory from the
lower arm.
Action Note
CAUTION

casol.
xx1700001880

150/3.20, -145/3.20 LID
Tip

xx1700000058

4 Repair
Continued
Action Note
Tip

xx1400000361

Tip

xx1700000056

4 Repair
Continued
LID, -150/3.20, -145/3.20 LID
Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
pins.
arm: Rotation tool
• + = pin 2
• - = pin 5

M12 (25 of 27 pcs)
xx1400000359

4 Repair
Continued
Action Note
maining M12 screws.
xx1300000659
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
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
pins.
arm: Rotation tool
• + = pin 2
• - = pin 5

4 Repair
Continued
Action Note

ers.
xx1300002246

xx1300002245
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

4 Repair
Continued
Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
lower arm.
arm: Rotation tool
lease the brakes.
• + = pin 2
• - = pin 5
xx1700000057

4 Repair
Continued
Action Note
maining screws.
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
Refitting the cable harness - lower arm
Action Note
1
Tip

xx1300000668
2 Run the upper end of the cable harness up

through the lower arm.
xx1300000733

Note

of the lower arm.
xx1300000734

4 Repair
Continued
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

of the lower arm.
xx1300000558
Action Note
house.
xx1300000541

4 Repair
Continued
Action Note
xx1300000543

4
Tip

xx1300000668
A B C D
5 Foundry Plus:
aged.
fitted.
xx1400000382
A Gasket
B Cable guide
C Washer
D Cover

4 Repair
Continued
Action Note
arm tube.
Tip

working together:
Note

DressPack tube!
Note

xx1400000356
xx1300000820

4 Repair
Continued
Action Note
into the wrist.
Tip

working together:
the cable harness.

wrist.
xx1300000746

tube.
Note

upper arm.
xx1700000340
xx1700000339

4 Repair
Continued
Action Note
Note
Foundry Plus:
xx1300000557

in the upper arm.
xx1700000690

xx1400000092

4 Repair
Continued
Action Note
xx1700001803
xx1700001804

fitted.
Note
Foundry Plus:
rectly
xx1200000045

4 Repair
Continued
Action Note
Note

xx1300001973
xx1300000544
Action Note
gland opening.
xx1300000738
Note
xx1200001067

4 Repair
Continued
Action Note
on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

6 Refit the o-ring.
Tip

7
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Action Note
gland opening.
xx1300000738

inner screw.
Note
xx1200001016

4 Repair
Continued
Action Note
on the connectors.
xx1200001015
xx1200001021
5
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

Note

properly fitted.

page 839.
xx1500001029
xx1300000489

4 Repair
Continued
Action Note
Screws: M5x12.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
xx1600002061
xx1300000596

tors.
2
Note

xx1200001081

xx1300000667

4 Repair
Continued
Action Note
xx1300001113
Note

carrier.
Tip

bottom.
xx1300000485

ment screws.
xx1300000484

4 Repair
Continued
Action Note
motor.
Note

cable.
xx1300000488

xx1200001095
9
CAUTION

aged.
xx1200001080

4 Repair
Continued
Concluded refitting of the cable harness
Action Note
xx1500001029
xx1300000489

4 Repair
Continued
Action Note
xx1500001030
xx1300000490

so it will not be damaged when the wrist
cover is fitted.
xx1600002061
xx1300000596

tors.

4 Repair
Continued
Action Note
4 Foundry Plus:
xx1400000383

5 Use caution in order not to damage the
cable harness when the wrist cover is refit-
ted, by following this method:
1 Hold the cover tilted. See figure!
2 Put the cable harness on the cover.
position.
screws.
xx1300000772

6 If the robot is equipped with DressPack How to refit the DressPack cable package
cable package: is described in the product manual "IRB
• Refit the distance to the wrist cover. 6700 DressPack". For article number see
• Refit the ball joint housing to the References on page 10.
distance.
• Refit the bracket with the ball joint
housing to the upper arm tube.
• Refit the process turning disk.

4 Repair
Continued
Action Note
7 Refit the bracket to the frame.
xx1200001184
8 Refit the connection plate.
xx1200001332
9 If used, refit the DressPack in the ball joint

housings on the lower arm.
xx1400000195
Refitting the front shaft of the balancing device

Action Note
1 Turn the power to the robot on temporarily.

4 Repair
Continued
Action Note
2 Use caution and jog the robot to the calibration
position (if not already done).
3
DANGER
Turn off all:

area.
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
Verify that the link ear is correctly turned.
xx1300000784
B
8 Foundry Plus:
Apply Mercasol on the surfaces on the shaft and
front ear.
A
A
C
xx1400000368
A Front link ear

B Shaft
C Mercasol (red dotted lines)

4 Repair
Continued
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

press tool.
DANGER

injury.
Read and follow enclosed user instructions for
the tool.
11 Apply locking liquid (Loctite 2701) on the threads

of the screw, first entering the threads in the
frame.
xx1300000782
12 Secure the shaft with screw and washer. Tightening torque: 180 Nm
xx1200001279

4 Repair
Continued
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
Concluded refitting of the front shaft
Action Note
1 Remove the lifting accessory from the bal-
ancing device.

4 Repair
Continued
Action Note
2 Refit the cable bracket (if not already refit-
ted).
xx1200001283
3
DANGER
Do not use the Distance tool: 3HAC030662-

001 to unload or restore the pressure of
the balancing device spring unit! This tool
is only used to lock the spring unit in a
compressed position, after axis-2 has been
this position!
the robot, only use the hydraulic press tool
Dismantle and mounting tool 3HAC028920-
001.
4 Jog axis-2 to: This is done in order to compress the

• -30° or +30°. spring unit inside the balancing device be-
fore refitting or removal of the distance tool.
5
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
6 Remove the distance tool.
xx0800000480

7 Refit the cover plate. Attachment screws: M10 quality 12.9 (4
pcs)
xx1300000554
Action Note
1 Remove the lifting accessory.

4 Repair
Continued
Action Note
3
DANGER

on page 116.

4 Repair
4.6.1 Replacing spherical roller bearing, link ear
4.6 Frame and base
Location of spherical roller bearing

The spherical roller bearing is located in the link ear of the balancing device.
xx1300000773
A Attachment screws M6x10 quality 8.8-A2F (2 pcs)

B End cover
C Radial sealing with dust lip, 50x68x8 (2 pcs)
D O-ring 85x3
E Spherical roller bearing
F Washer

to be performed.
2 Replace the spherical roller bearing.
3 Restore the balancing device.

4 Repair
Continued
Spare part

Spherical roller bearing kit 3HAC045815-001 The maintenance kit contains:
• End cover
• Radial sealing with
dust lip, 50x68x8 (2
pcs)
• O-ring 85x3
• Spherical roller bearing
• Washer
Consumables

Protection plug 3HAC4836-26 Located at the front link ear of the bal-
Only compatible with shaft ancing device.
3HAC072597-001. See Shaft
link ear versions on page 472.
VK cover, 28x7 3HAA2166-12 Located at the front link ear of the bal-
Locking liquid - Loctite 2400 (or equivalent Loctite 243)

DANGER

a balancing device!
Hydraulic press equipment, 3HAC074411-001 Used to unload or restore a balancing

balancing device device.
bearings.
tool.
tools.
tools.

4 Repair
Continued

Lock screw, M16x120 - Used to secure lower arm.
closed.
Unloading the balancing device

Use the correct tool for locking the balancing device springs in compressed position
Locking of the compressed balancing device springs in an unloaded position, can
be done in two different ways using two different tools:
• Distance tool (compression of the balancing device springs is done with help
of the robot itself)
• Hydraulic press equipment, balancing device (compression of the balancing
device springs is done with the tool)
The situations when to use which tool are very different, see When to use which
tool on page 455.
The method described in this procedure, describes how to use the Distance tool
(3HAC030662-001). The Distance tool can not be used to unload or restore the
pressure of the balancing device spring unit! The Distance tool is only used to
keep the balancing device springs in a locked position, after they have been
unloaded with the help of the robot itself (as described in this procedure) and with
the balancing device still being fitted on the robot.
When to use which tool

To unload or restore a balancing device which cannot be done with the help of the
robot itself, the Hydraulic press equipment, balancing device (3HAC074411-001)
must be used. See user instructions enclosed with the tool.
Illustration Art. no. Note
3HAC030662-001 This tool is only used to keep the balan-
Distance tool cing device in a locked, already unloaded
position. The balancing device springs
has been unloaded with the help of the
robot itself.
Use this tool:
• to lock the balancing device
springs in a compressed position
(compressed by the robot)
See Unloading the balancing device
xx1400000726
springs with the robot and locking posi-
tion with the Distance tool on page 457.
DANGER

a balancing device! This means that this
tool can never be removed from a balan-
cing device while the balancing device
is removed from the robot.

4 Repair
Continued
Illustration Art. no. Note

3HAC074411-001 This tool is used to unload or restore a
Hydraulic press equipment, balancing device. The balancing device
balancing device can either be installed on a robot or not.
This tool also locks the balancing device
in an unloaded position after unloading.
xx1300000672 Use this tool:
• to unload a balancing device
without the help of the robot itself
• to unload a balancing device that
needs to be restored after it has
been removed from the robot
• to unload a balancing device not
fitted on the robot, such as a
spare part.
See Unloading the balancing device
springs and locking position with the
Hydraulic press equipment, balancing
device on page 456
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
Turn off all:

working area.

balancing device.
DANGER

xx1300000554

4 Repair
Continued
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

the press tool.
DANGER

serious injury.
for the tool.
tool (3HAC030662-001).
Action Note
1
DANGER

this position!
(3HAC074411-001).

3
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
balancing device.
DANGER

xx1300000554

pcs)
DANGER

properly fitted. A
xx0800000480

device.
9
DANGER
Turn off all:

working area.

4 Repair
Continued
Removing the spherical roller bearing

Use these procedures to remove the spherical roller bearing in the link ear.
Preparations before removing the spherical roller bearing
Action Note
1 Verify that the balancing device is un- See Unloading the balancing device on
loaded. page 455.
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
Turn off all:

working area.

6
CAUTION

ing cradle) is
140 kg (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)
185 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.

4 Repair
Continued
Action Note
xx1300000661
8 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.
Action Note
pull it out.
xx1200001278
xx1900002311

4 Repair
Continued
Action Note
xx1900002146
xx1200001279

tool.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.

4 Repair
Continued
Action Note
xx1200001283

rest on the frame.
xx1200001281
Removing the spherical roller bearing, link ear
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

4 Repair
Continued
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

the press tool.
DANGER

serious injury.
for the tool.
Refitting the spherical roller bearing

Refitting the spherical roller bearing, link ear
Action Note
1 Wipe clean all contact surfaces from resid-
ual grease.

4 Repair
Continued
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
Make sure that the sealing is turned accord-

ing to the figure.
xx1300000839
4 Use a plastic mallet or similar on the Press

tool J and refit the radial sealing.
xx1300000777
5 Apply some grease on the surface for the

bearing.

4 Repair
Continued
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

the press tool.
DANGER

serious injury.
for the tool.
7 Refit the o-ring.
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 Repair
Continued

Action Note
3
DANGER
Turn off all:

area.
3HAC15556-1
the shaft.
from contamination.
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
front ear.
A
A
C
xx1400000368
A Front link ear

B Shaft

4 Repair
Continued
Action Note
Note
Foundry Plus:
plied.
xx1200001280
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.

frame.
xx1300000782
xx1200001279

4 Repair
Continued
Action Note
xx1200001278
xx1900002311
xx1300000783
grease. 10 Nm
xx1900002146
Action Note
ancing device.

4 Repair
Continued
Action Note
ted).
xx1200001283
3 Remove the locking screw (M16x120).
xx1200001116
4 Foundry Plus:
Apply Mercasol in the hole for the locking
screw.
xx1400000372

4 Repair
Continued
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
Turn off all:

working area.
Remove the Distance tool.

unloaded and locked in unloaded position
with the Hydraulic press equipment, balan-
cing device:
Restore the balancing device according to User instructions are enclosed with the
instructions for the press equipment. tool.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.
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

4 Repair
4.6.2 Replacing the balancing device
Location of the balancing device

The balancing device is located as shown in the figure.
xx1300000660

to be performed.
2 Replace the balancing device.
Spare part
Spare parts Spare part number Note

Balancing device See Product manual, spare

4 Repair
Continued
Consumables

Grease 3HAA1001-294 Tribol GR 100-0 PD
Protection plug 3HAC4836-26 Located at the front link ear of the bal-
VK cover, 28x7 3HAA2166-12 Located at the front link ear of the bal-
VK cover, 90x12 3HAA2166-28 Located at the cradle of the balancing
device. 2 pcs required.
Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat. Recommen-
ded drying time is 24h.
Flange sealant for conical fit- - Loctite 5400 (or equivalent Loctite 577)
tings
Shaft link ear versions
Shaft link ear Shaft link ear

3HAC072597-001 3HAC044036-001
xx1900002309 xx1900002310

Threaded bar, M16x340 -
Anvil 3HAC047273-001 Included in the tool kit Dismantle and
mounting tool (3HAC028920-001).
Hydraulic press equipment, 3HAC074411-001 Used to unload or restore a balancing
balancing device device.
bearings.
tool.

4 Repair
Continued

tools.
tools.
closed.

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
Turn off all:

working area.

balancing device.
DANGER

xx1300000554

4 Repair
Continued
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

the press tool.
DANGER

serious injury.
for the tool.
Removing the balancing device

Use these procedures to remove the balancing device.
Preparations before removing the balancing device
Action Note
1 Verify that the balancing device is un- See Unloading the balancing device on
loaded. page 473.
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).
of the lower arm, in order to avoid acci-
dents or damage.
xx1200001116
4
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
Attaching lifting accessory to the balancing device
Action Note
1
CAUTION

ing cradle) is
140 kg (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)
185 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
xx1300000661

4 Repair
Continued
Removing the rear shafts

Perform this procedure on both sides.
Action Note
1 Remove the both VK covers using one of VK cover, 90x12: 3HAA2166-28
the recommended 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
Vent hole for air pressure:
xx1700002189
2 Wipe off any residual grease inside the re-

cess.

4 Repair
Continued
Action Note
3 Unscrew the attachment screws on each
shaft.
xx1300000663
M16x70 quality steel 12.9 Gleitmo 603

4 Remove retaining ring, bore on one side.
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

the press tool.
DANGER

serious injury.
for the tool.

4 Repair
Continued
Action Note
pull it out.
xx1200001278
xx1900002311
xx1900002146

4 Repair
Continued
Action Note
xx1200001279

tool.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.

xx1200001283

rest on the frame.
xx1200001281

4 Repair
Continued
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
The distance tool shall, under no circum-

stance, be fitted on or be removed from a
balancing device that not is fitted to the
robot!
Fitting and removing this tool can only be
done in a safe way with axis-2 in -30° or
+30° position and with the balancing device
fitted to the robot.
Refitting the balancing device

Use this procedure to refit the balancing device.
Action Note
1
CAUTION

ing cradle) is
140 kg (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)
185 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.

4 Repair
Continued
Action Note
xx1300000661
Unloading a new spare part, balancing device

Before a new spare part balancing device is fitted, the springs must be unloaded
using the Hydraulic press equipment, balancing device (3HAC074411-001).
Action Note
1 Remove the cover plate on the back of the balan-
cing device.
DANGER
DO NOT remove any other screws than the rear

cover attachment screws.
xx1300000554

4 Repair
Continued
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

press tool.
DANGER

injury.
the tool.
Refitting the rear shafts

Perform this procedure on both sides.
Action Note
1
DANGER
Turn off all:

working area.
2 Lift the balancing device into position in

the cradle.
3 Apply a big screwdriver between the cradle
and the balancing device, as shown in the
figure when the shafts are refitted.
xx1300000838

4 Repair
Continued
Action Note
4 Apply the refitting tool and press the shafts Dismantle and mounting tool:
into position one at a time. 3HAC028920-001
tool.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.
5 Foundry Plus: C
Apply Mercasol on matching surfaces on

the axis and balancing device. See the fig-
B
ure!
xx1400000367
A Mercasol (red dotted lines)

B Balancing device
C Shaft
6 Fit the retaining ring.
xx1300000664

4 Repair
Continued
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
8 Refit new VK covers. VK cover, 90x12, 3HAA2166-28
xx1300000837
9 Unscrew both screws in the cradle and fill Grease: 3HAA1001-294

the bearing with grease from the inner hole
(see figure) until grease appears in the
outer hole.
xx1300000832
10 Refit the screws.

11 Wipe clean from residual grease.
12
DANGER

on page 116.

4 Repair
Continued

Action Note
3
DANGER
Turn off all:

area.
3HAC15556-1
the shaft.
from contamination.
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
front ear.
A
A
C
xx1400000368
A Front link ear

B Shaft

4 Repair
Continued
Action Note
Note
Foundry Plus:
plied.
xx1200001280
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.

frame.
xx1300000782
xx1200001279

4 Repair
Continued
Action Note
xx1200001278
xx1900002311
xx1300000783
grease. 10 Nm
xx1900002146
Action Note
ancing device.

4 Repair
Continued
Action Note
ted).
xx1200001283
3 Remove the locking screw (M16x120).
xx1200001116
4 Foundry Plus:
Apply Mercasol in the hole for the locking
screw.
xx1400000372

4 Repair
Continued
Action Note
locked in unloaded position with the Dis-
tance tool:
Jog axis-2 to:
• -30° or +30°.
DANGER
Turn off all:

working area.
Remove the Distance tool.

unloaded and locked in unloaded position
with the Hydraulic press equipment, balan-
cing device:
Restore the balancing device according to User instructions are enclosed with the
instructions for the press equipment. tool.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.
xx1300000554

4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Location of rear bearings, balancing device

The rear bearings of the balancing device are located in the cradle, one on each
side.
xx1300000785
Spare parts

Maintenance set cradle 3HAC045822-001 The maintenance kit contains all neces-
sary parts to replace the bearing, includ-
ing VK covers.
VK covers can be ordered separately,
3HAA2166-28 (2 pcs).
Consumables

VK cover, 90x12 3HAA2166-28 Located at the cradle of the balancing
device. 2 pcs required.

4 Repair
Continued

DANGER

a balancing device!

closed.
Threaded bar, M16x340 -
bearings.
tool.

tool (3HAC030662-001).
Action Note
1
DANGER

this position!
(3HAC074411-001).


4 Repair
Continued
Action Note
3
DANGER
Turn off all:

working area.

balancing device.
DANGER

xx1300000554

pcs)
DANGER

properly fitted. A
xx0800000480

device.

4 Repair
Continued
Action Note
9
DANGER
Turn off all:

working area.
Removing the bearing, cradle

Use these procedures to remove the bearing in the cradle.
Preparations before removing the rear bearings
Action Note
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).
dents or damage.
xx1200001116
3
DANGER
Turn off all:

working area.


4 Repair
Continued
Action Note
5
CAUTION

ing cradle) is
140 kg (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)
185 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
xx1300000661
Removing the shaft end, cradle

The procedure of removing the shaft end in the cradle is the same on both sides.
Note
Remove one shaft end at a time!

4 Repair
Continued
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
Vent hole for air pressure:
xx1700002189
2 Wipe off all residual grease inside the re-

cess.
3 Unscrew the attachment screw securing
the shaft.
xx1300000663

4 Repair
Continued
Action Note
4 Remove the retaining ring bore.
xx1300000664
5 Before pulling out the shaft end, put a big

screw driver between the cradle and balan-
cing device and use it as a distance tool.
xx1300000838
6 IRB 6700 -235/2.65, -205/2.80, -175/3.05, - Dismantle and mounting tool:

150/3.20, -200/2.60, -155/2.85. 3HAC028920-001
Pull out the shaft end with bearing, sealing User instructions are enclosed with the
and distance using the dismantle and tool.
mounting tool, according to user instruc-
tions enclosed with the equipment.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.

4 Repair
Continued
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

the press tool.
DANGER

serious injury.
for the tool.
Refitting the bearing, cradle

Use these procedures to refit the bearing in the cradle.
Refitting the shaft end and rear bearings
Action Note
1 Wipe clean all contact surfaces from resid-
ual grease and other contamination inside
the recess.
2 Foundry Plus: C
Apply Mercasol on matching surfaces on

the axis and balancing device. See the fig-
B
ure.
xx1400000367
A Mercasol (red dotted lines)

B Balancing device
C Shaft

4 Repair
Continued
Action Note
3 Apply some grease in the hole for the
bearing in the cradle.
Note
Do not apply grease on surfaces with Mer-

casol.
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

the press tool.
DANGER

serious injury.
for the tool.
5 Fit the retaining ring bore.
xx1700000343
6 Apply locking liquid on the attachment Loctite 2400 (or equivalent Loctite 243), -
screw.

4 Repair
Continued
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
8 Fit a VK cover to protect the bearing.
Remove the lifting accessories
Action Note
Action Note
1 Refit the retaining ring bore.
xx1300000664

4 Repair
Continued
Action Note
2 Refit the VK-cover. VK cover, 90x12, 3HAA2166-28
Note
Temporarily remove the screw on the

cradle to let go of overpressure if the VK
covers are hard to fit.
xx1700002189
3 Unscrew both screws and refill grease from Grease: 3HAA1001-294

the inner hole (See figure).
xx1300000832
4 Refit the screws.
xx1300000833
5 Wipe clean from residual grease.

6 Remove the Distance tool.

4 Repair
Continued
Action Note
xx1300000554
8
DANGER

on page 116.

4 Repair
4.6.4 Replacing the stop pin
Location of the stop pin

The stop pin is located as shown in the figure.
xx1300000475
Spare part

Stop pin See Product manual, spare


Locking liquid - Loctite 2400 (or equivalent Loctite
243)
Foundry plus: 3HAC034903-001 Mercasol 3110 Waxcoat. Recom-
Rust preventive mended drying time is 24h.

4 Repair
Continued
Removing the stop pin
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
2 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
If the axis-1 is not in this position the stop

pin will not be able to go free from the axis-
1 oil plug draining, when removed.
xx1300000478
3
DANGER
Turn off all:

working area.

use caution and remove it by unscrewing
the set screw, cup point.
CAUTION
The mechanical stop weighs 5 kg and may

unexpectedly fall down when the set screw
is removed.
xx1300000476

4 Repair
Continued
Action Note
5 Remove the stop pin.
xx1300000477
Refitting the stop pin
Action Note
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.).
xx1400000378
2 Fit the stop pin.
xx1300000477

4 Repair
Continued
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 Repair
4.7.1 Replacing the axis-1 motor
4.7 Motors
Location of the axis-1 motor

The motor is located as shown in the figure.
xx1200001064

This list is a brief summary of the replacement procedure, containing the major
actions to be performed.
1 Attach the lifting tools
2 Replace the motor
3 Remove the lifting tools.
Spare parts

Axis-1 motor See Product manual, spare

4 Repair
Continued
Consumables

Grease 3HAC042536-001 Used to lubricate o-rings, Shell Gadus
S2.
O-ring i 3HAB3772-111 (circu- D=169.5x3
lar profile) / Used on motor cover.
3HAC054692-002
(hexagon profile)
O-ring 3HAB3772-107 D=102x3
Used on motor flange.

Lifting accessory, motor 3HAC14459-1
Removal tool kit M12 and M14 3HAC057339-002 Required dimension of removal tool
depends on motor type A or B, see
Identifying the motor by article number
on page 839
Used to push out the motor, if neces-
sary.
Always use removal tools in pairs.
Bits extender 3HAC12342-1 300 mm, bits 1/2"
Leak-down tester -

4 Repair
Continued

Action Note
calibration:
Removing the axis-1 motor

These procedures describe how to remove the motor.
Preparations before removing the axis-1 motor
Action Note
2 Jog the robot to the synchronization posi-
tion.
3
DANGER
Turn off all:

guarded space.

4 Repair
Continued
Action Note
1 Foundry Plus.
plates.
xx1400000722
2 Foundry Plus.
xx1400000723
3 Foundry Plus.
xx1400000724
Disconnecting the motor cables
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1200001067
Action Note
1
DANGER

are turned off.
2 Unscrew the attachment screws and Bits extender: 3HAC12342-1

washers.
Use a bits extender to reach the screws.
xx1200001071
3 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2

4
CAUTION
Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

4 Repair
Continued
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.
6
CAUTION
The weight of the motor is 25 kg

accordingly.
7 Attach the lifting accessories. Lifting accessory (chain): 3HAC15556-1

Lifting accessory, motor: 3HAC14459-1.
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
Handling the tool incorrectly will cause xx2100000666

serious injury.
for the tool.
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
10 Disconnect the brake release tool / 24 VDC

power supply.

4 Repair
Continued
Refitting the axis-1 motor

These procedures describes how to refit the motor.
Preparations prior to refitting motor

Action Note
1
DANGER

off.
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
4 Make sure the o-ring is seated in the groove.
Tip
Lubricate the o-ring with some grease for a better

fitting in the groove.
xx1200001020

4 Repair
Continued
Action Note
5 If the motor is a new spare part, remove the cover.
xx1200001135
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).
Securing the axis-1 motor
Action Note
2
CAUTION
The motor weighs 25 kg.

accordingly.
3 Apply the lifting accessory. Lifting accessory, motor: 3HAC14459-1.

4 Fit the rotation tool. Rotation tool: 3HAB7887-1

4 Repair
Continued
Action Note
connector.
DANGER

serious injury.
for the tool.
Note
If a 24 VDC power supply is used instead

of the brake release tool, connect it to
connector R2.MP1:
• pin 2 = 24V
• pin 5 = 0V
6
CAUTION

ive force is used.
7 Lower the motor into position. Lifting accessory (chain): 3HAC15556-1

• Make sure that the motor pinion is Lifting accessory, motor: 3HAC14459-1.
properly mated to the gear in the
gearbox.
• Make sure that the motor pinion
does not get damaged.
• Make sure that the direction of the
cable gland exit is facing the correct
way.
xx1200001072

4 Repair
Continued
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.
power supply.
Connecting the motor cables
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
Note
xx1200001067

on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
6 Refit the o-ring.
Tip

7
CAUTION

aged.
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
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
Make sure that the axis-1 and axis-2 motor

cables are run through the hole in the pro-
tection plates correctly.
xx1400000723

4 Repair
Continued
Action Note
2 Foundry Plus:
Secure the axis-1 and axis-2 motor cables
with a cable tie.
xx1400000722

4
DANGER

on page 116.

4 Repair
Location of the motor

The motor is located as shown in the figure.
xx1200001112

1 Drain the axis-2 gearbox
2 Attach the lifting tools
3 Replace the motor
4 Remove the lifting tools
5 Refill the axis-2 gearbox with oil.
Spare parts


4 Repair
Continued
Consumables

Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat. Recommen-
ded drying time is 24h.
O-ring i 3HAB3772-111 (circu- D=169.5x3
lar profile) / Used on motor cover.
3HAC054692-002
(hexagon profile)
O-ring 3HAB3772-107 D=102x3

Lifting accessory, motor 3HAC15534-1 Lifting instruction 3HAC15640-2 en-
closed.
Removal tool kit M12 and M14 3HAC057339-002 Used to push out the motor, if neces-
sary.
Size depending on motor type, see
Type A vs type B motors on page 839.
Leak-down tester -

4 Repair
Continued

Action Note
calibration:
Removing the motor

These procedures describes how to remove the motor.
Action Note
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
Secure the weight of the lower arm with a

lock screw, before releasing the brakes on
the axis-2 motor as well as before removing
the axis-2 motor or the axis-2 gearbox.

4 Repair
Continued
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.
dents or damage.
Note
Tighten the lock screw manually, no tools

needed.
xx1200001116
6
DANGER
Turn off all:

guarded space.
7 Remove any equipment hindering access

to the motor.
Action Note
1
DANGER

are turned off.

xx1200001135

4 Repair
Continued
Action Note
xx1200001070
xx1200001066

Tip

the same position.
xx1200001067
Action Note
1 Before removing the motor, make sure that
the axis-2 gearbox is completely drained.

4 Repair
Continued
Action Note
2
DANGER
When releasing the holding brakes of the

motor, the lower arm will be movable and
may fall down if not secured. Verify that the
lower arm is secured as previously de-
scribed, before continuing.
3 To release the brake, connect the 24 VDC

power supply.
Connect to connector R2.MP2, axis-2 mo-
tor:
• + = pin 2
• - = pin 5
4 Remove the attachment screws. Bits extender: 3HAC12342-1
Use a bits extender in order to reach the
screws.
xx1200001117

Tip

to make the motor slide better.
6
CAUTION

ive force is used.
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
8 Disconnect the 24 VDC power supply.

4 Repair
Continued
Action Note
9
CAUTION

accordingly.
10 Carefully lift the motor out on the guide

pins, in order to get the pinion away from
the gear and let it rest on the guide pins.
11 Fasten the lifting accessory. Attach the Lifting accessory, motor: 3HAC15534-1
lifting chain to the accessory and an over- Lifting accessory (chain): 3HAC15556-1
head crane.
12 Remove the motor by sliding it out on the Make sure the pinion is not damaged.
guide pins and lift it off.
xx1200001118
Refitting the motor


Action Note
1
DANGER

off.

groove.

4 Repair
Continued
Action Note
3 Fit a new o-ring.
xx1200001019
Tip

xx1200001020
xx1200001135

4 Repair
Continued
Action Note
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).
Action Note
2
CAUTION

accordingly.
3 Apply the lifting accessory. Lifting accessory, motor: 3HAC15534-1

Lifting accessory (chain): 3HAC15556-1
4
Note
Make sure the cable gland opening is

turned the correct way.
xx1200001120
5 Lift the motor and put it on the guide pins

as close as possible to its final position
without pushing the motor pinion into the
gear.
6 Remove the lifting accessory and allow the
motor to rest on the guide pins.

4 Repair
Continued
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.
tor:
• + = pin 2
• - = pin 5
9
CAUTION

ive force is used.
10 Use caution and fit the motor in its final

position while at the same time rotating the
motor pinion slightly using the rotation tool.
• Make sure that the motor pinion is
properly mated to the gear of the
gearbox.
cable exit is facing the correct way.
11 Fit two of the attachment screws and Screws: M10x30 Steel 12.9 Gle
washers. 603+Geo500
12 Remove the guide pins and replace with
the remaining attachment screws.
Use a bits extender in order to reach the Screw dimension: M10x30 Steel 12.9 Gle
screws. 603+Geo500 (4 pcs)
xx1200001117
14 Perform a leak-down test. See Performing a leak-down test on

page 202.

4 Repair
Continued
Action Note
gland opening.
xx1300000738
Note
xx1200001067

on the connectors.
xx1200001066

4 Repair
Continued
Action Note
Note file)
file)
file)
file)
xx1200001070

6 Refit the o-ring.
Tip

7
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
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

4 Repair
Continued
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.
6
DANGER

on page 116.

4 Repair

The axis-3 motor is located as shown in the figure.
xx1200001113
Spare part

Consumables

O-ring i 3HAB3772-111 (circular pro- D=169.5x3
file) / 3HAC054692-002 Used on motor cover.
(hexagon profile)
O-ring 3HAB3772-107 D=102x3

4 Repair
Continued

closed.
Lifting accessory, motor 3HAC15534-1 Lifting instruction 3HAC15640-2 en-
closed.
sary.
Leak-down tester -

Action Note

4 Repair
Continued
Action Note
calibration:
Removing the motor


Use this procedure to do the necessary preparations before removing the motor.
Action Note
2 Drain the axis-3 gearbox. See Draining the axis-3 gearbox on
page 175.
3 Unload the upper arm using one of these
methods:
• Use caution and jog axis-3 to maxim-
um + position. Release the brakes
and let the upper arm rest against
the axis-3 damper.
• Use a fork lift to rest the upper arm
onto.
• Use lifting slings and an overhead
crane to rest the upper arm onto.
4
DANGER
Turn off all:

guarded space.
5 Remove any equipment hindering access

to the motor.
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1200001067

Action Note
2
DANGER

motor, the upper arm will be movable and
may fall down if not secured. Verify that
the upper arm is secured as previously
described, before continuing.

power supply.
Connect to connector R2.MP3:
• + = pin 2
• - = pin 5
4 Unscrew the attachment screws that hold Bits extender: 3HAC12342-1
the motor.
xx1200001126

4 Repair
Continued
Action Note
Tip

6
CAUTION

ive force is used.
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
page 839
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

accordingly.
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
The pinion must have been parted from

the gear before the motor is angled. If not
there is a risk of damaging the pinion and xx1200001125
gear.

4 Repair
Continued
Action Note
13 Remove the motor by lifting it straight out. Make sure the pinion is not damaged.
xx1200001131
Refitting the motor


Action Note
1
DANGER

off.

groove.
3 Fit a new o-ring.
xx1200001019

4 Repair
Continued
Action Note
Tip

xx1200001020
xx1200001135

glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).

4 Repair
Continued

Use this procedure to secure the motor.
Action Note
2
CAUTION

accordingly.
3 Apply the lifting accessories to the motor. Lifting accessory, motor: 3HAC15534-1
Note
Make sure the cable gland exit is turned ac-

cording to figure.
xx1700000273
4 Lift the motor on to the guide pins and let it

hang with the outer end a little lower when
resting on the guide pins. Do not push the
motor pinion into the gear yet.
This is done in order to fit the motor with the
axis-4 motor still fitted.
xx1200001131


4 Repair
Continued
Action Note
power supply.
• + = pin 2
• - = pin 5
8
CAUTION
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used.
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.
page 202.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
Note
xx1200001067

on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
6 Refit the o-ring.
Tip

7
CAUTION

aged.
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
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.

4 Repair
Continued
Action Note
4
DANGER

on page 116.

4 Repair

xx1200001114
Spare parts

Consumables

O-ring i 3HAB3772-110 (circular pro- D=119x3
(hexagon profile)
O-ring 3HAB3772-107 D=102x3

4 Repair
Continued

sary.
Long AllenKeySocketIN19L - Length: 140 mm.
6-140
Leak-down tester -

Action Note
calibration:

4 Repair
Continued
Removing the motor

Action Note
• 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
Turn off all:

guarded space.
Action Note
1
DANGER

are turned off.

xx1200001135

4 Repair
Continued
Action Note
xx1200001070
xx1200001066

Tip

the same position.
xx1200001067
Action Note
1
CAUTION
Use caution when releasing the brakes!

Axis-4 can move unexpectedly!

4 Repair
Continued
Action Note
power supply.
• + = 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
5
CAUTION

ive force is used.
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

accordingly.

9 Remove the motor by carefully lifting it
straight out/straight up (if the upper arm
points upwards).
Make sure the pinion is not damaged.
xx1200001138

4 Repair
Continued
Refitting the motor


Action Note
1
DANGER

off.

groove.
3 Fit a new o-ring.
xx1200001019
Tip

xx1200001020

4 Repair
Continued
Action Note
xx1200001135

glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).
Action Note

4 Repair
Continued
Action Note
2 Put the motor onto the guide pins.
xx1700000291
3
Note

xx1200001130
4
CAUTION

accordingly.
This requires two persons co-operating, if
the motor is installed from above (if the
upper arm is pointing upwards).
power supply.
• + = pin 2
• - = pin 5

4 Repair
Continued
Action Note
7
CAUTION

ive force is used.
8 Push the motor carefully in position while

at the same time rotating the motor pinion
slightly.
gearbox.
cable gland is facing the correct
way.
10 Secure the motor with its attachment Tightening torque: 35 Nm.
screws and washers. Screws: M8x30 quality 12.9 Gleitmo (4 pcs)
xx1200001137

page 202.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
Note
xx1200001067

on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
6 Refit the o-ring.
Tip

7
CAUTION

aged.
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Action Note
1 Refill the gearbox with oil, if gearbox has See Filling oil into the axis-4 gearbox on
been drained. page 182.
3
DANGER

on page 116.

4 Repair

The axis-5 motor is located inside the wrist, as shown in the figure.
xx1500001899
Spare part

Heat protection plate See Product manual, spare Required, if replacing a type
parts - IRB 6700/IRB 6700Inv A motor with a type B motor.
2 plates required.
See Type A vs type B motors
on page 839.
Consumables

O-ring i 3HAB3772-110 (circular pro- D=119x3
(hexagon profile)
O-ring 3HAB3772-107 D=102x3
Required tools

sary.
Long AllenKeySocketIN19L - Length: 140 mm.
6-140

4 Repair
Continued

Leak-down tester -

Action Note
calibration:

Use these procedures to remove the motor.
Action Note

4 Repair
Continued
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
Turn off all:

guarded space.

Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1400000355

package.
xx1400000206
xx1300002247

4 Repair
Continued
Action Note
plate.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
Note
Tip

xx1500001029
xx1300000489
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1300000656
Action Note
1 Unscrew the attachment screws that secure Bits extender: 3HAC12342-1
the motor, using a bits extender.
xx1200001017
2
CAUTION

ive force is used.
3 If needed, fit removal tools in opposite Removal tool kit M12 and M14:
holes. 3HAC057339-002

4 Repair
Continued
Action Note
4
CAUTION

accordingly.
5 Use caution and lift the motor out. Be

careful not to damage the pinion.
xx1200001018

The procedures describe how to refit the motor.
Preparations before refitting the axis-5 motor
Action Note
1
DANGER
Turn off all:

guarded space.

4 Repair
Continued
Action Note
2 Wipe clean the contact surfaces from any
contamination.
Also wipe clean the o-ring groove.
xx1200001019
3 Check the o-ring. O-ring, 3HAB3772-107

Replace if damaged.
4 Lubricate the o-ring with some grease.
5 Make sure the o-ring is seated in the
groove.
xx1200001020
Action Note
1
CAUTION

ive force is used.

4 Repair
Continued
Action Note
3 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
• + = pin 2
• - = pin 5
4
CAUTION

accordingly.
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

4 Repair
Continued
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

page 202.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
inner screw.
Note
xx1200001016

on the connectors.
xx1200001015
xx1200001021
5
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

Note

properly fitted.

page 839.
xx1500001029
xx1300000489

4 Repair
Continued
Action Note
Screws: M5x12.
xx1500001030
xx1300000490

4 Repair
Continued
Action Note
in a way that it will not be damaged when tion plates.
xx1500001672
xx1300000596

tors.
2 Foundry Plus:
xx1400000383


4 Repair
Continued
Action Note
the wrist.
cover.
position.
screws.
4 Foundry Plus:
on the wrist.
7
DANGER

on page 116.

4 Repair
Location of axis-6 motor

xx1200001080
Spare part

Consumables

Gasket i 3HAC033489-001/ Used on motor cover.
3HAC044252-001

4 Repair
Continued

O-ring 3HAB3772-107 D=102x3
(IRB 6700-235/2.65, -220/2.65 Used on motor flange.
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)
3HAB3772-102
(IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID)
i Information about which of the two types of gasket to choose is found in Product manual, spare
parts - IRB 6700/IRB 6700Inv.

sary.
Leak-down tester -

Action Note

4 Repair
Continued
Action Note
calibration:

Use these procedures to remove the motor.
Action Note
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
Turn off all:

guarded space.

4 Repair
Continued
Action Note
xx1300002247
Action Note
1
DANGER

are turned off.

xx1200001080
xx1300000488

4 Repair
Continued
Action Note
the cable bracket.
xx1300000484

er.
Note

carrier.
xx1300000485
xx1300001113

xx1300000666

4 Repair
Continued
Action Note
1 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
• + = pin 2
• - = pin 5
2 Unscrew the motor attachment screws.
xx1200001090
3
CAUTION

ive force is used.
by fitting the removal tool, motor to the at- 3HAC057339-002
tachment holes of the motor. Always use removal tools in pairs.
5
CAUTION

accordingly.

4 Repair
Continued
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

Use this procedure to refit the motor.

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
groove.
3 Fit a new o-ring.
xx1200001019
Tip

xx1200001020
xx1200001135

4 Repair
Continued
Action Note
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).
Action Note
1
DANGER

are turned off.

power supply.
• + = pin 2
• - = pin 5
3
CAUTION

ive force is used.

4 Repair
Continued
Action Note
4 Check the gasket.
Replace if damaged.
xx1200001094
5
CAUTION

accordingly.

4 Repair
Continued
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

4 Repair
Continued
Action Note
8 Refit the axis-6 motor cables by carefully
pushing them and the carrier into position.
xx1300001113
9 Tighten the M4 screw that holds the carrier.
Note

carrier.
xx1300000485
10 Refit the cable bracket.
xx1300000484

page 202.
12 Disconnect the 24 V DC power supply.

4 Repair
Continued
Action Note
13 Reconnect the connectors.
xx1200001084
14 Check the gasket. Gasket: 3HAC033489-001/ 3HAC044252-

Information about which of the two types
of gasket to choose is found in Product
manual, spare parts - IRB 6700/IRB
6700Inv.
xx1200001095
xx1200001082

4 Repair
Continued
Action Note
in a way that it will not be damaged when tion plates.
xx1500001672
xx1300000596

tors.
2 Foundry Plus:
xx1400000383


4 Repair
Continued
Action Note
the wrist.
cover.
position.
screws.
4 Foundry Plus:
on the wrist.
7
DANGER

on page 116.

4 Repair
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)
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.
Location of the axis-1 gearbox

The axis-1 gearbox is located as shown in the figure.
xx1200001183

4 Repair
Continued

1 Drain the axis-1 gearbox.
2 Remove the cabling from the base.
3 Remove the axis-1 motor.
4 Remove the complete arm system (including frame and balancing device)
as a package.
5 Replace the axis-1 gearbox.
6 Refit in reverse order.
Spare parts
Spare parts Article number Note

Axis-1 gearbox See Product manual, spare
Consumables

Locking liquid - Loctite 2400 (or equivalent Loctite
243)
Flange sealant - Loctite 574
O-ring 3HAB3772-93
O-ring 3HAB3772-164 or
3HAC061327-002 (de-
pends on gearbox vari-
ant, see Product manual,
spare parts - IRB 6700)
O-ring i 3HAB3772-111 (circular /
profile) / 3HAC054692-
002 (hexagon profile)
O-ring 3HAB3772-107
Cable straps -
Sealing ring -

of oil.
4 Repair
Continued

kg.
closed.
on page 839
sary.
Aligning tool 3HAC046645-003 Used for aligning the gearbox against
the frame, so that the play in the motor
does not need to be adjusted.
Guide for reduction gear 3HAC043870-009 Used to guide axis-1 gear and frame
during refitting.
Valid for 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.
Leak-down tester -

4 Repair
Continued
Required documents


Action Note
calibration:
Removing the axis-1 gearbox

These procedures describe how to remove the gearbox.
Preparations before removing the axis-1 gearbox

Use this procedure to do the necessary preparations, before removing the axis-1
gearbox.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 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.
3 Begin draining the axis-1 gearbox. See Draining the axis-1 gearbox on
page 163.

4 Repair
Continued
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
Turn off all:

space.

and remove it by unscrewing the set screw.
CAUTION
The mechanical stop pin weighs 5 kg and

may fall down when the set screw is removed.
xx1300000476

the cable bracket.
xx1200001184

4 Repair
Continued
Action Note
8 Cut the cable tie inside the frame recess.
xx1200001237
9 Lift up the part of the cable harness shown

in the figure, and let it rest against the
bracket.
This is done to be able to reach all attach-
ment screws inside the recess.
xx1200001240
10 Unscrew five of the six attachment screws

inside the frame recess, that secure the frame
to the gearbox.
Note
Leave the outermost screw fitted as a safety

precaution.
xx1200001189
xx1200001185

4 Repair
Continued
Action Note
11 Unscrew five of the six attachment screws
under the balancing device.
Note
Leave the screw closest to the axis-1 motor

fitted.
xx1200001238
xx1200001239
Robot position
-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
• Axis 1: no significance as long as the robot
is secured to the foundation.
• Axis 2: -40°
• Axis 5. +90°
xx1200001132
2
DANGER
Turn off all:

area.


4 Repair
Continued
-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

off.
2
CAUTION
The complete arm system weigh (according to

variants) .
1100 kg (IRB 6700 -235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
1115 kg (IRB 6700 -220/2.65 LID, -200/2.80 LID, -
155/3.05 LID, -145/3.20 LID, -175/2.60 LID, -
140/2.85 LID)
ingly.
xx1200001133
xx1200001234

4 Repair
Continued
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

7 Jog axis-3 slowly until the roundsling is stretched
(approximately +58°), to carry the weight of the
lower arm and frame.
WARNING
Without the roundsling the weight of the lower

arm and frame is applied to the axis-3 gear during
lifting, which risks to damage the gear.
xx1200001235
3 mm.
xx1400002196
Fender washer
xx1200001134

4 Repair
Continued
Action Note
in the arm house and to a roundsling run through Roundsling, 1 m: Length: 1 m, lift-
xx1200001236
Action Note
1 Foundry Plus.
plates.
xx1400000722
2 Foundry Plus.
xx1400000723

4 Repair
Continued
Action Note
3 Foundry Plus.
xx1400000724
Action Note
1
DANGER

are turned off.

xx1200001135
xx1200001070

4 Repair
Continued
Action Note
xx1200001066

Tip

the same position.
xx1200001067
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
washers.
xx1200001071

4
CAUTION

ive force is used.
6
CAUTION

accordingly.


4 Repair
Continued
Action Note
connector.
DANGER

serious injury.
for the tool.
xx1200001072

power supply.
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
xx1300000561
• R1.MP
• R1.SMB
xx1300000591

in the base.
xx1400000366

xx1400000354

4 Repair
Continued
Action Note
secure the bracket.
DressPack hoses.
xx1400000078

tube in the base.
Note

xx1400000088
Action Note
balancing device.
xx1300000732

device.

4 Repair
Continued
Lifting away the complete arm system

Use this procedure to lift away the complete arm system.
Action Note
1 Raise the overhead crane to stretch the
chains and roundslings.
Make sure that the roundsling between the
wrist and the frame is stretched.
holes and replace them with guide pins.
Tip

to make the frame slide better.
xx1700001635
Guide pin, M16x200: 3HAC13120-3
xx1700001636

3 Remove the remaining attachment screws,
that hold the frame to the axis-1 gearbox.
4
CAUTION
The complete arm system weighs: .

1100 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
1115 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
accordingly.

4 Repair
Continued
Action Note
5 Use caution and lift the complete arm sys-
tem.
xx1700001637
6 Move away the complete arm system.

7
DANGER
Make sure that the complete arm system

is resting completely stable on the floor
before removing the lifting accessories. Do
not change the position of the axes from
the position described earlier.
Removing the gearbox
Action Note
1 Remove the attachment screws and washers
that secure the gearbox to the base.
xx1200001186

4 Repair
Continued
Action Note
2 Fit two guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2
Tip

to make the gearbox slide better.
xx1700001653

3 Fit two lifting eyes manually in opposite holes Lifting eye: 3HAC14457-4
in the gearbox.
CAUTION
Leave a couple of millimeters of space

between the lug and the surface of the gear-
box. The surface of the gearbox is a sealing
surface, not to be damaged.
xx1700002193
4
CAUTION
The weight of the gearbox is

92 kg (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)
140 kg (IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
accordingly.

4 Repair
Continued
Action Note
5 Attach the lifting accessory (chain) to the Lifting accessory (chain): 3HAC15556-1
gearbox.
xx1700002194
6 Protect the sealing areas on top of the protec-

tion tube, to avoid damaging them.
xx1700001655
7 Lift away the gearbox.
WARNING
When the gearbox is lifted, make sure not to

damage the Pendulum Calibration bracket.
xx1400001983

4 Repair
Continued
Refitting the axis-1 gearbox

These procedures describe how to refit the axis-1 gearbox.
Preparations of robot base

Use this procedure to do the necessary preparations before refitting the gearbox.
Action Note
1 Check the protection tube for damages.
Especially check the surface for the radial
sealing. See figure!
Replace if damaged.
xx1300000779
2 Fit guide pins in opposite holes in the base. Guide pin, M12x150: 3HAC13056-2
Tip Always use guide pins in pairs.

xx1700001642
3 Wipe clean the contact surfaces on the base

and the surfaces of the protection tube from
any contamination.
4 Put grease on the protection tube.

4 Repair
Continued
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

box. The surface of the gearbox is a sealing
surface, not to be damaged.
xx1700002190
2 Attach the lifting accessory (chain). Lifting accessory (chain): 3HAC15556-1
xx1700002191
3
CAUTION

92 kg (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)
140 kg (IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
accordingly.

4 Repair
Continued
Action Note
contamination.
xx1200001245
5 Wipe clean and put some grease on a new O-ring: 3HAB3772-93.

o-ring.
Note
Do not reuse an old o-ring!
6 Fit the o-ring in the groove of the gearbox.
xx1200001244
7 Wipe clean the surfaces of the hole in axis-1

gearbox.
xx1700002192

4 Repair
Continued
Refitting the gearbox to the base
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
2 Lower the gearbox very carefully onto the

guide pins and onto the protection tube.
Note
Make sure that the o-ring is still fitted cor-

rectly when the gearbox is being fitted.
xx1700001641

4 Remove the lifting accessory and the lifting
eyes.
5 Fit the attachment screws and washers.
Tighten by hand.
xx1200001186
Attachment screws: M12x90 (16 pcs)

4 Repair
Continued
Action Note
6 Torque tighten all screws. Tightening torque: 120 Nm.
7 Remove the guide for the reduction gear.
xx1700002038
Preparations before refitting the arm system
Action Note
1 Remove old residues of flange sealant and
other contamination from the contact sur-
faces on the gearbox.
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

4 Repair
Continued
Action Note
6 Apply guide pins in opposite holes in the Guide pin, M16x200: 3HAC13120-3
gearbox.
Note
Make sure that the guide pins are fitted in

the correct holes in the gearbox. See fig-
ures!
Tip

xx1300000823
xx1300000822

7 Prepare the aligning tool. Aligning tool: 3HAC046645-003
1 Put some grease on the o-ring of the Used for aligning the gearbox against the
aligning tool. frame, so that the play in the motor does
2 Put some grease on the part of the not need to be adjusted.
aligning tool that will mate with the
hole in the gearbox.
3 Also put some grease in the match-
ing hole in the gearbox.
The aligning tool is now prepared to be fit-
ted. Wait until the arm system is lifted into
position and the arm system orientation is
verified visually before fitting the tool.
xx1700001659

4 Repair
Continued
Refitting the arm system
Action Note
1
CAUTION
The arm system weighs .

1100 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
1115 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
accordingly.
2 Make sure that all lifting accessories still

is fitted correctly on the arm system.
3 Attach the upper arm lifting accessory For a more detailed description see Attach-
(chain) to an overhead crane (or similar) ing the lifting accessories on page 596.
and then to the lifting eye in the arm house Lifting accessory (chain): 3HAC15556-1
and to a roundsling run through the wrist.
Roundsling, 1 m: Length: 1 m, lifting capa-
city: 1,000 kg.
xx1200001236
4 Lift the arm system up to reach the contact

surfaces underneath the frame.
5 Remove old residues of flange sealant from
the contact surfaces.

4 Repair
Continued
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
The amount of screw holes differ between

the frame and the gearbox. See figures for
correct entering holes for the guide pins.
xx1300000823
Position of Guide pin, M16x150:
xx1300000822
8 Lower the arm system to align the longest Position of Guide pin, M16x200:
guide pin into the hole.
Note
The outer screw hole in the gearbox (next

to the motor pinion hole) is not used.
xx1300000823

4 Repair
Continued
Action Note
9 Lower the arm system to align the other Position of Guide pin, M16x150:
guide pin into the hole.
xx1300000822
10 Visually verify through the axis-1 motor

hole that the hole is aligned with the pinion
hole in the gearbox.
xx1700002040
xx1700002041

4 Repair
Continued
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.
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.
page 202.
18 Remove the aligning tool, after the leak-
down test is completed successfully.

4 Repair
Continued

Action Note
1
DANGER

off.

groove.
3 Fit a new o-ring.
xx1200001019
Tip

xx1200001020
xx1200001135

4 Repair
Continued
Action Note
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).
Action Note
2
CAUTION

accordingly.


4 Repair
Continued
Action Note
connector.
DANGER

serious injury.
for the tool.
Note

connector R2.MP1:
• pin 2 = 24V
• pin 5 = 0V
6
CAUTION

ive force is used.

gearbox.
way.
xx1200001072

4 Repair
Continued
Action Note
603+Geo500 (4 pcs)
xx1200001071
done). page 202.
power supply.
Action Note
in this order:
• R1.MP
• R1.SMB
xx1300000732

4 Repair
Continued
Action Note
xx1300000736

xx1300000591

xx1400000354

4 Repair
Continued
Action Note
xx1400000078

xx1200000052
xx1300000561

4 Repair
Continued
Action Note
gland opening.
xx1300000738
Note
xx1200001067

on the connectors.
xx1200001066

4 Repair
Continued
Action Note
Note file)
file)
file)
file)
xx1200001070

6 Refit the o-ring.
Tip

7
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Action Note
2 Turn on the power to the robot and jog to:
• axis 1 = -5°
• axis 2 = +10°
3
DANGER
Turn off all:

working area.
4 Secure the remaining attachment screws Tightening torque: 300 Nm.

that previously were not accessible.
5 Refill oil in the gearbox. See Filling oil into the axis-1 gearbox on
page 165.

4 Repair
Continued
Action Note
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.).
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
8 Secure the cable harness inside the frame

recess with a cable strap.
xx1200001237

4 Repair
Continued
Action Note
9 Refit the cable bracket on the frame.
xx1200001246

11
DANGER

on page 116.

4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID)
-220/3.00 LID)
Validity of this section - variant
Note
-270/2.70 LID, -245/3.00, -220/3.00 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

4 Repair
Continued

to be performed.
1 Drain the axis-1 gearbox.
2 Remove the cabling from the base.
3 Remove the axis-1 motor.
4 Remove the complete arm system (including frame and balancing device)
as a package.
6 Refit in reverse order.
Spare parts


of oil.
sary.
kg.
closed.

4 Repair
Continued

on page 839
sary.
Support legs 3HAC15535-1
Leak-down tester -
Consumables
Equipment, etc Article number Note

Flange sealant - Loctite 574
Locking liquid - Loctite 2400 (or equivalent
Loctite 243)
O-ring 3HAB3772-160 414.3x5.7. Located between
the gearbox and the frame.
O-ring 3HAB3772-97 Located at the oil inlet under-
neath of gearbox.
(hexagon profile)
O-ring 3HAB3772-107 D=102x3
Sealing ring 3HAC047474-001 Located in the frame, on top
of the protection tube.
O-ring 3HAB3772-57 Located on the sealing ring.

4 Repair
Continued

Radial sealing with dust lip 3HAB3701-51 Located in the frame, under-
neath the sealing ring.
Cable straps -
Required documents

Technical reference manual - Lubrication in 3HAC042927-001
gearboxes

Action Note
calibration:

These procedures describe how to remove the gearbox.

Use this procedure to do the necessary preparations, before removing the gearbox.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.

4 Repair
Continued
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
Turn off all:

space.
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.
and remove it by unscrewing the attachment
screw.
CAUTION
The mechanical stop weighs 5 kg.
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
It will not be possible to remove the

screws completely at this point.

4 Repair
Continued
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
xx1400000723
10 Foundry Plus.
xx1400000724

4 Repair
Continued
Robot position
Action Note
• 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°
xx1200001132
2
DANGER
Turn off all:

area.
Attaching the lifting accessories to the arm system
Action Note
1
DANGER

off.
2
CAUTION
The complete arm system weighs .

1,300 kg (IRB 6700 -300/2.70, -245/3.00)
1,320 kg (IRB 6700 -270/2.70 LID, -220/3.00 LID)
ingly!

4 Repair
Continued
Action Note
xx1200001133
4 Fit a lifting eye to the arm house, with a fender Lifting eye: 3HAC16131-1
3 mm.
xx1400002196
xx1200001134

4 Repair
Continued
Attach the lifting chains

Use this procedure to attach the Lifting accessory (chain).
Action Note
1 Run a roundsling through the hole in the frame, Roundsling, 2.5 m: Length: 2.5 m.
continue up and over the upper arm. Lifting capacity: 2,000 kg.
Tip
When attaching the roundsling, make sure to

cross it over, creating a figure 8 of the roundsling.
xx1400002107
xx1400000728
A Upper arm
B Shackle
C Roundsling
D Hole in frame

4 Repair
Continued
Action Note
2 Connect the roundsling with a shackle. Lifting shackle SA-10-8-NA1
xx1400000729
3 Use caution and jog axis-3 slowly to stretch the

roundsling.
Note
Make sure the roundsling is stretched, so it can

carry the weight of the frame.

in the arm house and to the lifting eye in the wrist.
xx1400002108

4 Repair
Continued
Action Note
1
DANGER

are turned off.

xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1200001067
Action Note
1
DANGER

are turned off.

washers.
xx1200001071

4
CAUTION

ive force is used.

4 Repair
Continued
Action Note
6
CAUTION

accordingly.

connector.
DANGER

serious injury.
for the tool.
xx1200001072

power supply.

4 Repair
Continued
Action Note
1
DANGER

are turned off.
xx1300000561
• R1.MP
• R1.SMB
xx1300000591

in the base.
xx1400000366

4 Repair
Continued
Action Note
xx1400000354

secure the bracket.
DressPack hoses.
xx1400000078

tube in the base.
Note

xx1400000088
Action Note
balancing device.

4 Repair
Continued
Action Note
xx1300000732

device.
Lifting away the complete arm system
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
Guide pin, M16x120: 3HAC062397-001


4 Repair
Continued
Action Note
4 Unscrew the remaining attachment screws
as far as it is possible at this point.
xx1400002169
Note
It will not be possible to remove the

screws completely at this point.
5
CAUTION
The complete arm system weighs: .

1,300 kg (IRB 6700 -300/2.70, -245/3.00)
1,320 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
6 Lift away the complete arm system.
CAUTION
When the arm system has left the guide pins

it can move. Use caution in order to avoid
injury or damage!
Note
There will be some oil spill!
7 Put down the arm system on the floor.

8
DANGER
When the complete arm system is removed

and resting by itself on the floor, make sure
it is resting completely stable before remov-
ing the lifting accessories. Do not change the
position of the axes from the position de-
scribed earlier.

4 Repair
Continued
Removing the gearbox
Action Note
1 Remove the back plate.
xx1400002171
2 Fit two lifting eyes in opposite holes in the Lifting eye: 3HAC14457-4
gearbox.
CAUTION
Leave a couple of milimeters of space

box. This is done in order not to damage the
surface of the gearbox which is a sealing
surface.
xx1700000323
3
CAUTION
The weight of the gearbox and base together

is
240 kg (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)
305 kg (IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
accordingly.

4 Repair
Continued
Action Note
4 Attach the lifting accessory. Lifting accessory (chain): 3HAC15556-1
xx1700000324
5 Unscrew the attachment screws that hold the

base to the foundation and lift base and
gearbox up high enough to be able to fit the
four support legs.
xx1400002180
6 Secure the support legs to the foundation

using the same holes as to secure the base.
7 Lower the base and gearbox to the support
legs and secure.
xx1000000364
A Support legs: 3HAC15535-1.

4 Repair
Continued
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
This procedure is best performed by two

persons working together:
• one underneath the robot base making
sure that the bit is being fitted into the
screw head holes, all the way until they
reach the bottom
• one using the torque wrench, tighten-
ing the screws from beside the base. xx1400002172
9 Remove the protection tube from the base

by removing the two attachment screws and
pulling the tube downwards.
xx1700001375
Tip

xx1700000337

4 Repair
Continued
Action Note
11
CAUTION

92 kg (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)
140 kg (IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
accordingly.
12 Lift away the gearbox.
xx1700000566
13 Remove the old o-ring to use it as aid in

holding the screws during fitting of the new
gearbox.
A new o-ring must be installed to the new
gearbox.
xx1700001378
14 Make sure that the o-ring between base and

gearbox is not lost.
xx1400002175

4 Repair
Continued

These procedures describe how to refit the axis-1 gearbox.
Preparations before refitting the axis-1 gearbox
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
A Support legs: 3HAC15535-1.

2 Fit two lifting eyes in opposite holes in the Lifting eye: 3HAC14457-4
gearbox.
CAUTION

box. This is done in order not to damage the
surface of the gearbox which is a sealing
surface.
xx1700000325
3
CAUTION

92 kg (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)
140 kg (IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
accordingly.

4 Repair
Continued
Action Note
4 Attach the lifting accessory and lift the gear- Lifting accessory (chain): 3HAC15556-1
box.
xx1700000326
5 Wipe the contact surfaces between gearbox

and base clean from any contamination.
xx1700000567
6 Wipe clean the o-ring groove for the small o-

ring beneath the gearbox.
xx1400002175
7 Replace the small o-ring between base and O-ring: 3HAB3772-97.

gearbox with a new.
Clean the new o-ring, put some grease on it
and place it in the groove.

4 Repair
Continued
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
Refitting the gearbox to the base
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
Do not use the new o-ring!
xx1400002176

4 Repair
Continued
Action Note
2 Make sure that the locating pin in the base
will match its hole in the gearbox.
xx1400002177
3 With all screws in position, lower the gearbox

carefully down against the base with guid-
ance from the guide pins.
Note
Make sure that the small o-ring underneath

the gearbox, stays fitted correctly when the
gearbox is being fitted.
Note
Be careful not to collide with the calibration

bracket at the base.
xx1700000328
O-ring: 3HAB3772-97.
xx1400002178
4 Lower the lifting accessory so that the chain

is no longer stretched.

4 Repair
Continued
Action Note
5 Fit the attachment screws that secure the Attachment screws: M20x60 (12 pcs)
gearbox to the base, from underneath.
xx1400002172
6 Remove the guide pins and fit the two remain-

ing screws.
7 Secure the attachment screws. Tightening torque: 500 Nm.
Tip
This procedure is best performed by two

persons working together:
• one underneath the robot base making
sure that the bit is being fitted into the
screw head holes, all the way until they
reach the bottom
• one using the torque wrench, tighten-
ing the screws from beside the base.
8 Check the protection tube for damages.

Especially inspect the surface for the sealing
ring.
Replace if damaged.
xx1700001374
9 Wipe the surfaces of the protection tube and

the hole in axis-1 gearbox clean from any
contamination.
10 Put some grease on the protection tube.

4 Repair
Continued
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
Refitting the base to the foundation
Action Note
1
CAUTION
The weight of the gearbox and base together

is
240 kg (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)
305 kg (IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
accordingly.
2 Stretch the lifting accessories to take the

weight of base and gearbox.
3 Unscrew the screws that secure the base to
the support legs and lift up base and gearbox.
4 Remove the support legs.
5 Lower the base and gearbox to the founda-
tion.
6 Secure the base to the foundation. M24 x 100 (installation on base
plate/foundation) (8 pcs)
550 Nm (screws lubricated with Molykote
1000)
600-725 Nm, typical 650 Nm (screws none
or lightly lubricated)

4 Repair
Continued
Preparations before refitting the arm system
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.
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
A new o-ring also needs to be cleaned!
xx1700000336

4 Repair
Continued
Action Note
6 Apply flange sealant in two strings according Flange sealant, Loctite 574: -.
to the figure.
xx1700000415
7 Apply some grease on:

• the outside of the bearing
• the guiding part of the bearing
• the edge of the protection tube
• the edge around the gearbox.
8 Apply guide pins in the guide pin holes in the Guide pin, M16x120: 3HAC062397-001 (2
gearbox. pcs).
Tip

xx1700000329
Refitting the arm system
Action Note
1
CAUTION
The arm system weighs .

1,300 kg (IRB 6700 -300/2.70, -245/3.00)
1,320 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly!
2 Make sure that all lifting accessories still is See Attachment points of lifting accessory
fitted correctly on the arm system. on page 217.

4 Repair
Continued
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
4 Lift the arm system up, to be able to reach

the contact surfaces underneath the frame.
6 Before putting the complete arm system on
to the guide pins, make sure that the hole
pattern will match and that the guide pins will
enter the correct holes in the frame.
7 Remove the big o-ring that holds the attach-
ment screws in the temporary position and
let them drop down on the base.
Note
Make sure that none of the screws are miss-

ing or in the wrong position.
8 Lift the complete arm system and lower it

slowly down over the guide pins, until it is
possible to insert the attachment screws
manually.
CAUTION
Do not lower the arm system completely at

this stage! The attachment screws must be
fitted in two steps. If not, the complete arm
system will risk resting on the attachment
screws in the wrong position!
9 Fit the attachment screws manually as far as Attachment screws: M16x110

possible. Lower the complete arm system
slowly in steps, until all attachment screws
no longer can reach the base, when the arm
system is lowered all the way down.
10 Make sure that the complete arm system is
lowered all the way down.

4 Repair
Continued
Action Note
11
Note
The attachment screw at the axis-1 synchron-

ization plate can not be reached to be se-
cured at this stage. Make sure it is still in its
place and will not be damaged in the contin-
ued procedure.
12 Secure all screws now possible to reach. Bit holder: 3HAC029090-001.

Note
A bits holder is needed to be able to reach

the attachment screws.
13 Manually rotate axis-1 to a position where the

remaining attachment screw can be secured.
14 Remove the guide pins and refit the two
plastic protection plugs or the two M16
screws.
xx1700000320
xx1700000321

4 Repair
Continued
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
2
CAUTION

accordingly.


4 Repair
Continued
Action Note
connector.
DANGER

serious injury.
for the tool.
Note

connector R2.MP1:
• pin 2 = 24V
• pin 5 = 0V
6
CAUTION

ive force is used.

gearbox.
way.
xx1200001072

4 Repair
Continued
Action Note
603+Geo500 (4 pcs)
xx1200001071
done). page 202.
power supply.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
Note
xx1200001067

on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
6 Refit the o-ring.
Tip

7
CAUTION

aged.
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Refilling oil in the gearbox
Action Note
1 Refill oil in the gearbox. See Changing oil, axis-1 gearbox
on page 162.

4 Repair
Continued
Action Note
in this order:
• R1.MP
• R1.SMB
xx1300000732

xx1300000736

xx1300000591

4 Repair
Continued
Action Note
xx1400000354

xx1400000078

xx1200000052

4 Repair
Continued
Action Note
xx1300000561
Refitting the mechanical stop and remaining cable brackets
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
2 Refit the mechanical stop pin and secure it Tightening torque: 10 Nm

with the attachment screw.
Locking liquid (Loctite 243) on screw.
xx1400002179

4 Repair
Continued
Action Note
3 Secure the cable harness inside the frame
hole with a cable strap.
xx1200001237
xx1200001246
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.
2
DANGER

on page 116.

4 Repair
-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
-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.
-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.
Space required beside

This section describes how to replace the gearbox without needing to remove the
cable harness and DressPack cable package (if installed) from the robot.
The described procedure requires free space on the floor, in front of the frame
(with axis-1 in calibration position). There should be enough space to place two
pallets as shown in the figures in the procedures below.
DANGER
The base shall be fitted to the foundation when performing this procedure! Valid
in both examples described below.
xx1300002303
Example 1: Position with space for pallets in front of the robot. Axis-1 in calibration
position.

4 Repair
Continued
If needed, run axis-1 into a position that gives the required space. The figure shows
an example.
xx1300002304
Example 2: Axis-1 jogged to a position where it is possible to find the required

space in another position of axis-1 than calibration position.
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.

4 Repair
Continued

xx1200001276
Spare parts

Consumables

O-ring 3HAB3772-107 D=102x3
(hexagon profile)
O-ring 3HAB3772-144 (D=309.3x3.1) Located between the gearbox
/ 3HAB3772-48 (D=319.3x5.7) and the frame.
Size depends on gearbox
model. Measure the groove
to see dimension of the o-
ring.
VK cover 3HAA2166-28 VK 28x7
Locking liquid (Loctite 2701) -

4 Repair
Continued

24h.

of oil.
kg.
closed.
sary.
Lifting accessory, gearbox 3HAC046112-001
tools.

4 Repair
Continued

tools.
Leak-down tester -
Required documents


Action Note
calibration:

Use these procedures to remove the gearbox.

4 Repair
Continued
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.
Preparations before replacing the axis-2 gearbox
Action Note
2
DANGER
Turn off all:

working area.
3 Begin draining the gearbox. See Draining the axis-2 gearbox on

page 170.
tool (3HAC030662-001).
Action Note
1
DANGER

this position!
(3HAC074411-001).


4 Repair
Continued
Action Note
3
DANGER
Turn off all:

working area.

balancing device.
DANGER

xx1300000554

pcs)
DANGER

properly fitted. A
xx0800000480

device.

4 Repair
Continued
Action Note
9
DANGER
Turn off all:

working area.
Action Note
1
CAUTION

ing cradle) is
140 kg (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)
185 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
xx1300000661

4 Repair
Continued
Action Note
pull it out.
xx1200001278
xx1900002311
xx1900002146

4 Repair
Continued
Action Note
xx1200001279

tool.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.

xx1200001283

rest on the frame.
xx1200001281

4 Repair
Continued
Robot position
-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


• Axis-1: no significance as long as
tion
• Axis-2: -45°
• Axis-3: +65° (approximately)
• Axis-4: 0°
• Axis-5: 0°
• Axis-6: 0°.
xx1200001250
3
DANGER
Turn off all:

working area.


4 Repair
Continued
-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

ing to variants) .
510 kg (IRB 6700 -235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
525 kg (IRB 6700 -220/2.65 LID, -200/2.80 LID, -
155/3.05 LID, -145/3.20 LID, -175/2.60 LID, -
140/2.85 LID)
ingly!
xx1200001133
xx1200001234
4 Insert a M8x50 securing screw, not more than 10-

15 mm, into the screw hole shown in the figure.
This is done to secure the roundsling from gliding
when lifting.
If DressPack cable package is installed: use the
ball joint housing instead, in the same way.
xx1200001251

4 Repair
Continued
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
6 Adjust the roundsling on the other side of the

lower arm, so that the roundsling runs on the left
side of the most lower of the four bosses.
xx1200001253
8 Stretch the roundsling between the wrist and the

Note

9
DANGER
Turn off all:

area.

4 Repair
Continued
Action Note
3 mm.
xx1400002196
xx1200001134
11 If the robot is equipped with DressPack, unscrew

the attachment screws of the bracket that holds
the ball joint housings on the wrist. The DressPack
can stay fitted in the ball joint housing.
xx1400000355
12 Move the DressPack cable package over to the

other side of where the lifting accessory will be
attached to the shackle on the arm house.
the arm house and to a roundsling run through Roundsling, 1 m: Length: 1 m, lift-
xx1200001254

and roundslings.

4 Repair
Continued
Action Note
supply.
• + = pin 2
• - = pin 5

Use this procedure to disconnect the motor cables.
Action Note
1
DANGER

are turned off.

xx1200001135
xx1200001070

4 Repair
Continued
Action Note
xx1200001066

Tip

the same position.
xx1200001067
Action Note
2
DANGER


power supply.
tor:
• + = pin 2
• - = pin 5

4 Repair
Continued
Action Note
screws.
xx1200001117

Tip

6
CAUTION

ive force is used.
3HAC057339-002
page 839
9
CAUTION

accordingly.

head crane.

4 Repair
Continued
Action Note
xx1200001118
Loosening the cable brackets

Use this procedure to lift the lower and upper arm un-separated.
Action Note
1 If robot is equipped with DressPack: How to remove the DressPack cable pack-
• Open the two ball joint housings age is described in more detail in the
from the lower arm and lift away the product manual "IRB 6700 DressPack". For
cabling from the ball joint housings. article number see References on page 10.
xx1400000195

4 Repair
Continued
Action Note
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

lower arm!
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
Tip

xx1300000788

4 Repair
Continued
Action Note
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
Using the method to replace the gearbox

with cable harness and DressPack fitted,
is only a recommendation. If it is not pos-
sible 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.
2
CAUTION
The lower and upper arms together weigh

.
510 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
525 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
accordingly!

4 Repair
Continued
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
Use extreme caution when lifting the upper

arm. The cable harness is still partly con-
nected.
xx1300000790
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.
5 Use caution and lift the arm system and lay
it down safely on the pallets.

Use the procedure to remove gearbox.
Action Note
Tip

xx1300002249
2 Leave one of the upper attachment screws

and remove the rest. The remaining screw
is used to prevent the gearbox from falling
down.
3
CAUTION
The gearbox weighs 83 kg.

accordingly.

4 Repair
Continued
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.

Use these procedures to refit the gearbox.
Follow the order of the procedures according to the order they are presented.
CAUTION
harness!
Refitting the gearbox

Use this procedure to refit the gearbox.
Action Note
1
CAUTION

accordingly!
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
This must also be done on a new spare

part.

contamination.
Note

4 Repair
Continued
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
8 Fit the o-ring in the groove.
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

xx1700000445
11 Lift the gearbox and let it rest on the guide

pins.
12 Slide the gearbox into position.

4 Repair
Continued
Action Note
13 Fit the attachment screws and washers
now accessible.
xx1400002188
Attachment screws: M12x90 12.9 Gleitmo

(30 pcs).
15 Remove the guide pins and fit the remain-
ing attachment screws and washers.
16 Secure the gearbox with its attachment Tightening torque: 120 Nm.
screws.

Action Note
1
DANGER

off.

groove.
3 Fit a new o-ring.
xx1200001019

4 Repair
Continued
Action Note
Tip

xx1200001020
xx1200001135

glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).
Action Note

4 Repair
Continued
Action Note
2
CAUTION

accordingly.

4
Note

xx1200001120

gear.
power supply.
tor:
• + = pin 2
• - = pin 5
9
CAUTION

ive force is used.

gearbox.
washers. 603+Geo500

4 Repair
Continued
Action Note
xx1200001117

page 202.
Lifting back and refitting the lower and upper arm

Use this procedure to lift back and refit the lower and upper arm un-separated.
Action Note
1 Connect the 24 VDC power supply to the
axis-2 motor to release the brakes of the
motor.
2 Fit the rotation tool, if not already fitted. Rotation tool: 3HAB7887-1
axis-2 gearbox. Always use guide pins in pairs.
Tip

xx1400000360

4 Repair
Continued
Action Note
4
CAUTION

.
510 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
525 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
accordingly!
5 Attach the lifting accessories, if not already

fitted.
6 Clean all contact surfaces between lower Use:
arm and axis-2 gearbox. Cleaning agent.
Isopropanol.
7 Use caution and slowly lift the lower and
upper arm together.
Make sure:
• not to stretch any of the cables
• that the arm package is level when
lifted.
8 Before putting the arms on the guide pins,
make sure that the hole pattern is matched
and in the correct position for all screws.
9 If the hole pattern is not matching, use the Rotation tool: 3HAB7887-1
rotation tool and adjust.
xx1300000819
10 Slide the lower arm on to the guide pins.

11 Use caution and move the arms into posi-
tion at the axis-2 gearbox on the guide pins.

4 Repair
Continued
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.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
Note
xx1200001067

on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
6 Refit the o-ring.
Tip

7
CAUTION

aged.
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Refitting the cabling

Use this procedure to refit the cabling.
Action Note
1 Use caution and push the cable harness
into the lower arm.

4 Repair
Continued
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

of the lower arm!
xx1200001282
xx1200001283
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 housings. page 10.
xx1400000195

4 Repair
Continued

Action Note
3
DANGER
Turn off all:

area.
3HAC15556-1
the shaft.
from contamination.
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
front ear.
A
A
C
xx1400000368
A Front link ear

B Shaft

4 Repair
Continued
Action Note
Note
Foundry Plus:
plied.
xx1200001280
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.

frame.
xx1300000782
xx1200001279

4 Repair
Continued
Action Note
xx1200001278
xx1900002311
xx1300000783
grease. 10 Nm
xx1900002146
Action Note
ancing device.

4 Repair
Continued
Action Note
ted).
xx1200001283
3
DANGER

this position!
001.

5
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
xx0800000480

pcs)
xx1300000554
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.

4 Repair
Continued
Action Note
4
DANGER

on page 116.

4 Repair
-220/3.00 LID)
Note
-270/2.70 LID, -245/3.00, -220/3.00 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.

The described procedure requires free space on the floor, in front of the lower arm,
so that the upper and lower arm can be laid down with the cabling still attached to
the robot. There should be enough space to place two pallets on the floor. If needed,
run axis-1 into a position that gives the required space.
DANGER
The base shall be fitted to the foundation when performing this procedure! Valid
in both examples described below!
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.

4 Repair
Continued

xx1200001276

to be performed.
1 Remove the upper and lower arm together, as a package.
Spare parts


DANGER

a balancing device!

4 Repair
Continued

of oil.
kg.
closed.
sary.
Lifting accessory, gearbox 3HAC046112-001
tools.
tools.
Leak-down tester -

4 Repair
Continued

Consumables

O-ring 3HAB3772-107 D=102x3
(hexagon profile)
O-ring 3HAB3772-144 D=309.3x3.1
Used on gearbox.
VK cover 3HAA2166-28 VK 28x7
Locking liquid (Loctite 2701) -
Required documents


Action Note

4 Repair
Continued
Action Note
calibration:

Use these procedures to remove the gearbox.
Follow the order of the separate procedures according to the order they are
presented.
CAUTION
harness!
Preparations before replacing the axis-2 gearbox
Action Note
2
DANGER
Turn off all:

guarded space.

page 170.

4 Repair
Continued
tool (3HAC030662-001).
Action Note
1
DANGER

this position!
(3HAC074411-001).

3
DANGER
Turn off all:

working area.

balancing device.
DANGER

xx1300000554

4 Repair
Continued
Action Note
pcs)
DANGER

properly fitted. A
xx0800000480

device.
9
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
1
CAUTION

ing cradle) is
140 kg (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)
185 kg (IRB 6700-300/2.70, -270/2.70 LID,
-245/3.00, -220/3.00 LID)
accordingly.
xx1300000661

4 Repair
Continued
Action Note
pull it out.
xx1200001278
xx1900002311
xx1900002146

4 Repair
Continued
Action Note
xx1200001279

tool.
xx0900000813

the press tool.
DANGER

serious injury.
for the tool.

xx1200001283

rest on the frame.
xx1200001281

4 Repair
Continued
Robot position
Action Note
1
Note


• Axis 1: position the axis 1 to be able
to put down the arm system after
removal
• Axis 2: -60°
• Axis 4: +90°
• Axis 5: 0° (-90° if DressPack is in-
stalled)
• Axis 6: 0° (+90° if DressPack is in-
stalled)
xx1200001250
3
DANGER
Turn off all:

guarded space.

Action Note
1
CAUTION

ing to variants) .
650 kg (IRB 6700 -300/2.70, -245/3.00)
670 kg (IRB 6700 -270/2.70 LID, -220/3.00 LID)
ingly!

4 Repair
Continued
Action Note
xx1400002106
3 In order to secure the roundsling from gliding

when lifting:
Insert a M12x50 securing screw, not more
than 10-15 mm, into the screw hole shown
in the figure.
Use the ball joint housing in the same way.
xx1200001251
4 Run a roundsling around the lower arm, place it Roundsling, 2.5 m: Length: 2.5 m.
accordingly: Lifting capacity: 2,000 kg.
Place the roundsling beneath the securing
screw.
Place the roundsling beneath the ball joint
housing on the outside of the lower arm.
xx1400002105
5 Run the roundsling up and over the upper arm.

6 Connect both ends of the roundsling with a
shackle.
xx1400000729

4 Repair
Continued
Action Note
7 Stretch the roundsling between the upper and the
Note

8
DANGER
Turn off all:

area.
3 mm.
xx1400002196
xx1200001134

the arm house and to the lifting eye in the wrist.
xx1400002104

4 Repair
Continued
Action Note
and roundslings.
supply.
• + = pin 2
• - = pin 5
Loosening the cable brackets

Use this procedure to loosen required cable brackets.
Action Note
1 If robot is equipped with DressPack: How to remove the DressPack cable pack-
• Open the two ball joint housings age is described in more detail in the
from the lower arm and lift away the product manual "IRB 6700 DressPack". For
cabling from the ball joint housings. article number see References on page 10.
xx1400000195

4 Repair
Continued
Action Note
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

lower arm.
xx1300000540
3 Unscrew the attachment screws of the

cable bracket on the frame and let it hang
loose.
xx1200001283
Fitting guide pins to the lower arm

Use this procedure to prepare the removal of the lower arm.
Action Note
Tip

xx1400002181

4 Repair
Continued
Action Note
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
Using the method to replace the gearbox

with cable harness and DressPack fitted,
is only a recommendation. If it is not pos-
sible 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.
2
CAUTION

.
650 kg (IRB 6700 -300/2.70, -245/3.00)
670 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly!
3 Remove the remaining screw and lift away

the lower and upper arm together.
Let the cabling run in the lower arm. Make
sure not to stretch any cabling!
Note
Two persons required. One person to oper-

ate the overhead crane and one person to
handle the arm system.
xx1700000442

4 Repair
Continued
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.

Use this procedure to disconnect the motor cables.
Action Note
1
DANGER

are turned off.

xx1200001135
xx1200001070

4 Repair
Continued
Action Note
xx1200001066

Tip

the same position.
xx1200001067
Action Note
2
DANGER


power supply.
tor:
• + = pin 2
• - = pin 5

4 Repair
Continued
Action Note
screws.
xx1200001117

Tip

6
CAUTION

ive force is used.
3HAC057339-002
page 839
9
CAUTION

accordingly.

head crane.

4 Repair
Continued
Action Note
xx1200001118

Use the procedure to remove gearbox.
Action Note
Tip

xx1700000443

4 Repair
Continued
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

accordingly!
4 Remove the remaining screw left in the

gearbox.
xx1400002185
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 Let the gearbox slide out on the guide pins.

4 Repair
Continued
Action Note
xx1400002186

presented.
CAUTION
fitted to the robot. Use the utmost caution not to cause any damage to the cable
harness!
Refitting the gearbox

Use this procedure to refit the gearbox.
Action Note
1
CAUTION
The gearbox weighs according to vari-

ant110 kg.
accordingly!
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.
Note
This must also be done on a new spare

part!

4 Repair
Continued
Action Note
contamination.
Note
6 Check the condition of the o-ring.

Replace if damaged.
7 Lubricate the o-ring with some grease, for
9 Foundry Plus:
Apply Mercasol on the surfaces shown in
the figure.
xx1400000374
10 Fit two guide pins in opposite holes (M12). Guide pin, M12x150: 3HAC13056-2

xx1700000445
11 Lift the gearbox and let it rest on the guide

pins.
12 Slide the gearbox into position.

4 Repair
Continued
Action Note
13 Fit the attachment screws now accessible.
xx1400002188
Screw dimension: There are two versions

of the robot frame. Depending on which
frame the robot is equipped with, the depth
of the screw holes in the frame, used for
the axis-2 gearbox, differ. The frame that
is configured for Axis Calibration, has a
calibration pin and bushing as shown in
the figure. For this frame, screws with di-
mension M12x90 should be used. For a
frame without the calibration pin and
bushing, screws with dimension M12x80
should be used..
Screw quality: 12.9 Gleitmo (totally 32 pcs)
xx1500002118

15 Remove the guide pins and fit the remain-
ing attachment screws.
16 Secure the gearbox with its attachment Tightening torque: 120 Nm.
screws.

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
groove.
3 Fit a new o-ring.
xx1200001019
Tip

xx1200001020
xx1200001135

4 Repair
Continued
Action Note
glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).
Action Note
2
CAUTION

accordingly.

4
Note

xx1200001120

gear.

4 Repair
Continued
Action Note
power supply.
tor:
• + = pin 2
• - = pin 5
9
CAUTION

ive force is used.

gearbox.
washers. 603+Geo500
xx1200001117

page 202.
Lifting back and refitting the lower and upper arm

Use this procedure to lift back and refit the lower and upper arm un-separated.
Action Note
1 Connect the 24 VDC power supply to the
axis-2 motor to release the brakes of the
motor.

4 Repair
Continued
Action Note
2 Fit the rotation tool, if not already fitted. Rotation tool: 3HAB7887-1
axis-2 gearbox. Always use guide pins in pairs.
Tip

xx1400002189
4
CAUTION

.
650 kg (IRB 6700 -300/2.70, -245/3.00)
670 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly!
5 Apply the lifting accessories, if not already

fitted.
6 Lift the lower and upper arm.
Make sure:
• not to stretch any of the cables
• that the arm package is level when
lifted.
7 Align the lower arm with the gearbox in
height. Match the upper edge of the gear-
box with the corresponding edge inside the
lower arm cavity.
Tip
This operation is best performed by two

persons working together.
xx1700000692

4 Repair
Continued
Action Note
8 Rotate the gear to match the hole pattern Rotation tool: 3HAB7887-1
in the lower arm, using the rotation tool.
Note
Some of the screw holes in the gear are

unused.
xx1300000819
9 Slide the lower arm onto the guide pins,

when the hole pattern is matched and in
the correct position for all screws.
10 Slide the lower arm on to the guide pins.
11 Use caution and move the arms into posi-
tion at the axis-2 gearbox on the guide pins.
Rotate the axis-2 gearbox until the hole
pattern is matching the holes in the lower
arm.
13 Fit all now accessible attachment screws.
xx1400002190
14 Remove the two guide pins and fit the re-

maining attachment screws.
15 Secure the lower arm to the axis-2 gearbox Tightening torque M16: 300 Nm.
with its attachment screws.

4 Repair
Continued
Action Note
gland opening.
xx1300000738
Note
xx1200001067

on the connectors.
xx1200001066

4 Repair
Continued
Action Note
Note file)
file)
file)
file)
xx1200001070

6 Refit the o-ring.
Tip

7
CAUTION

aged.

4 Repair
Continued
Action Note
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Refitting the cabling

Use this procedure to refit the cabling.
Action Note
1 Use caution and push the cable harness
into the lower arm.
2 Refit the axis-2 lower arm metal clamp and
the axis-3 lower arm metal clamp located
Note

of the lower arm!
xx1200001282
xx1200001283

4 Repair
Continued
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

Action Note
3
DANGER
Turn off all:

area.
3HAC15556-1
the shaft.
from contamination.

4 Repair
Continued
Action Note
in the lower arm.
Note
xx1300000784
B
8 Foundry Plus:
front ear.
A
A
C
xx1400000368
A Front link ear

B Shaft
Note
Foundry Plus:
plied.
xx1200001280

4 Repair
Continued
Action Note
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.

frame.
xx1300000782
xx1200001279

4 Repair
Continued
Action Note
xx1200001278
xx1900002311
xx1300000783
grease. 10 Nm
xx1900002146
Action Note
ancing device.

4 Repair
Continued
Action Note
ted).
xx1200001283
3
DANGER

this position!
001.

5
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
xx0800000480

pcs)
xx1300000554
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.

4 Repair
Continued
Action Note
4
DANGER

on page 116.

4 Repair
4.8.5 Replacing the axis-3 gearbox

The described procedure requires free space on the floor, at the right-hand side
of the balancing device (seen from behind). There should be enough space to place
two pallets in a row.
If needed, run axis 1 into a position that gives the required space at the right-hand
side of the balancing device.
DANGER
Do not unscrew the attachment screws that secure the robot to the foundation!
If unscrewed, the robot will be unstable.

xx1300000515

4 Repair
Continued

1 Remove the upper arm from the robot and position it as shown in the figure,
for easy removal of the axis-3 gearbox.
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.
Spare parts

Axis-3 gearbox See Product manu-
al, spare parts - IRB
6700/IRB 6700Inv
Consumables

24h.
O-ring 3HAB3772-107 D=102x3
(hexagon profile)
O-ring 3HAB3772-145 (D=266.3x3.5) Used on 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)
3HAB3772-120 (D=264.3x5.7)
(IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID)

4 Repair
Continued

of oil.
closed.
Lifting accessory, gearbox 3HAC046128-001 i
3HACxx ii
3HAC046112-001 iii
sary.
Screws M8x75, fully threaded - Used to push out the gearbox, if neces-
sary.
Pinion 3HAC067546-001 iv Used for rotating the axis-3 gearbox
3HAC067547-001 v when refitting upper arm.
3HAC067545-001 vi
Leak-down tester -
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
iv 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
v IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
vi IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID

4 Repair
Continued

Action Note
calibration:

Use these procedures to remove the axis-3 gearbox.
Follow the order of the separate procedure according to the order they are
presented.
Action Note

4 Repair
Continued
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

upper arm is secured as previously de-
4 Release the holding brakes for the axis-3

motor to make the upper arm rest tightly
against the mechanical stop.
5
DANGER
Turn off all:

guarded space.

page 175.

4 Repair
Continued
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
It is not needed to disconnect the lower

end connectors of the DressPack (as the
figure shows). Connectors are only hidden
to get a better view of which screw to be
removed.
xx1200001331
A Attachment screw to be removed

B Attachment screw not to be removed
8 Unscrew the two attachment screws that
holds the bracket of the DressPack cable
package (if one is fitted), and let it hang
down together with the rest of the
DressPack cable package.
xx1200001332
9 Put two pallets on the floor, at the right-

hand side of the robot.
Note
This position is only a recommendation. If

it is not possible to put the upper arm close
enough to the robot and keep the cable
harness partly fitted, it may be necessary
to remove the cable harness and
DressPack in the upper arm and wrist first.

4 Repair
Continued

Use this procedure to disconnect the motor cables on the axis-3 and axis-4 motors.
Action Note
1
DANGER

are turned off.

xx1200001135
xx1200001070
xx1200001066

4 Repair
Continued
Action Note
Tip

the same position.
xx1200001067

Action Note
2
DANGER

may fall down if not secured. Verify that
the upper arm is secured as previously
described, before continuing.

power supply.
• + = pin 2
• - = pin 5
4 Unscrew the attachment screws that hold Bits extender: 3HAC12342-1
the motor.
xx1200001126

4 Repair
Continued
Action Note
Tip

6
CAUTION

ive force is used.
by using the removal tool in the remaining 3HAC057339-002
holes for the motor. Removal tool kit M12 and M14:
3HAC057339-002
page 839
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

accordingly.
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
The pinion must have been parted from

the gear before the motor is angled. If not
there is a risk of damaging the pinion and xx1200001125
gear.

4 Repair
Continued
Action Note
13 Remove the motor by lifting it straight out. Make sure the pinion is not damaged.
xx1200001131
Keeping cabling installed in upper arm - loosening the cable brackets

This procedure is valid if wanting to keep the cabling installed in the upper arm,
when removing the upper arm from the robot. If this is not possible due to lack of
space where to put the upper arm, the cable harness must be removed from the
upper arm, see Removing the cable harness - upper arm and wrist on page 240.
Use this procedure to loosen required cable brackets of the robot cable harness,
in order to get the longest possible length of the cable harness between the lower
and upper arm.
Action Note
the axis-3 lower arm metal clamp (the one
closest to the axis-3 gearbox) located on
the inside of the lower arm.
Note
The screw is reached from the outside of

the lower arm!
xx1800000042

4 Repair
Continued
Action Note
the cable bracket on top of the arm house.
xx1300000541

the cable bracket under the arm house.
xx1300000543
Note

xx1300001973
xx1300000544

4 Repair
Continued
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
7 If the robot is equipped with DressPack:

Lift the DressPack cable package at the
arm house up and put the cable bracket on
the cable guide where the velcro strap
normally is fitted. Secure the temporary
position with a velcro strap or similar, to
ensure it will not fall down or damage any-
thing.

4 Repair
Continued

Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
xx1200001133
xx1400002196
xx1200001134

4 Repair
Continued
Action Note
and in the wrist.
xx1200001308

xx1400002197
LID, -175/3.05, -155/3.05 LID, -150/3.20, -145/3.20 LID
Action Note
pins.
Note

are removed!
Tip

xx1300000659

4 Repair
Continued
Action Note
xx1300000747
Action Note
Note

are removed!
Tip

xx1300002245

xx1300002246

4 Repair
Continued
Action Note
Note

are removed!
Tip

xx1400002563

xx1400002564
Action Note
1
Note

xx1400002197

4 Repair
Continued
Action Note
xx1300001610
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,

-140/2.85 LID
TBD
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID
xx1700000059

pared area.
CAUTION

harness.

4 Repair
Continued
Action Note
3 gearbox:
ure.

Use this procedure to remove the gearbox.
Action Note
holes and replace them with guide pins. Always use guide pins in pairs.
IRB 6700-235/2.65, -220/2.65 LID, -205/2.80,
Tip -200/2.80 LID, -175/3.05, -155/3.05 LID, -
150/3.20, -145/3.20 LID
xx1300001969
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,

-140/2.85 LID
TBD
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID
xx1700000370

4 Repair
Continued
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
IRB 6700-200/2.60, -175/2.60 LID, -155/2.85,

-140/2.85 LID
TBD
IRB 6700-300/2.70, -270/2.70 LID, -245/3.00,
-220/3.00 LID
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
There is a risk that the gearbox may glide

out and fall down before the lifting access-
ory is applied, if pulled out to far.

4 Repair
Continued
Action Note
6
CAUTION
The axis-3 gearbox weighs .

• 56 kg (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)
• 85 kg (IRB 6700-300/2.70, -270/2.70
LID, -245/3.00, -220/3.00 LID)
accordingly.
7 Apply the lifting accessory to the gearbox. Lifting accessory, gearbox:

3HAC046128-001 i
3HACxx ii
3HAC046112-001 iii
8
Note
There will be some oil spill when the gear-

box is removed. Put some oil absorbent
cloth or paper below the gearbox.
9 With the gearbox attached to the lifting ac-

cessory, remove the gearbox by letting it
slide out on the guide pins.
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

Use these procedures to refit the axis-3 gearbox.
presented.
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
2
CAUTION
The axis-3 gearbox weighs .

• 56 kg (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)
• 85 kg (IRB 6700-300/2.70, -270/2.70
LID, -245/3.00, -220/3.00 LID)
accordingly.
3 Apply the lifting accessory to the gearbox. Lifting accessory, gearbox:

3HAC046128-001 i
3HACxx ii
3HAC046112-001 iii
4 Lift the gearbox so that it rests on the side.
Note
This shall also be done on a new spare

part.
6 Check the condition of the o-ring. O-ring: .

Replace if damaged. 3HAB3772-145 (D=266.3x3.5)
(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)
3HAB3772-120 (D=264.3x5.7)
(IRB 6700-200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID)
7 Wipe clean the contact surfaces, both on
the gearbox and in the upper arm.
8 Lubricate the o-ring with some grease.
Tip

11 Lift the gearbox to the upper arm and let it

rest on the guide pins.
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

4 Repair
Continued
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
2 Remove the guide pins and replace with Screws: M12x70.

the remaining attachment screws and
washers.
xx1300001969
3 Secure the remaining attachment screws. Tightening torque: 120 Nm.


4 Repair
Continued
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

M12x70.
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

4 Repair
Continued
Action Note
xx1400002194

M12x70.
Action Note
CAUTION

casol.
xx1700001880

4 Repair
Continued
Action Note
150/3.20, -145/3.20 LID
Tip

xx1700000058

Tip

xx1400000361

Tip

xx1700000056

4 Repair
Continued
LID, -150/3.20, -145/3.20 LID
Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
pins.
arm: Rotation tool
• + = pin 2
• - = pin 5

M12 (25 of 27 pcs)
xx1400000359

4 Repair
Continued
Action Note
maining M12 screws.
xx1300000659
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
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
pins.
arm: Rotation tool
• + = pin 2
• - = pin 5

4 Repair
Continued
Action Note

ers.
xx1300002246

xx1300002245
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

4 Repair
Continued
Action Note
1
CAUTION

360 kg (IRB 6700 -235/2.65, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
375 kg (IRB 6700 -220/2.65 LID, -200/2.80
LID, -155/3.05 LID, -145/3.20 LID, -175/2.60
LID, -140/2.85 LID)
465 kg (IRB 6700 -300/2.70, -245/3.00)
481 kg (IRB 6700 -270/2.70 LID, -220/3.00
LID)
accordingly.
lower arm.
arm: Rotation tool
lease the brakes.
• + = pin 2
• - = pin 5
xx1700000057

4 Repair
Continued
Action Note
maining screws.
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
DANGER

off.

groove.
3 Fit a new o-ring.
xx1200001019
Tip

xx1200001020

4 Repair
Continued
Action Note
xx1200001135

glasses.
xx1600000576
xx1800000101
xx2200002188
Protection filter
(Foundry Plus).

Use this procedure to secure the motor.
Action Note
2
CAUTION

accordingly.

4 Repair
Continued
Action Note
3 Apply the lifting accessories to the motor. Lifting accessory, motor: 3HAC15534-1
Note
Make sure the cable gland exit is turned ac-

cording to figure.
xx1700000273
4 Lift the motor on to the guide pins and let it

hang with the outer end a little lower when
resting on the guide pins. Do not push the
motor pinion into the gear yet.
This is done in order to fit the motor with the
axis-4 motor still fitted.
xx1200001131

power supply.
• + = pin 2
• - = pin 5
8
CAUTION
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used.

4 Repair
Continued
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.
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.
page 202.
Refitting cable brackets

This procedure is valid if the cabling has been kept installed in the upper arm,
when removing the upper arm from the robot. If the cable harness in the upper
arm instead has been removed completely, see Refitting the cable harness - upper
arm and wrist on page 275.
Use this procedure to refit the cable brackets.
Action Note
2 Move the cable harness and DressPack
back to the correct side of the robot.
3 Refit the axis-3 lower arm metal clamp (the
one closest to the axis-3 gearbox) located
Note
The screw is reached from the outside of

the lower arm!
xx1800000042

4 Repair
Continued
Action Note
4 Fasten the cable bracket on top of the arm
house.
xx1300000541
5 Fasten the cable bracket under the arm

house.
xx1300000543

Note

xx1300001973
xx1300000544

4 Repair
Continued
Action Note
7 Refit the DressPack cable package into the
ball joint housings on the lower arm and
close them.
xx1400000195

Use this procedure to connect the motor cables.
Action Note
gland opening.
xx1300000738

4 Repair
Continued
Action Note
Note
xx1200001067

on the connectors.
xx1200001066

Note file)
file)
file)
file)
xx1200001070

4 Repair
Continued
Action Note
6 Refit the o-ring.
Tip

7
CAUTION

aged.
screws.
Note

Note

properly fitted.
xx1200001135

sealed.
Refitting DressPack cable packages
Action Note

4 Repair
Continued
Action Note
2 Fit the bracket of the DressPack cable
package (if one is fitted) under the arm
house with its screws.
xx1200001332
3 Secure the bracket of the DressPack cable

package (if one is fitted) with its attachment
screws.
Note
It is not needed to disconnect the lower

end of the DressPack as the figure shows.
Connectors are only hidden here to get a
better view of which screw to refit.
xx1200001331
A Removed screw.
B Screw unscrewed but not removed.
Concluding procedures
Action Note
page 177.

4 Repair
Continued
Action Note
3
DANGER

on page 116.

4 Repair

xx1300000824
Spare parts

parts - IRB 6700/IRB
6700Inv
Consumables

O-ring 3HAB3772-107 D=102x3
(IRB 6700-235/2.65, -220/2.65 Used on motor flange.
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)
3HAB3772-102
(IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID)
Gasket 3HAC033489-001/ Used on motor cover.
3HAC044252-001

4 Repair
Continued

O-ring 3HAB3772-58 Used on 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)
3HAB3772-105
(IRB 6700-200/2.60, -175/2.60
LID, -155/2.85, -140/2.85 LID)
3HAB3772-161
(IRB 6700-300/2.70, -270/2.70
LID, -245/3.00, -220/3.00 LID)

Leak-down tester -

Action Note

4 Repair
Continued
Action Note
calibration:

Use these procedures to remove the axis-6 gearbox.
Action Note
2
DANGER
Turn off all:

guarded space.
3 Drain the gearbox. See Draining the axis-6 gearbox on

page 189.
4 Remove all equipment fitted on the turning
disc.

4 Repair
Continued
Action Note
5 If installed, remove the DressPack axis-6
support.
xx1400000208
xx1400000223
6 Jog the robot to:

• Axis 1 = No significance (as long as
tion).
• Axis 2 = +25°
• Axis 3 = +20°
• Axis 4 = 0°
• Axis 5 = -55°
• Axis 6 = -10°
7
DANGER
Turn off all:

guarded space.

4 Repair
Continued
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
xx1300000492
2 - IRB 6700-200/2.60, -175/2.60 LID, -

155/2.85, -140/2.85 LID
xx1300002302
3 - IRB 6700-300/2.70, -270/2.70 LID, -

245/3.00, -220/3.00 LID
xx1400002195

4 Repair
Continued
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)
(IRB 6700-300/2.70, -270/2.70 LID, -
245/3.00, -220/3.00 LID)
xx1700001600
2
CAUTION

ive force is used.

4 Repair
Continued
Action Note
If required fit two attachment screws and
press out the gearbox.
xx1700001601

Action Note
1
DANGER

are turned off.
2 Ensure a tight fitting of the sealing accord- O-ring:

ing to following steps: 3HAB3772-58
• Remove the o-ring and wipe it clean.
(IRB 6700-235/2.65, -220/2.65 LID, -
205/2.80, -200/2.80 LID, -175/3.05, -155/3.05
Note LID, -150/3.20, -145/3.20 LID)
3HAB3772-105
The o-ring needs to be cleaned also
on a new spare part. (IRB 6700-200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID)
• Check the o-ring. 3HAB3772-161
Replace if damaged. (IRB 6700-300/2.70, -270/2.70 LID, -
• Wipe clean the contact surfaces 245/3.00, -220/3.00 LID)
from any contamination.
• Put some grease on the o-ring.
• Fit the o-ring in the groove of the
gearbox.
xx1300000828

4 Repair
Continued
Action Note
3 Foundry Plus:
Apply Loctite 574 on the surface shown in
the figure.
xx1400000717
Action Note
1
CAUTION

ive force is used.
2 Fit the gearbox to the wrist.
CAUTION
Be careful not to damage motor pinion or

gears!
xx1700001601

4 Repair
Continued
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)
(IRB 6700-200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID)
(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

page 202.
5 Jog axis-5 to horizontal position.
page 190.
Action Note
2 Wipe clean the contact surfaces.

4 Repair
Continued
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

150/3.20, -145/3.20 LID Gleitmo 603 (24 pcs)
Secure the turning disc with its attachment Washers: Steel 8.4x13x1.5 (24 pcs)
screws and washers.
xx1300000492

screws and washers. Washers: (3 pcs)
xx1300002302

4 Repair
Continued
Action Note
screws and washers. Washers: Steel 11x17x25 (21 pcs)
xx1400002195
Action Note
1 Refit the synchronization plate axis-6.
xx1300000825

3
DANGER

on page 116.

This page is intentionally left blank
5 Calibration
5.1.1 Introduction and calibration terminology
5 Calibration
5.1 Introduction to calibration
5.1.1 Introduction and calibration terminology
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.

5 Calibration
5.1.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration or Cal-
position. ibration Pendulum i
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the serial measurement board (SMB) or
other robot memory.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with Absolute accuracy has
a sticker next to the identification plate of the
robot (IRC5).
A robot calibrated with Absolute accuracy has
the option information printed on its name
plate (OmniCore).
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.
xx0400001197

5 Calibration
Continued
Type of calibration Description Calibration method

Optimization Optimization of TCP reorientation perform- Wrist Optimization
ance. The purpose is to improve reorientation
accuracy for continuous processes like weld-
ing and gluing.
Wrist optimization will update standard calib-
ration data for axes 4 and 5.
i The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use
the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration
menu on the FlexPendant.
If no data is found related to standard calibration, contact the local ABB Service.
Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of many of
ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). This
calibration method is not used on OmniCore robots.
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference calibration
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.
Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 6700. It is
the recommended method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Wrist Optimization method

Wrist Optimization is a method for improving reorientation accuracy for continuous
processes like welding and gluing and is a complement to the standard calibration
method.
The actual instructions of how to perform the wrist optimization procedure is given
on the FlexPendant.

5 Calibration
Continued
CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after replacements that do not include taking apart the robot
structure, standard calibration is sufficient.
The Absolute Accuracy option varies according to the robot mounting position.
This is printed on the robot name plate for each robot. The robot must be in the
correct mounting position when it is recalibrated for absolute accuracy.
References
Article numbers for the calibration tools are 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.

5 Calibration
5.1.3 When to calibrate
5.1.3 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed

If resolver values are changed, the robot must be re-calibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 807. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reachability of a robot
is changed, it needs to be re-calibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
5.2 Synchronization marks and axis movement directions
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 6700
Axis 1 Axis 2
xx1300000868
xx1300000869
Axis 3 Axis 4
xx1300000870 xx1300000871

5 Calibration
Continued
Axis 5 Axis 6
Two variants of synchronization mark plates.
xx1300000872
xx1300000873
xx1500000845

5 Calibration
5.2.2 Calibration movement directions for all axes
5.2.2 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
Manual movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!
xx0200000089

5 Calibration
5.3.1 Updating revolution counters on IRC5 robots
5.3 Updating revolution counters
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.
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 804.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 808.
Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position. Do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 6700-235/2.65, -220/2.65 Yes No
LID, -205/2.80, -200/2.80 LID,
-175/3.05, -155/3.05 LID, -
150/3.20, -145/3.20 LID, -
200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID
IRB 6700-300/2.70, -270/2.70 No No
LID, -245/3.00, -220/3.00 LID
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).

5 Calibration
Continued
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.
xx1500000942
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943

5 Calibration
Continued
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
4 A screen is displayed, tap Rev. Counters.
en0400000771

5 Calibration
Continued
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
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 829.

5 Calibration
5.3.2 Updating revolution counters on OmniCore robots
Introduction
This section describes how to do a rough calibration of each manipulator axis by
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 804.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 812.
Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position. Do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 6700-235/2.65, -220/2.65 Yes No
LID, -205/2.80, -200/2.80 LID,
-175/3.05, -155/3.05 LID, -
150/3.20, -145/3.20 LID, -
200/2.60, -175/2.60 LID, -
155/2.85, -140/2.85 LID
IRB 6700-300/2.70, -270/2.70 No No
LID, -245/3.00, -220/3.00 LID
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).

5 Calibration
Continued
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant
(OmniCore).
Action
1 On the start screen, tap Calibrate.
The calibration summary page for the mechanical unit is displayed.
2 In the Calibration Methods menu, select Revolution Counters.
3 In the Selection column select the axes for which revolution counters need to be up-
dated.
4 Tap Update.
A dialog box is displayed warning that the updating operation cannot be undone.
5 Tap OK to update the revolution counter.
6
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 829.

5 Calibration
5.4.1 Description of Axis Calibration
5.4 Calibrating with Axis Calibration method
Instructions for Axis Calibration procedure given on the FlexPendant

This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.
Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
A fixed calibration pin/bushing is installed on each robot axis at delivery.
The Axis Calibration procedure described roughly:
1 A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully 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.

5 Calibration
Continued
Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.
Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.
Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
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.
Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
Validation
In the mentioned routines, it is also possible to validate the calibration data.
Position of robot axes

The robot axes should be positioned close to 0 degrees before commencing the
calibration program. The axis chosen for calibration is then automatically run by
the calibration program to its exact calibration position during the calibration
procedure.
It is possible to position some of the other axes in positions different from 0 degrees.
Information about which axes are allowed to be jogged is given on the FlexPendant.

5 Calibration
Continued
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
Requirements for axis positioning during calibration
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.
System containing SafeMove

SafeMove will lose its synchronization to the controller if a new calibration is done.
New calibration values have to be downloaded to SafeMove, and a new SafeMove
calibration has to be done. Make sure that the user rights admit to change the
safety settings and to synchronize SafeMove.
For robots with EPS, the same applies as for SafeMove.

5 Calibration
5.4.2 Calibration tools for Axis Calibration
Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. There is no risk for bad calibrations as long as the
calibration tool is in one piece.
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.

Calibration tool box, 3HAC055412-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot.
Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.
WARNING
If any part is missing or damaged, the tool must be replaced immediately.
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring

5 Calibration
Continued
Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.
xx1500000951
A Outer diameter
Identifying the calibrating tools

It is possible to make the calibration tool identifiable with, for example, an RFID
chip. The procedure of how to install an RFID chip is described below.
Note
The tool identifier is NOT delivered from ABB, it is a customized solution.
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
The maximum dimensions on the RFID chip must

not exceed Ø7.9 mm x 8.0 mm, Ø5.9 mm x 8.0
mm or Ø3.9 mm x 8.0 mm (depending on calibra-
tion tool size).
2 There is a cavity on one end of the calibration tool

in which the RFID chip can be installed.
Install the RFID chip according to supplier instruc-
tions.
Install the chip in flush with the tool end.

5 Calibration
5.4.3 Installation locations for the calibration tools
5.4.3 Installation locations for the calibration tools
Location of fixed calibration items

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
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.
Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.

5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
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.

Clean cloth -
Spare parts

Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure.
After the calibration method has been started on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 814.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.
4 Validate the synchronization marks.
5 The robot moves to preparation position.
6 Remove the protective cover from the fixed pin and the protection plug from
the bushing, if any, and install the calibration tool.

5 Calibration
Continued
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.
Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER
While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robot's working area is empty,
as the robot can make unpredictable movements.
2 Wipe the calibration tool clean. Use a clean cloth.
Note
The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.
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.
Starting the calibration procedure

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

displayed only if there is more than one mechan-
ical unit available.
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.

5 Calibration
Continued
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.
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
The three-position enabling device on the Press and hold the three-position enabling
FlexPendant has been released during robot device and press Play.
movement.
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 806
Axis Calibration with SafeMove option

To be able to run Axis Calibration, SafeMove needs to be unsynchronized. The
Axis Calibration routine recognizes if the robot is equipped with SafeMove and will
force SafeMove to unsynchronize automatically.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine. When a warning message is displayed, tap Acknowledge
to confirm the unsynchronized state and continue Axis Calibration procedure.
CAUTION
SafeMove must be synchronized after the calibration is completed.

5 Calibration
Continued
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
Protection cover and plug set:

3HAC056806-001.
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. Ensure that the sealing is not
damaged.
Replace the plug and the sealing with new spare
part, if missing or damaged.
xx1500000952
Protection cover and plug set:

3HAC056806-001.
4 If the standard calibration data for axes 4, 5 or 6 See Calibrating with Wrist Optimiz-
should be updated with wrist optimization, run the ation method on page 826.
calibration routine Wrist Optimization.

5 Calibration
5.4.5 Reference calibration
Brief introduction to Reference Calibration

Reference calibration is a faster method compared to Fine calibration, as it refers
to a previously made calibration.
1 Create a backup of the current robot system.
2 Check that the active calibration offset values corresponds to the values on
the calibration label (located on the lower arm or the base).
3 Jog the manipulator so that all axes are in zero position (ex use MoveAbsJ
instruction). Check that all axis scales are aligned with calibration marks.
4 If the scales differ from calibration marks it might depend on wrong turns of
the revolution counters. Make a marker line on the corresponding axis to be
able to validate the result of the calibration. If more than one motor revolutions
are wrong, the calibration will fail.
5 Use a verification position. This is especially recommended if all axes were
not aligned with the synchronization marks (step 3). Reuse an existing
position that is suitable and accurate so it can be used to validate the repair.
Use a position where a deviation in axis calibration gives a big deviation in
positioning. Note! Check the position after each repair in one axis.
6 Use Reference calibration to save reference values for all axes that is to be
replaced. Make sure that the values are saved in RobotStudio or FTP program.
The files are located in "Active system folder name/HOME/RefCalibFiles".
7 Perform the repair.
8 Make sure that the tooling and process equipment are the same as when
creating the reference. Use Reference calibration to update the system with
new calibration offset value for the repaired axis.
9 Check the position against the verification position (step 5).
10 Proceed with the repair of the next axis, if necessary, and repeat (step 8-9)
for every axis.
11 (For system containing SafeMove or EPS) Download new calibration values
to SafeMove. Use Visual SafeMove in RobotStudio.(For system containing
SafeMove) Download new calibration values to SafeMove. Use Visual
SafeMove in RobotStudio.
12 (For system containing SafeMove or EPS) Synchronize SafeMove to activate
SafeMove.(For system containing SafeMove) Synchronize SafeMove to
activate SafeMove.
13 Perform test run.
14 Update the calibration label with new resolver values (calibration values).
Manual tuning of calibration offset

Manual tuning of calibration offset is normally not needed, but can be useful in
some situations. The requirement to do manual tuning is that there is a known
accurate position, that worked accurately before the repair (step 5, see Brief
introduction to Reference Calibration on page 823).

5 Calibration
Continued
Example "Adjust axis 4":

1 Create a backup.
2 Run the manipulator to the verification position. (The manipulator position
is now deviating from the verification position.)
3 Read and note current axis 4 value in degrees (example: 96.3 degrees).
4 Manually jog, only axis 4, so that the manipulator is correctly positioned to
the verification position.
5 Read and note current axis 4 value in degrees (example: 94.2 degrees).
6 Move the manipulator to its calibration position.
7 Calculate the angle difference (ie 96.3-94.2=2.1 degrees).
8 Manually jog axis 4 the calculated angle difference (-2.1). NOTE! The direction
+/- shall be the same direction as the direction used when axis 4 was manually
jogged to coincide with the verification process. In the example -2.1 degrees.
9 Make a new manual fine calibration of axis 4 with axis in -2.1 degrees position.
10 Check again against the verification position.
11 Repeat the manual tuning if needed.
12 Create a new reference if the intention is to use the reference in the future.

5 Calibration
5.5 Calibrating with Calibration Pendulum method
5.5 Calibrating with Calibration Pendulum method
Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.

5 Calibration
5.6 Calibrating with Wrist Optimization method
When to run Wrist Optimization

Wrist Optimization routine is run to improve TCP reorientation performance.
Calibrating the robot with standard calibration method overwrites the optimized
positions of axes 4, 5. Re-run the Wrist Optimization routine after standard
calibration to re-achieve the optimized positions of the wrist axes.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine Wrist Optimization.
2 Modify targets for 4-point tool frame definition, in Wrist Optimization routine.
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
3 Improved calibration data to the wrist axes is identified and presented.

4 Optimized positions for the wrist axes are presented.

5 Calibration
Continued
5 The robot moves to the optimized positions for the wrist axes and
automatically overwrites previous calibration data.
WARNING
Robot moves automatically when pressing Calibrate.
6 Wrist optimization is finished.

7 Redefine / verify TCP for all tools.

5 Calibration
5.7 Verifying the calibration
5.7 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 829.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 804.
3 Write down the values on a new label and stick it on top
of the calibration label.
The label is located on the lower arm.

5 Calibration
5.8 Checking the synchronization position
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.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 804 and Updating revolution
counters on page 807.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 804 and
date the revolution counters. Updating revolution counters on page 807.

5 Calibration
Continued
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 Tap Code.
2 Create a new program.
3 Use MoveAbsJ in the Add Instruction menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 804 and Updating revolution
counters on page 807.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 Tap Jog.
2 From the Mechanical unit list select a
mechanical unit.
3 From the Motion mode section, select an
axis-set that need to be jogged.
For example, to jog axis 2, select the axis
set Axis 1-3.
4 Follow the screen instruction on joystick
movements to understand the direction of
the axis that you want to move and move
the joystick.
5 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
6 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 804 and
date the revolution counters. Updating revolution counters on page 807.

6 Decommissioning
6.1 Introduction to decommissioning
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
The decommissioning process shall be preceded by a risk assessment.
Disposal of materials used in the robot

All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
See also Environmental information on page 832.
Transportation
Prepare the robot or parts before transport, this to avoid hazards.

6 Decommissioning
6.2 Environmental information
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
Materials used in the product

The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Covers, synchronization brackets

Batteries, Lithium Serial measurement board
Cast iron/nodular iron Base, lower arm, upper arm
Copper Cables, motors
Neodymium Brakes, motors
Nickel Turning disc (foundry)
Oil, grease Gearboxes
Plastic/rubber Cables, connectors, drive belts, and so on.
Steel Gears, screws, base frame, and so on.

6 Decommissioning
Continued
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:
• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

6 Decommissioning
6.3 Scrapping of robot
6.3 Scrapping of robot
Note
The decommissioning process shall be preceded by a risk assessment.
Important when scrapping the robot
DANGER
The risk assessment should consider hazards arising in the decommissioning,

such as, but not limited to:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.
• A used robot does not have the same performance as on delivery. Springs,
brakes, bearings, and other parts might be worn or broken.

6 Decommissioning
6.4 Decommissioning of balancing device
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
Equipment Article num- Note

ber
Protective clothing that also covers - Must protect against spatter of sparks
face and hands and flames.
Cutting torch with a long shaft - For opening housing and cutting coils.
The long shaft is a safety requirement.
Other tools and procedures may be These procedures include references
required. See references to these to the tools required.
procedures in the step-by-step in-
structions below.
DANGER
Do not, under any circumstances, deal with the balancing device in any other
way than that detailed in the product documentation! For example, attempting
to open the balancing device is potentially lethal!
Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing
device is to be decommissioned.
Action Note
1 Remove the balancing device from the robot. Detailed in section Replacing the balan-
cing device on page 471.
2 Send the device to a decommissioning Make sure the decommissioning com-
company. pany is well informed about the stored
energy built up by high tensioned com-
pression springs and that the device
contains some grease.
The following procedure contains useful
information about decommissioning.

6 Decommissioning
Continued
Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact
ABB Robotics for further consultation.
Action Note
1
DANGER
There is stored energy built up by high

tensioned compression springs inside the
balancing device! When a coil is cut the
released tension creates a spatter of
sparks and flames.
The working area must be free of flam-
mable materials. Position the balancing
device so that the spatter will be directed
away from personnel.
2 Clamp the device at the working location.

Place the device at ground level so that
the hole and spring coils are cut from a
safe distance and somewhat from above.
3
DANGER
The hole must be cut as specified in the

figure. Pieces of the spring can be thrown
out from the cylinder at high speed if the
hole is cut larger than specified!
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!

6 Decommissioning
Continued
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
7 Robot description
Identifying the motor visually

Type B motors include evacuation on the motor flange to indicate failure of primary
sealing between the gearbox and the motor. Robots with protection type Foundry
Plus have a sight glass installed in the evacuation holes.
Use the images to identify which type of motor is installed on each robot axis.
Type A motor Type B motor
xx1500001058 xx1500001057
No evacuation on type A motors. The type B motor include evacuation on the

motor flange.
Attachment holes M14 (axis 1, 2, 3) Attachment holes M12 (axis 1, 2, 3)

Use the table to identify which type of motor is installed on each robot axis by
article number. The article numbers specified are found in WebConfig.
Contact ABB Service for further assistance regarding which motor type is installed
on the robot, if needed.
The columns for reach refer to the robot variant designation.
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

7 Robot description
Continued
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.
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
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

8.2 Applicable standards
8.2 Applicable standards
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
Other standards used in design
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
Region specific standards and regulations
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

8.3 Unit conversion
8.3 Unit conversion
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

8.4 Screw joints
8.4 Screw joints
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.
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. It is recommended by ABB for M6-M20 screw joints. Screws treated
with Gleitmo may be reused 3-4 times before the coating disappears. After this the
screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Generally, screws are lubricated with Gleitmo 603 mixed with Geomet 500 or
Geomet 702 in proportion 1:3. Geomet thickness varies according to screw
dimensions, refer to the following.
Dimension Lubricant Geomet thickness
M6-M20 (any length except Gleitmo 603 + Geomet 500 3-5 μm
M20x60)
M6-M20 (any length except Gleitmo 603 + Geomet 720 3-5 μm
M20x60)
M20x60 Gleitmo 603 + Geomet 500 8-12 μm
M20x60 Gleitmo 603 + Geomet 720 6-10 μm
Screws lubricated in other ways

Screws lubricated with Molykote 1000 or Molykote P1900 should only be used
when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.

8.4 Screw joints
Continued
Lubricant Article number

Molykote 1000 (molybdenum disulphide grease) 3HAC042472-001
Molykote P1900 (molybdenum disulphide grease) 3HAC070875-001
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
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Tightening torque for oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
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

8.4 Screw joints
Continued
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
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M5 8
M6 14
M8 28 35
M10 55 70
M12 96 120
M16 235 300
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent
Water and air connectors

water and air connectors when one or both connectors are made of brass.
Note

Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -

Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

8.5 Weight specifications
8.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
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
The arm weighs 25 kg.

ingly.

8.6 Standard toolkit
8.6 Standard toolkit
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the 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.
Contents, standard toolkit
Qty Tool Comment

1 Ring-open-end spanner 8-19 mm
1 Socket head cap 2.5-17 mm
1 Torx socket no: 20-60
1 Box spanner set
1 Torque wrench 10-100 Nm
1 Torque wrench 75-400 Nm
1 Ratchet head for torque wrench 1/2
2 Hexagon-headed screw M10x100
1 Hexagon-headed screw M16x90
1 Hex bit socket head cap no. 14 socket 40 mm L=100 mm
1 Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm
1 Hex bit socket head cap no. 6 socket 40 mm L=145 mm
1 Hex bit socket head cap no. 6 socket 40mm bit L=220 mm
1 Plastic mallet

8.7 Special tools
8.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard toolkit on page 848, and of special tools, listed directly in the instructions
and also gathered in this section.
Special tools

8.7 Special tools
Rear bearing (balancing

Spherical roller bearing
Brake release unit
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
3HAC15556-1 Lifting accessory (chain) x x x x x x
xx1200001241
3HAC14459-1 Lifting accessory, motor x x

3HAC15534-1 Lifting accessory, motor x x x
3HAC046112-001 Lifting accessory, gearbox x
3HAC046128-001 iii
3HACxx iv Lifting accessory, gearbox x
3HAC046112-001 v
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

8.7 Special tools

Brake release unit
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
Fender washer
- Outer diameter: minimum 26 mm, x x x x x
maximum 30 mm, hole diameter:
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
3HAC030662-001 Distance tool x x x x
xx1400000726
Hydraulic press tool, balancing

3HAC020902-001 x
device
xx1300000672
3HAC11731-1 Hydraulic cylinder x x x x

3HAC13086-1 Hydraulic pump 80 MPa x x x x
- Threaded bar, M16x340 x x x x

8.7 Special tools

Brake release unit
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
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
3HAC046645-003 Aligning tool x
xx1700001659
- Long AllenKeySocketIN19L 6-140 x x x

3HAC12342-1 Bits extender x x x x x
3HAC15716-1 Calibration Pendulum toolkit vii x x x x x x x x x x x x x x
Calibration tool box, Axis
3HAC055412-001 x x x x x x x x x x x x x x
Calibration vii
3HAC043870-009 Guide for reduction gear x
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

8.7 Special tools

Brake release unit
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
3HAC067546-001 viii
3HAC067547-001 ix Pinion x
3HAC067545-001 x
xx1800001147
3HAB7887-1 Rotation tool x x x x x x x x x x x x

i Tool depending on motor types. See Type A vs type B motors on page 839.
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
iii 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
iv IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
v IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID
Included in Dismantle and mounting tool (3HAC028920-001).
vii The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant.
viii 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
ix IRB 6700-200/2.60, -175/2.60 LID, -155/2.85, -140/2.85 LID
x IRB 6700-300/2.70, -270/2.70 LID, -245/3.00, -220/3.00 LID

8.8 Lifting accessories and lifting instructions
8.8 Lifting accessories and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction 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
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
All documents can be found via myABB Business Portal, www.abb.com/myABB.

10 Circuit diagrams
10.1 Circuit diagrams
10 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
Product Article numbers for circuit diagrams

Circuit diagram - OmniCore V250XT 3HAC074000-008
Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Manipulators

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 1600/1660 3HAC021351-003

Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001

10 Circuit diagrams
Continued

3HAC029940-001
Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
3HAC025744-001
Circuit diagram - IRB 910SC 3HAC056159-002

Index
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

Index
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

Index
axis 2 release brakes, 37

replacing, 520 replacements, report, 201
axis 3 replacing
replacing, 534 axis-6 gearbox, 787
axis 4 axis-6 motor, 575
replacing, 547 axis-5 motor, 558
motor cooling fan, 109 axis-2 motor, 520
motor seal axis-1 gearbox, 590, 709
inspecting, 122 axis-1 motor, 506
MoveAbsJ instruction, 829–830 balancing device, 471
battery, 193
N brake release unit, 298
national regulations, 30 cable harness, 238, 262
negative directions, axes, 806 gearbox axis-1, 631
neodymium lower arm, 385
disposal, 832 mechanical stop pin, 502
nodular iron SMB unit, 292
disposal, 832 turning disc, 372
upper arm, 303
O wrist, 347
oil, 34 xx, 490
amount in gearboxes, 160 report replacements, 201
disposal, 832 requirements on foundation, 45
type of oil, 160 responsibility and validity, 19
oil change restricting
axis 1, 162 working range axis 1, 99, 102
axis 2, 169 revolution counters
axis 3, 174 storing on FlexPendant, 808, 812
axis 4, 180 updating, 807, 811
axis 5, 184 risk of burns, 34
axis 6, 188 risk of tipping, 53
oil level robot
gearbox axis 1, 124 labels, 23
gearbox axis 2, 129 lifting, 72, 75
gearbox axis 3, 132 protection class, 46
gearbox axis 4, 135 protection types, 46
gearbox axis 5, 137 securing to foundation, 81
gearbox axis 6, 139 securing to track motion, 82
operating conditions, 46 symbols, 23
option roundslings
Extended working range, 99 lifting the robot, 75
original spare parts, 19 rubber
disposal, 832
P
pedestal S
installed on pedestal, 30 safety
personnel brake testing, 38
requirements, 20 ESD, 57
plastic fire extinguishing, 31
disposal, 832 release robot axes, 37
positive directions, axes, 806 signal lamp, 108
PPE, 20 signals, 21
product standards, 842 signals in manual, 21
protection classes, 46 symbols, 21
protection type, 46 symbols on robot, 23
protective equipment, 20 test run, 116
protective wear, 20 safety devices, 31
safety equipment
R mechanical stop, 102
rear bearings signal lamp, 158
replacing, 490 safety hazard
recycling, 832 hydraulic system, 32
regional regulations, 30 pneumatic system, 32

Index
safety signals securing robot, 82

in manual, 21 transportation, 831
safety standards, 842 transporting the robot, 62
scales on robot, 804 transport support, 62
schedule of maintenance, 119 troubleshooting
screw joints, 844 oil spills, 198
securing safety, 39
base plate, 66 turning disc
securing the robot to foundation, attachment screws, 80 replacing, 372
serial measurement board type A motors, 839
replacing, 292 type B motors, 839
shipping, 831
signal lamp, 108 U
signals upcycling, 832
safety, 21 updating revolution counters, 807, 811
SMB upper arm
replacing, 292 replacing, 303
SMB battery users
extension of lifetime, 193 requirements, 20
replacing, 193
speed V
adjusting, 115 validity and responsibility, 19
stability, 53 velocity
standards, 842 adjusting, 115
ANSI, 842 verifying calibration, 828
CAN, 842
start of robot in cold environments, 115 W
steel weight, 43
disposal, 832 axis-1 gearbox, 608, 611, 651–652
stop pin axis-1 gearbox and base, 648, 657
replacing, 502 axis-1 motor, 512, 514, 602, 621, 643, 662
storage conditions, 45 balancing device, 391, 459, 475, 480, 494, 678, 716
symbols base plate, 65, 71
safety, 21 robot, 74, 78, 606, 616, 647, 659
synchronization position, 807, 811 upper arm, complete, 236, 320, 327–328, 330, 408,
sync marks, 804 423–424, 426, 760, 773–774, 776
system integrator requirements, 30 working range
restricting axis 1, 102
T wrist
temperatures replacing, 347
operation, 46 Wrist Optimization
storage, 45 overview of method, 826
testing
brakes, 38 Z
torques on foundation, 44 zero position
track motion checking, 829

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 10-732 50 00
ABB AS
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
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2 Installation and commissioning 41

Product manual - IRB 6700 5

6 Product manual - IRB 6700

4.4.2 Refitting the cable harness ....................................................................... 262

Product manual - IRB 6700 7

6.2 Environmental information .................................................................................. 832

7 Robot description 839

8 Reference information 841

9 Spare parts 855

10 Circuit diagrams 857

8 Product manual - IRB 6700

Overview of this manual

Product manual scope

It is the responsibility of the integrator to conduct a risk assessment of the final

Who should read this manual?

Continues on next page

Document name Document ID

For OmniCore robots

Document name Document ID

For IRC5 robots

Document name Document ID

Continues on next page

Continues on next page

Continues on next page

Continues on next page

Product manual - IRB 6700 15

All documents can be found via myABB Business Portal, www.abb.com/myABB.

Technical reference manuals

Continues on next page

• Examples of how to use the application.

Product manual - IRB 6700 17

How to read the product manual

18 Product manual - IRB 6700

1.1.1 Limitation of liability

Spare parts and equipment

Product manual - IRB 6700 19

1.1.2 Requirements on personnel

Personal protective equipment

20 Product manual - IRB 6700

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

WARNING Signal word used to indicate a potentially hazardous

ELECTRICAL Signal word used to indicate a potentially hazardous

CAUTION Signal word used to indicate a potentially hazardous

ELECTROSTATIC Signal word used to indicate a potentially hazardous

NOTE Signal word used to indicate important facts and

Continues on next page

Symbol Designation Significance

22 Product manual - IRB 6700

1.2.2 Safety symbols on manipulator labels

Symbols on safety labels

Continues on next page

Before disassembly, see product manual

Continues on next page

Continues on next page

Continues on next page

Adjustable chain sling with shortener