ROBOTICS

Product manual
IRB 6700
Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012
 Product manual
IRB 6700 - 235/2.65
IRB 6700 - 205/2.80
IRB 6700 - 175/3.05
IRB 6700 - 150/3.20
IRB 6700 - 200/2.60
IRB 6700 - 155/2.85
IRB 6700 - 300/2.70
IRB 6700 - 245/3.00
IRC5

Document ID: 3HAC044266-001

Revision: N

© Copyright 2013 - 2018 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
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.

© Copyright 2013 - 2018 ABB. All rights reserved.

Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 14
How to read the product manual ...................................................................................................... 16

1 Safety 17
1.1 General safety information .................................................................................. 17
1.1.1 Limitation of liability ................................................................................. 17
1.1.2 Protective stop and emergency stop ........................................................... 19
1.2 Safety actions ................................................................................................... 20
1.2.1 Fire extinguishing .................................................................................... 20
1.2.2 Emergency release of the robot axes .......................................................... 21
1.2.3 Make sure that the main power has been switched off .................................... 22
1.3 Safety risks ...................................................................................................... 23
1.3.1 Safety risks during installation and service work on robots .............................. 23
1.3.2 Moving robots are potentially lethal ............................................................ 25
1.3.3 First test run may cause injury or damage .................................................... 26
1.3.4 Work inside the working range of the robot .................................................. 27
1.3.5 Enabling device and hold-to-run functionality ............................................... 28
1.3.6 Risks associated with live electric parts ....................................................... 29
1.3.7 The unit is sensitive to ESD ....................................................................... 31
1.3.8 Hot parts may cause burns ....................................................................... 32
1.3.9 Safety risks related to pneumatic/hydraulic systems ...................................... 33
1.3.10 Brake testing .......................................................................................... 34
1.3.11 Safety risks during handling of batteries ...................................................... 35
1.3.12 Safety risks during work with gearbox lubricants (oil or grease) ....................... 36
1.4 Safety signals and symbols ................................................................................. 38
1.4.1 Safety signals in the manual ...................................................................... 38
1.4.2 Safety symbols on product labels ............................................................... 40

2 Installation and commissioning 47

2.1 Introduction ...................................................................................................... 47
2.2 Unpacking ....................................................................................................... 48
2.2.1 Pre-installation procedure ......................................................................... 48
2.2.2 Working range ........................................................................................ 52
2.2.3 Risk of tipping/stability ............................................................................. 58
2.2.4 Main dimensions ..................................................................................... 59
2.3 On-site transportation ........................................................................................ 61
2.3.1 Robot transportation precautions ............................................................... 61
2.3.2 Securing the robot with a transport support ................................................. 65
2.4 On-site installation ............................................................................................ 67
2.4.1 Brief installation procedure ....................................................................... 67
2.4.2 Lifting the base plate ................................................................................ 68
2.4.3 Securing the base plate ............................................................................ 69
2.4.4 Lifting the robot ...................................................................................... 75
2.4.4.1 Lifting the robot with fork lift .......................................................... 75
2.4.4.2 Lifting the robot with roundslings .................................................... 76
2.4.5 Orienting and securing the robot ................................................................ 80
2.4.6 Manually releasing the brakes ................................................................... 85
2.4.7 Loads fitted to the robot, stopping time and braking distances ......................... 87
2.4.8 Fitting equipment to the robot ................................................................... 88
2.5 Restricting the working range .............................................................................. 96
2.5.1 Axes with restricted working range ............................................................. 96
2.5.2 Mechanically restricting the working range of axis 1 ...................................... 97
2.6 Electrical connections ........................................................................................ 99
2.6.1 Robot cabling and connection points .......................................................... 99

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Table of contents

2.7 Installation of options ......................................................................................... 102

2.7.1 Signal lamp (option) ................................................................................. 102
2.7.2 Installing the motor cooling fan (option) ...................................................... 103
2.8 Start of robot in cold environments ...................................................................... 109

3 Maintenance 111
3.1 Introduction ...................................................................................................... 111
3.2 Maintenance schedule and expected component life ............................................... 112
3.2.1 Specification of maintenance intervals ........................................................ 112
3.2.2 Maintenance schedule ............................................................................. 113
3.2.3 Expected component life ......................................................................... 115
3.3 Inspection activities ........................................................................................... 116
3.3.1 Inspecting the motor seal ......................................................................... 116
3.3.2 Inspecting the oil level in axis-1 gearbox ..................................................... 118
3.3.3 Inspecting the oil level in axis-2 gearbox ..................................................... 123
3.3.4 Inspecting the oil level in axis-3 gearbox ..................................................... 126
3.3.5 Inspecting the oil level in axis-4 gearbox ..................................................... 129
3.3.6 Inspecting the oil level in axis-5 gearbox ..................................................... 131
3.3.7 Inspecting the oil level in axis-6 gearbox ..................................................... 133
3.3.8 Inspecting the balancing device ................................................................ 136
3.3.9 Inspecting the cable harness .................................................................... 140
3.3.10 Inspecting the information labels ................................................................ 142
3.3.11 Inspecting the axis-1 mechanical stop pin ................................................... 146
3.3.12 Inspecting the additional mechanical stops ................................................. 148
3.3.13 Inspecting the fork lift accessory ................................................................ 150
3.3.14 Inspecting the dampers ........................................................................... 152
3.3.15 Inspecting the signal lamp (option) ............................................................. 154
3.4 Replacement/changing activities .......................................................................... 156
3.4.1 Type of lubrication in gearboxes ................................................................ 156
3.4.2 Changing oil, axis-1 gearbox ..................................................................... 158
3.4.3 Changing oil, axis-2 gearbox ..................................................................... 165
3.4.4 Changing oil, axis-3 gearbox ..................................................................... 170
3.4.5 Changing oil, axis-4 gearbox ..................................................................... 176
3.4.6 Changing oil, axis-5 gearbox ..................................................................... 180
3.4.7 Changing oil, axis-6 gearbox ..................................................................... 184
3.4.8 Replacing the SMB battery ....................................................................... 189
3.5 Lubrication activities .......................................................................................... 192
3.5.1 Lubricating the spherical roller bearing, balancing device .............................. 192
3.6 Cleaning activities ............................................................................................. 194
3.6.1 Cleaning the IRB 6700 ............................................................................. 194

4 Repair 197
4.1 Introduction ...................................................................................................... 197
4.2 General procedures ........................................................................................... 198
4.2.1 Performing a leak-down test ...................................................................... 198
4.2.2 Mounting instructions for bearings ............................................................. 199
4.2.3 Mounting instructions for seals .................................................................. 201
4.2.4 Dismantle and mounting tool, 3HAC028920-001 ............................................ 203
4.2.5 Cut the paint or surface on the robot before replacing parts ............................ 204
4.2.6 The brake release buttons may be jammed after service work ......................... 205
4.3 Lifting associated procedures .............................................................................. 206
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85) .................................................... 206
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70,
-245/3.00) .............................................................................................. 211
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700-235/2.65, -205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85) .................. 217
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700
-300/2.70, -245/3.00) ................................................................................ 223

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 Table of contents

4.3.5 Attaching lifting accessories to the upper arm ............................................... 228

4.4 Complete robot ................................................................................................. 231
4.4.1 Removing the cable harness .................................................................... 231
4.4.2 Refitting the cable harness ....................................................................... 255
4.4.3 Replacing the SMB ................................................................................. 285
4.4.4 Replacing the brake release unit ............................................................... 291
4.5 Upper and lower arms ........................................................................................ 296
4.5.1 Replacing the upper arm .......................................................................... 296
4.5.2 Replacing the wrist ................................................................................. 340
4.5.3 Replacing the turning disc ........................................................................ 365
4.5.4 Replacing the process turning disc ............................................................. 371
4.5.5 Replacing the lower arm .......................................................................... 377
4.6 Frame and base ................................................................................................ 443
4.6.1 Replacing spherical roller bearing, link ear ................................................... 443
4.6.2 Replacing the balancing device ................................................................. 461
4.6.3 Replacing the rear bearings on the balancing device ..................................... 479
4.6.4 Unloading the balancing device ................................................................. 492
4.6.5 Restoring the balancing device ................................................................. 496
4.6.6 Replacing the stop pin ............................................................................. 499
4.7 Motors ............................................................................................................ 503
4.7.1 Replacing the axis-1 motor ....................................................................... 503
4.7.2 Replacing the axis-2 motor ....................................................................... 517
4.7.3 Replacing the axis-3 motor ....................................................................... 530
4.7.4 Replacing the axis-4 motor ....................................................................... 543
4.7.5 Replacing the axis-5 motor ....................................................................... 554
4.7.6 Replacing the axis-6 motor ....................................................................... 571
4.8 Gearboxes ....................................................................................................... 586
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700
- 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85) .......... 586
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00) ........... 626
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700
- 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85) .......... 664
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00) ........... 701
4.8.5 Replacing the axis-3 gearbox .................................................................... 738
4.8.6 Replacing the axis-6 gearbox .................................................................... 776

5 Calibration 787
5.1 Introduction to calibration ................................................................................... 787
5.1.1 Introduction and calibration terminology ...................................................... 787
5.1.2 Calibration methods ................................................................................. 788
5.1.3 When to calibrate ................................................................................... 790
5.2 Synchronization marks and axis movement directions ............................................. 791
5.2.1 Synchronization marks and synchronization position for axes ......................... 791
5.2.2 Calibration movement directions for all axes ................................................ 793
5.3 Updating revolution counters ............................................................................... 794
5.4 Calibrating with Axis Calibration method ............................................................... 798
5.4.1 Description of Axis Calibration .................................................................. 798
5.4.2 Calibration tools for Axis Calibration ........................................................... 800
5.4.3 Installation locations for the calibration tools ............................................... 802
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 803
5.5 Calibrating with Calibration Pendulum method ........................................................ 809
5.6 Verifying the calibration ...................................................................................... 810
5.7 Checking the synchronization position .................................................................. 811

6 Decommissioning 813
6.1 Environmental information .................................................................................. 813
6.2 Scrapping of robot ............................................................................................. 815
6.3 Decommissioning of balancing device ................................................................... 816

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Table of contents

7 Robot description 819

7.1 Type A vs type B motors .................................................................................... 819

8 Reference information 821

8.1 Introduction ...................................................................................................... 821
8.2 Applicable standards ......................................................................................... 822
8.3 Unit conversion ................................................................................................. 824
8.4 Screw joints .................................................................................................... 825
8.5 Weight specifications ......................................................................................... 828
8.6 Standard toolkit ................................................................................................ 829
8.7 Special tools .................................................................................................... 830
8.8 Lifting accessories and lifting instructions .............................................................. 835

9 Spare parts 837

9.1 Spare part lists and illustrations ........................................................................... 837

10 Circuit diagrams 839

10.1 Circuit diagrams ................................................................................................ 839

Index 841

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 Overview of this manual

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.

Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.

Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.

Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.

Product manual scope

The manual covers 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.

Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety, service Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.

Continues on next page

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Overview of this manual
Continued

Chapter Contents
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards, etc.
Spare parts and exploded Reference to the spare part list for the robot.
views
Circuit diagram Reference to the circuit diagram for the robot.

References
Documentation referred to in the manual, is listed in the table below.
Document name Document ID
Product manual, spare parts - IRB 6700/IRB 6700Inv 3HAC044268-001
Product specification - IRB 6700 3HAC044265-001
Directions for use - Fork lift accessory for IRB 6700 3HAC048484-002
Circuit diagram - IRB 6700 3HAC043446-005
Product manual - DressPack/SpotPack IRB 6700 3HAC044270-001
Operating manual - General safety information i 3HAC031045-001
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Product manual - IRC5 3HAC021313-001
IRC5 with main computer DSQC 639.
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Calibration Pendulum 3HAC16578-1
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revisions
Revision Description
- First edition.
A The following updates are done in this revision:
• The variants IRB 6700-200/2.60 and IRB 6700-155/2.85 are added.
• Some illustrations showing IRB 6640 are replaced with IRB 6700.
• The information is updated in Lifting with fork lift accessory. ABB
recommends that the fork lift accessories are removed before
powering up the robot.
B The following updates are done in this revision:
• The protection type Foundry Plus is added throughout the manual.

Continues on next page

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 Overview of this manual
Continued

Revision Description
C The following updates are done in this revision:
• The variants IRB 6700-300/2.70 and -245/3.00 are added
throughout the manual.
• The maximum allowed deviation in levelness of the base plate
and foundation is changed, see Securing the base plate on
page 69.
• Added information about which axes are affected by non-integer
gear ratio, see Updating revolution counters on page 794.
• Removed faulty listed washer from consumables tabe, section
Replacing the upper arm on page 296.
• Added tightening torque for R1.SMB and 7th axis connector, ses
Refitting the cable harness on page 255.
• 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 80. Corrected to 8 pcs.
• Added an alternative tightening torque for robot attachment bolts,
see Orienting and securing the robot on page 80.
• 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 80.
• Updated base plate drawings and added information regarding
guide pins, see Securing the base plate on page 69.
• Thread lines were missing. Now added in figure.
• Figure updated so locating hole is shown at "12 o'clock".
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 16.
• New standard calibration method is introduced (Axis Calibration).
See Calibration on page 787.
• 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 368.
• Flattened cylindrical guide pin is removed for the base plate, re-
placed with a cylindrical. See Securing the base plate on page 69.
• O-ring type changed in Replacing the axis-1 gearbox (IRB 6700 -
300/2.70, IRB 6700 - 245/3.00) on page 626.
• Sections "Inspecting oil level" and "Changing oil in gear box" are
updated with information for 300/2.70 and 245/3.00.

Continues on next page

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Overview of this manual
Continued

Revision Description
F The following updates are done in this revision:
• Corrected the article number for the rotation tool to 3HAB7887-1.
• Removed the tool measuring ring for radial seal from special tools
list, since it is not used for the robot.
• Removed the article number for the leak-down tester, since it is
not a purchable equipment.
• Removed the article number for the threaded bar used for pressing
the rear balancing device bearing in place, since it is not a
purchable equipment.
• Corrected the article number for the fork lift from 3HAC047054-
002 to 3HAC047054-003.
• Edited information regarding deciding calibration routine in each
repair section.
• Added a warning that calibration pin must be inserted in the calib-
ration bushing until it snaps, see Description of Axis Calibration
on page 798.
• Added warning regarding risk of pinching, in Description of Axis
Calibration on page 798.
• Added information about inspection of calibration tool prior to
usage, see Examining the calibration tool on page 800.
• Added information about the calibration procedure, see Overview
of the calibration procedure on the FlexPendant on page 803, Re-
starting an interrupted calibration procedure on page 805.
• Added information about Axis Calibration when SafeMove is in-
stalled, see Axis Calibration with SafeMove option on page 806.
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 69.
• 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 94.
• 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.

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 Overview of this manual
Continued

Revision Description
K Published in release R17.2. The following updates are made in this revi-
sion:
• Caution about removing metal residues added in sections about
SMB boards.
• Information about Minimum resonance frequency added.
• Bending radius for static floor cables added.
• Applicable standards updated
• Added text regarding overhaul in section specification of mainten-
ance intervals.
• Section Start of robot in cold environments on page 109 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 800.
• Added sections in General procedures on page 198.
• Corrected the length of attachment screws for axis-1 and axis-2
motors.
• Guide tool for refitting the axis-1 gearbox is added to the repair
procedure and list of special tools.
• Safety restructured.
• Changed specification for axis-2 position before usage of distance
tool on the balancing device.
• The procedure for replacing 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.

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Product documentation

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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.

Product manuals
Manipulators, controllers, DressPack/SpotPack, 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.
• 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.
• Examples of how to use the application.

Continues on next page

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 Product documentation
Continued

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.

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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 17.

Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.

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 1 Safety
1.1.1 Limitation of liability

1 Safety
1.1 General 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 complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/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.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.

Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.

To be observed by the supplier of the complete system

The integrator is responsible 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 and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.

Continues on next page

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1 Safety
1.1.1 Limitation of liability
Continued

The integrator of the final application is required to perform an assessment of the

hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.

Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).

Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB, it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength of the robot could
be affected.

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1.1.2 Protective stop and emergency stop

1.1.2 Protective stop and emergency stop

Overview
The protective stops and emergency stops are described in the product manual
for the controller.

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1 Safety
1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the

manipulator or controller.

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1.2.2 Emergency release of the robot axes

1.2.2 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 85.
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 robot does not
increase the pressure on the trapped person, further increasing any injury.

DANGER

When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.

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1 Safety
1.2.3 Make sure that the main power has been switched off

1.2.3 Make sure that the main power has been switched off

Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.

Note

Switch off all main power switches in a MultiMove system.

Spot welding cabinet

Wait for 5 minutes to let the capacitors discharge after the power has been switched
off.

DANGER

Even if the main switch is switched off, the capacitors can cause electric shock
if not given the time to discharge.

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 1 Safety
1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot. Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install,
maintain, repair, or use the robot.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.

General risks during installation and service

The instructions in the product manual must always be followed.
Never turn the power on to the robot before it is properly fixed and bolted to its
foundation/support.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to remove the power cable to
the controller.
If the robot is installed at a height, hanging, or other than standing directly on the
floor, there may be additional risks than those for a robot standing directly on the
floor.
Energy stored in the robot for the purpose of counterbalancing certain axes may
be released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, which means, do not climb on the controller,
motors, or other parts during service work. There is a risk of slipping because of
the high temperature of the motors and oil spills that can occur on the robot. There
is also a risk of the robot being damaged.
To avoid damaging the product, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.

Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.

Continues on next page

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1.3.1 Safety risks during installation and service work on robots
Continued

If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. ABB is not liable for damages caused by
the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the robot.

Connection of external safety devices

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

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the installation.

Allergenic material
See Environmental information on page 813 for specification of allergenic materials
in the product, if any.

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1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal

Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the robot.

Safe handling

Action Note
1 Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.
2 Usually the hold-to-run function is active How to use the hold-to-run function is de-
only in manual full speed mode. To in- scribed in section How to use the hold-to-
crease safety it is also possible to activate run function in the Operating manual - IRC5
hold-to-run for manual reduced speed with with FlexPendant.
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.
3 Make sure no personnel are present within
the working range of the robot before
pressing the start button.

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1 Safety
1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description
After installation and performing service activities, there are several safety risks
to take into consideration before the first test run.

Safe handling
Use this procedure when performing the first test run after installation, maintenance,
or repair.

DANGER

Running the robot without fulfilling the following aspects, may involve a risk of
injury and cause severe 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 Install all safety equipment properly.
6 Make sure all personnel are standing at a safe distance from the robot, and is out of
its reach behind safety fences, or similar.
7 If maintenance or repair has been done, pay special attention to the function of the
part that was serviced.

Collision risks

CAUTION

When programming the movements of the robot, always identify potential collision
risks before the first test run.

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1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then the following
points must be observed:
• The operating mode selector on the controller must be in the manual mode
position to render the three-position enabling device operational and to block
operation from a computer link or remote control panel.
• The maximum speed of the robot is limited to 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot. Keep away from axes to not
get entangled with hair or clothing. Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside
the cell.
• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped
or crushed by the robot.
• To prevent anyone else from taking control of the robot, always put a safety
lock on the cell door and bring the three-position enabling device with you
when entering the working space.

WARNING

NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved
using the three-position enabling device or during other work inside the working
range of the robot.

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1 Safety
1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a manually operated, constant pressure
push-button which, when continuously activated in one position only, allows
potentially hazardous functions but does not initiate them. In any other position,
hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the
push-button only half-way to activate it. In the fully in and fully out positions,
operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant

which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach
pendant. This is to prevent anyone else from taking control of the robot
without his/her knowledge.

Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.

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 1 Safety
1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the main switch to
OFF) when repairing faults, disconnecting electric leads, and disconnecting or
connecting units.
The main supply to the robot must be connected in such a way that it can be turned
off from outside the working space of the robot.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation,
commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.

Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).

Continues on next page

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1 Safety
1.3.6 Risks associated with live electric parts
Continued

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.

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 1 Safety
1.3.7 The unit is sensitive to ESD

1.3.7 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

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

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1 Safety
1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description
During normal operation, many parts become hot. Touching these may cause
burns.
There is also a risk of fire if flammable materials are put on hot surfaces.

Safe handling
Always use your hand, at some distance, to feel if heat is radiating from the
potentially hot component before actually touching it.
Wait until the potentially hot component has cooled if it is to be removed or handled
in any other way.
Do not put anything on hot metal surfaces, e.g. paper or plastic.

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1.3.9 Safety risks related to pneumatic/hydraulic systems

1.3.9 Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the robot system.

Residual energy
Residual energy can be present in these systems. After shutdown, particular care
must be taken.
The pressure must be released in the complete pneumatic or hydraulic systems
before starting to repair them.
Work on hydraulic equipment may only be performed by persons with special
knowledge and experience of hydraulics.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Splashed oil may cause injury or fire.

Safe design
Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.

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1 Safety
1.3.10 Brake testing

1.3.10 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 robot axis to a position where the combined weight of the robot
arm and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the robot does not change position as the motors are switched off, then
the brake function is adequate.

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 1 Safety
1.3.11 Safety risks during handling of batteries

1.3.11 Safety risks during handling of batteries

Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Safe handling
Use safety glasses when handling the batteries.
In the event of leakage, wear rubber gloves and chemical apron.
In the event of fire, use self-contained breathing apparatus.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Pre-installation procedure on page 48.

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1 Safety
1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be

provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

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
When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are al-
reaction. 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

Continues on next page

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1.3.12 Safety risks during work with gearbox lubricants (oil or grease)
Continued

Warning Description Elimination/Action

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
by the manufacturer.
Do not mix types of oil
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

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
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
The magnetic oil plugs will take
Contaminated oil in care of any remaining metal
gear boxes chips.

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1 Safety
1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the the danger is not eliminated.
• Instruction about how to eliminate danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.

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-
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.
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.

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1.4.1 Safety signals in the manual
Continued

Symbol Designation Significance

NOTE Describes important facts and conditions.

TIP Describes where to find additional information or

how to do an operation in an easier way.

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1 Safety
1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
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 safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.

Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful 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 40.
The information labels can contain information in text (English, German, and
French).

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

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1.4.2 Safety symbols on product labels
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 disassemble, 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

Continues on next page

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1 Safety
1.4.2 Safety symbols on product labels
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

Continues on next page

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 1 Safety
1.4.2 Safety symbols on product labels
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

Continues on next page

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1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
Brake release buttons

xx0900000820

xx1000001140

Lifting bolt

xx0900000821

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

Continues on next page

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 1 Safety
1.4.2 Safety symbols on product labels
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

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 2 Installation and commissioning
2.1 Introduction

2 Installation and commissioning

2.1 Introduction

General
This chapter contains assembly instructions and information for installing the IRB
6700 at the working site.
More detailed technical data can be found in the Product specification for the IRB
6700 , such as:
• Load diagram
• Permitted extra loads (equipment), if any
• Location of extra loads (equipment), if any.

Safety information
Before any installation work is commenced, it is extremely important that all safety
information is observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 17 before performing any installation
work.

Note

If the IRB 6700 is connected to power, always make sure that the robot is
connected to protective earth before starting any installation work.
For more information see:
• Product manual - IRC5

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2 Installation and commissioning
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 49
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 51
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 51
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 49
• Protection classes, robot on page 51
• Requirements, foundation on page 50
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 58
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 67
11 Install required equipment, if any.
• Signal lamp (option) on page 102

Continues on next page

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 2 Installation and commissioning
2.2.1 Pre-installation procedure
Continued

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.

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!

Continues on next page

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2 Installation and commissioning
2.2.1 Pre-installation procedure
Continued

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
Torque z ±5.0 kNm i / ±6.5 kNm ii ±11.4 kNm i / ±15.5 kNm ii
i Valid for IRB 6700-235, -205, -175, -150, -200, -155.
ii Valid for IRB 6700-300, -245.

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.
Maximum tilt 0°
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 Application manual - Control-
time to have a ler software IRC5, section Motion Process Mode.
lower resonance
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 25 Hz. 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.

Continues on next page

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 2 Installation and commissioning
2.2.1 Pre-installation procedure
Continued

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.

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
Manipulator, protection type Standard IP67
Manipulator, protection type Foundry Plus IP67

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2 Installation and commissioning
2.2.2 Working range

2.2.2 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 and - 245/3.00:
+85° to -65° when axis 3 is within +70° to -45°
+85° to -58° when axis 3 is within +70° to -180°
ii Working range +120° to -120° for robots with LeanID, option 780-4.
iii Working range +220° to -220° for robots with LeanID, option 780-4.

Working range axis 5 and axis 6 for LeanID, option 780-4

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

Continues on next page

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 2 Installation and commissioning
2.2.2 Working range
Continued

Illustration, working range IRB 6700 - 235/2.65

This illustration shows the unrestricted working range of the robot.

3114
320
1187 920
1908 2650

Robot type Handling capacity Reach

IRB 6700 235 kg 2.65 m

Illustration, working range IRB 6700 - 205/2.80

This illustration shows the unrestricted working range of the robot. 3259
308

1281 958
2039 2794

Robot type Handling capacity Reach

IRB 6700 205 kg 2.80 m

Continues on next page

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2 Installation and commissioning
2.2.2 Working range
Continued

Illustration, working range IRB 6700 - 175/3.05

This illustration shows the unrestricted working range of the robot.

3520
726
1527 1109
2314 3056

Robot type Handling capacity Reach

IRB 6700 175 kg 3.05 m

Illustration, working range IRB 6700 - 150/3.20

This illustration shows the unrestricted working range of the robot.
3665
713

1604 1067
2445 3200

Robot type Handling capacity Reach

IRB 6700 150 kg 3.20 m

Continues on next page

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 2 Installation and commissioning
2.2.2 Working range
Continued

Illustration, working range IRB 6700 - 200/2.60

This illustration shows the unrestricted working range of the robot.

3065
282
1150 911

1859 2601

Robot type Handling capacity Reach

IRB 6700 200 kg 2.60 m

Illustration, working range IRB 6700 - 155/2.85

This illustration shows the unrestricted working range of the robot.
3312
529

1352 994
2106 2848

Robot type Handling capacity Reach

IRB 6700 155 kg 2.85 m

Continues on next page

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2 Installation and commissioning
2.2.2 Working range
Continued

Illustration, working range IRB 6700 - 300/2.70

This illustration shows the unrestricted working range of the robot.

3154
349
1187 957

1850 2720

Robot type Handling capacity Reach

IRB 6700 300 kg 2.70 m

Illustration, working range IRB 6700 - 245/3.00

This illustration shows the unrestricted working range of the robot.
3399
596

1518 1057

2097 2967

Robot type Handling capacity Reach

IRB 6700 245 kg 3.00 m

Continues on next page

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 2 Installation and commissioning
2.2.2 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

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2 Installation and commissioning
2.2.3 Risk of tipping/stability

2.2.3 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 shipping position is the most stable position.
Do not change the robot position before securing it to the foundation!

Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.

45°

65°

(20°)
°
70
890 50

570 55

xx1300000356

WARNING

The robot is likely to be mechanically unstable if not secured to the foundation.

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 2 Installation and commissioning
2.2.4 Main dimensions

2.2.4 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, -205/2.80, -175/3.05, -150/3.20, -200/2.60 and -155/2.85)
Radius ax1, front = 600 mm (IRB 6700-300/2.70 and -245/3.00)
C Radius ax1, back = 633 mm (IRB 6700-235/2.65, -205/2.80, -175/3.05, -150/3.20, -200/2.60 and -155/2.85)
Radius ax1, back = 700 mm (IRB 6700-300/2.70 and -245/3.00)

Robot variant A A D E F F G H J
LeanID LeanID
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
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

Continues on next page

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2 Installation and commissioning
2.2.4 Main dimensions
Continued

Robot variant A A D E F F G H J
LeanID LeanID
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 1718.5 1878.5 1212.5 222.5 187
IRB 6700 - 245/3.00 220 380 2321 1145 1968.5 2128.5 1462.5 222.5 186

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 2 Installation and commissioning
2.3.1 Robot transportation precautions

2.3 On-site transportation

2.3.1 Robot transportation precautions

General
This section describes ABB approved transportation precautions for ABB robots.

CAUTION

All transportation in or outside the plant, must be carried out according to 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 58.
• Always read and follow the instructions in section Pre-installation procedure
on page 48

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2 Installation and commissioning
2.3.1 Robot transportation precautions
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 65
• 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 63.
• Always use the recommended transport support described in sub section
Recommended transport support on page 64.

IRB 6700
C
D

xx0800000037

A Transport Support
B Hexagon socket head cap screw M16x140
C Threaded bar M10x200
D Nut M10

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 2 Installation and commissioning
2.3.1 Robot transportation precautions
Continued

Transport position with a transport support

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

IRB 6700

xx0800000040

Continues on next page

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2 Installation and commissioning
2.3.1 Robot transportation precautions
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)

IRB 6700
B
Variant 2.65 2.8 3.05 3.2 2.60 2.85 2.70 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

xx1300001603

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 2 Installation and commissioning
2.3.2 Securing the robot with a transport support

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

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2 Installation and commissioning
2.3.2 Securing the robot with a transport support
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 63.
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 63. 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 63
on page 85.
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 85

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 2 Installation and commissioning
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 48.

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 69.
3 Lift and secure the manipulator to the plat- See on page ?.
form/foundation. See on page ?.
4 Connect the manipulator to the controller. See
• Product manual - IRC5
5 Configure the safety settings. See
• Product manual - IRC5
6 How to start and run the robot is described in the See
product manual for the controller. • Product manual - IRC5
7 Install required equipment, if any.
• Signal lamp (option) on page 102
8 Make sure all safety requirements are met when
performing the first test run. These are further
described in First test run may cause injury or
damage on page 26.

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2 Installation and commissioning
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 68.
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.

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 2 Installation and commissioning
2.4.3 Securing the base plate

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 45 P7 -0,017
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 72
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)

Continues on next page

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2 Installation and commissioning
2.4.3 Securing the base plate
Continued

B
23 47 +0
,5 0 ,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
R1
C-C
xx1500000247

Continues on next page

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 2 Installation and commissioning
2.4.3 Securing the base plate
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

Continues on next page

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2 Installation and commissioning
2.4.3 Securing the base plate
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.

Continues on next page

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 2 Installation and commissioning
2.4.3 Securing 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

Equipment Article number Note

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 829.
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.

Continues on next page

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2 Installation and commissioning
2.4.3 Securing the base plate
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 73.
plate.
4 Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 68.
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 73.
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)

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 2 Installation and commissioning
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. Also follow the recommendations given in Robot
transportation precautions on page 61.
This section specifies available special aids and references to valid user
documentation for the lifting accessories.

Required tools and equipment

Equipment Article number Note

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.

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2 Installation and commissioning
2.4.4.2 Lifting the robot with roundslings

2.4.4.2 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 - 205/2.80 Roundsling, 2 m Roundsling, 2 m
IRB 6700 - 175/3.05 Roundsling, 2.5 m Roundsling, 2 m
IRB 6700 - 150/3.20 Roundsling, 2.5 m Roundsling, 2 m
IRB 6700 - 200/2.60 Roundsling, 2 m Roundsling, 2 m
IRB 6700 - 155/2.85 Roundsling, 2.5 m Roundsling, 2 m
IRB 6700 - 300/2.70 Roundsling, 2 m Roundsling, 2.5 m
IRB 6700 - 245/3.00 Roundsling, 2.5 m Roundsling, 2.5 m

C Roundsling, 2.5 m (4 pcs)

D Lifting eye, M20 (4 pcs)

Continues on next page

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 2 Installation and commissioning
2.4.4.2 Lifting the robot with roundslings
Continued

Required equipment
See quantity of roundslings in figure Attaching the roundslings on page 76.

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°)
45°
• Axis 2: -45°

65°
• Axis 3: +65°
• Axis 4: no significance
• Axis 5: +70°

(20°)
• Axis 6: no significance

WARNING °
70
890 50

The robot is likely to be mechanically un-

stable if not secured to the foundation.

570 55

xx1300000356

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2 Installation and commissioning
2.4.4.2 Lifting the robot with roundslings
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

Continues on next page

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 2 Installation and commissioning
2.4.4.2 Lifting the robot with roundslings
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 76.
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 76.
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.

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2 Installation and commissioning
2.4.5 Orienting and securing the robot

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

2x4
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)

Continues on next page

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 2 Installation and commissioning
2.4.5 Orienting and securing the robot
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

A Cylindrical guide pin

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)

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2 Installation and commissioning
2.4.5 Orienting and securing the robot
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 83.

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 76.
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 81.

Note

Lightly lubricate screws before as-

sembly.

6 Tighten bolts in a crosswise pattern to ensure

that the base is not distorted.

Continues on next page

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2.4.5 Orienting and securing the robot
Continued

Securing the robot to a track motion

Fitting manipulator to a standard carriage

xx1500000319

Pos Description
A Cylindrical guide pin

Note

There are versions with a flattened cylindrical guide pin in left rear of the base.

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2 Installation and commissioning
2.4.5 Orienting and securing the robot
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.

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 2 Installation and commissioning
2.4.6 Manually releasing the brakes

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 85.
axes.
If the robot is not connected to the controller, power
must be supplied to the connector R1.MP according
to the section Supplying power to connector R1.MP
on page 86.
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.

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2 Installation and commissioning
2.4.6 Manually releasing the brakes
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

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 2 Installation and commissioning
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

Stopping time and braking distances

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

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2 Installation and commissioning
2.4.8 Fitting equipment to the robot

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 91). 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)

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 2 Installation and commissioning
2.4.8 Fitting equipment to the robot
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

Continues on next page

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2 Installation and commissioning
2.4.8 Fitting equipment to the robot
Continued

(A)
400

200
xx1300000866

A Center of gravity 50 kg

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 2 Installation and commissioning
2.4.8 Fitting equipment to the robot
Continued

Holes for fitting extra equipment

Position of attachment holes - drawing 1
E G H
H J
A K

(150)
(109) (2x M12) 12
(150)

(2x M12)
J

D A

H 160
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.

Continues on next page

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2 Installation and commissioning
2.4.8 Fitting equipment to the robot
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 - 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
i Smallest circumscribed radius axis-4.

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 2 Installation and commissioning
2.4.8 Fitting equipment to the robot
Continued

Position of attachment holes - drawing 2

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
i Smallest circumscribed radius axis-3.

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2 Installation and commissioning
2.4.8 Fitting equipment to the robot
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,
30
° 6

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.

Fastener quality
Use suitable screws and tightening torque for your application, screws with quality
class 12.9 are recommended.

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 2 Installation and commissioning
2.4.8 Fitting equipment to the robot
Continued

Tool flange, LeanID

Below is the tool flange for option 780-4, LeanID. 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
Use suitable screws and tightening torque for your application, screws with quality
class 12.9 are recommended.

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2 Installation and commissioning
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.

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 2 Installation and commissioning
2.5.2 Mechanically restricting the working range of axis 1

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

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2 Installation and commissioning
2.5.2 Mechanically restricting the working range of axis 1
Continued

Required equipment

Equipment, etc. Article number Note

Movable mechanical stop set, axis 1 3HAC055744-001 IRB6700 235/2.65, 205/2.80,
(15°). 175/3.05, 150/3.20, 200/2.60,
155/2.85
Includes attachment screws and
an assembly drawing.
Movable mechanical stop set, axis 1 3HAC048533-003 IRB6700 300/2.70, 245/3.00
(15°).
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 97.
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.

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 2 Installation and commissioning
2.6.1 Robot cabling and connection points

2.6 Electrical connections

2.6.1 Robot cabling and connection points

Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.

DANGER

Turn off the main power before connecting any cables.

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 101.
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.

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.

Robot cable, power

Power cable length Article number

7m 3HAC026787-001
15 m 3HAC026787-002
22 m 3HAC026787-003
30 m 3HAC026787-004

Continues on next page

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2 Installation and commissioning
2.6.1 Robot cabling and connection points
Continued

Robot cable, signals

Signal cable length Article number

7m 3HAC2493-1
15 m 3HAC2530-1
22 m 3HAC2540-1
30 m 3HAC2566-1

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

Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.

xx1500001600

Continues on next page

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 2 Installation and commissioning
2.6.1 Robot cabling and connection points
Continued

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 103.

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
Harness - cooling, 15 m 3HAC022723-004 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11
Harness - cooling, 22 m 3HAC022723-005 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11
Harness - cooling, 30 m 3HAC022723-006 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11

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2 Installation and commissioning
2.7.1 Signal lamp (option)

2.7 Installation of options

2.7.1 Signal lamp (option)

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.

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 2 Installation and commissioning
2.7.2 Installing the motor cooling fan (option)

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 revision of Product manual, spare parts - IRB 6700/IRB 6700Inv on ABB
Library.

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.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section Stand-
ard toolkit on page 829.

Continues on next page

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2 Installation and commissioning
2.7.2 Installing the motor cooling fan (option)
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 robot working
area.

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

Continues on next page

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 2 Installation and commissioning
2.7.2 Installing the motor cooling fan (option)
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

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2 Installation and commissioning
2.7.2 Installing the motor cooling fan (option)
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

Continues on next page

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 2 Installation and commissioning
2.7.2 Installing the motor cooling fan (option)
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

Continues on next page

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2 Installation and commissioning
2.7.2 Installing the motor cooling fan (option)
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 101.

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.

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 2 Installation and commissioning
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.

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 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 17 before performing any service
work.

Note

If the IRB 6700 is connected to power, always make sure that the IRB 6700 is
connected to protective earth before starting any maintenance work.
For more information see:
• Product manual - IRC5

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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.

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.

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 3 Maintenance
3.2.2 Maintenance schedule

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 115

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals:

Every 20,000 hours i

Every 12,000 hours i

Every 40,000 hours i

Every 12 months

Every 36 months
Regularly

Maintenance activities Reference

Cleaning activities
Cleaning the IRB 6700 on
Cleaning the robot x
page 194
Inspection activities
Inspecting the motor seal on
Inspecting the motor seal ii x
page 116
Inspect the oil level in the
actual gearbox if there is a
suspected leakage, after an oil
Inspecting the oil level in gearboxes
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 136
Inspecting the cable harness
Inspecting the robot harness x iii
on page 140
Inspecting the information
Inspecting the information labels x
labels on page 142
Inspecting the dampers on
Inspecting the dampers x
page 152
Inspecting the axis-1
Inspecting the mechanical stop x mechanical stop pin on
page 146
Replacement/changing activities

Continues on next page

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3 Maintenance
3.2.2 Maintenance schedule
Continued

Every 20,000 hours i

Every 12,000 hours i

Every 40,000 hours i

Every 12 months

Every 36 months
Regularly
Maintenance activities Reference

Changing oil, axis-1 gearbox

Changing the oil in axis-1 gearbox x
on page 158
Changing oil, axis-2 gearbox
Changing the oil in axis-2 gearbox x
on page 165
Changing oil, axis-3 gearbox
Changing the oil in axis-3 gearbox x
on page 170
Changing oil, axis-4 gearbox
Changing the oil in axis-4 gearbox x
on page 176
Changing oil, axis-5 gearbox
Changing the oil in axis-5 gearbox x
on page 180
Changing oil, axis-6 gearbox
Changing the oil in axis-6 gearbox x
on page 184
Replacing the SMB battery on
Replacing the SMB battery pack x iv
page 189
Lubrication activities
Lubricating the spherical roller
Lubricating the balancing device bearings xv bearing, balancing device on
page 192
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 819.
iii Replace when damage or cracks is detected or life limit is approaching that specified in section
Expected component life on page 115.
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.

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 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.

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3 Maintenance
3.3.1 Inspecting the motor seal

3.3 Inspection activities

3.3.1 Inspecting the motor seal

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 819.

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

Robots with protection type Standard have a protection filter installed in the
evacuation hole.
Robots with protection type Foundry Plus have a transparent plug/sight glass
installed in the evacuation holes.

xx1800000101 xx1800000102

Protection filter (Standard). Transparent plug (Foundry Plus).

Continues on next page

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 3 Maintenance
3.3.1 Inspecting the motor seal
Continued

Inspecting the evacuation hole

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2
WARNING

Handling gearbox oil involves several safety risks.

Before proceeding, please read the safety inform-
ation in the section Safety risks during work with
gearbox lubricants (oil or grease) on page 36.

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.

xx1500001057

Replacing of motors is described

in the repair chapter Motors on
page 503.

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

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.

xx1200000950

IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20,
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Continues on next page

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

xx1500001655

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Required tools

Equipment Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Required consumables

Consumables Article number Note

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.

Required documents

Document name Document number

Technical reference manual - Lubrication in gearboxes 3HAC042927-001

Continues on next page

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3 Maintenance
3.3.2 Inspecting the oil level in axis-1 gearbox
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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

3 Make sure that the oil temperature is +25°C

± 10°C.

Continues on next page

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

Action Note
4 Open the oil plug.

xx1200000950

IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,

IRB 6700 - 175/3.05, IRB 6700 - 150/3.20,
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

xx1500001655

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

5 IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
Check the oil level.
Required oil level is: 58 mm ± 5 mm below
the sealing surface of the oil plug.

xx1300000692

Continues on next page

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

Action Note
6 IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
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 158.
8 Refit the oil plug. Tightening torque: 24 Nm.
9
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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 3 Maintenance
3.3.3 Inspecting the oil level in axis-2 gearbox

3.3.3 Inspecting the oil level in axis-2 gearbox

Location of oil plug

The gearbox has a level plug that is located as shown in the figure.

xx1200000952

Tightening torque: 24 Nm

Tightening torque: 24 Nm

Required tools

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Required consumables

Consumables Article number Note

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.

Required documents

Document name Document number

Technical reference manual - Lubrication in gearboxes 3HAC042927-001

Continues on next page

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3 Maintenance
3.3.3 Inspecting the oil level in axis-2 gearbox
Continued

Inspecting the oil level in axis-2 gearbox

Use this procedure to inspect the oil level in the gearbox.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2
WARNING

Handling gearbox oil involves several safety

risks. Before proceeding, please read the
safety information in the section Safety risks
during work with gearbox lubricants (oil or
grease) on page 36.

3 Make sure that the oil temperature is +25°C ±

10°C.
4 Open the oil plug.

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 165.
7 Refit the oil plug. Tightening torque: 24 Nm.

Continues on next page

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 3 Maintenance
3.3.3 Inspecting the oil level in axis-2 gearbox
Continued

Action Note
8
DANGER

Make sure all safety requirements are met

when performing the first test run. These are
further detailed in the section First test run may
cause injury or damage on page 26.

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3 Maintenance
3.3.4 Inspecting the oil level in axis-3 gearbox

3.3.4 Inspecting the oil level in axis-3 gearbox

Location of oil plug

The gearbox has a level plug that is located as shown in the figure.
IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20,
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

xx1200000955

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

xx1500001645

Tightening torque: 24 Nm

Required tools

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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

Required consumables

Consumables Article number Note

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.

Required documents

Document name Document number

Technical reference manual - Lubrication in gearboxes 3HAC042927-001

Inspecting the oil level in axis-3 gearbox

Use this procedure to inspect the oil level in the gearbox.
Action Note
1 Run the robot to calibration position.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Make sure that the oil temperature is +25°C

± 10°C.
4
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

Continues on next page

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

Action Note
5 Open the oil plug.

xx1200000955

IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,

IRB 6700 - 175/3.05, IRB 6700 - 150/3.20,
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

xx1500001645

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

6 Check the oil level.
Required oil level is: 0 - 20 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-3 gearbox on page 170.
8 Refit the oil plug. Tightening torque: 24 Nm.
9
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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 3 Maintenance
3.3.5 Inspecting the oil level in axis-4 gearbox

3.3.5 Inspecting the oil level in axis-4 gearbox

Location of oil plug

The gearbox has a level plug that is located as shown in the figure.

xx1200000957

Tightening torque: 24 Nm

Required tools

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Required consumables

Consumables Article number Note

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.

Required documents

Document name Document number

Technical reference manual - Lubrication in gearboxes 3HAC042927-001

Inspecting the oil level in axis-4 gearbox

Use this procedure to inspect the oil level in the gearbox.
Action Note
1 Run the robot to calibration position.

Continues on next page

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3 Maintenance
3.3.5 Inspecting the oil level in axis-4 gearbox
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Make sure that the oil temperature is +25°C

± 10°C.
4
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

5 Open the oil plug.

xx1200000957

6 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-4 gearbox on page 176.
8 Refit the oil plug. Tightening torque: 24 Nm.
9
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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 3 Maintenance
3.3.6 Inspecting the oil level in axis-5 gearbox

3.3.6 Inspecting the oil level in axis-5 gearbox

Location of oil plug

The gearbox has a level plug that is located as shown in the figure.

xx1200000959

Tightening torque: 24 Nm

Required tools

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Required consumables

Consumables Article number Note

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.

Required documents

Document name Document number

Technical reference manual - Lubrication in gearboxes 3HAC042927-001

Inspecting the oil level in axis-5 gearbox

Use this procedure to inspect the oil level in the gearbox.
Action Note
1 Run the robot to calibration position.

Continues on next page

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3 Maintenance
3.3.6 Inspecting the oil level in axis-5 gearbox
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Make sure that the oil temperature is +25°C

± 10°C.
4
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

5 Open the oil plug.

xx1200000959

6 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-5 gearbox on page 180.
8 Refit the oil plug. Tightening torque: 24 Nm.
9
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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 3 Maintenance
3.3.7 Inspecting the oil level in axis-6 gearbox

3.3.7 Inspecting the oil level in axis-6 gearbox

Location of oil plug

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

xx1600002049

Tightening torque: 24 Nm

Required tools

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Required consumables

Consumable Article number Note

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.

Required documents

Document name Document number

Technical reference manual - Lubrication in gearboxes 3HAC042927-001

Continues on next page

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3 Maintenance
3.3.7 Inspecting the oil level in axis-6 gearbox
Continued

Inspecting the oil level in axis-6 gearbox

Use this procedure to inspect the oil level in the gearbox.
The procedure includes two alternative positions for axis 5, where one of the
positions makes it possible to use the filling plug as a level plug.
Action Note
1 Run the robot to calibration position.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Make sure that the oil temperature is +25°C

± 10°C.
4
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

5 Open the oil plug.

xx1600002049

Continues on next page

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 3 Maintenance
3.3.7 Inspecting the oil level in axis-6 gearbox
Continued

Action Note
6 Method 1
Check the oil level. Required oil level is:
• IRB 6700 - 235/2.65, IRB 6700 -
205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20
50 mm ± 5 mm below the sealing
surface of the oil plug.
• IRB 6700 - 200/2.60, IRB 6700 -
155/2.85
50 mm ± 5 mm below the sealing
surface of the oil plug.
• IRB 6700 - 300/2.70, IRB 6700 -
245/3.00
45 mm ± 5 mm below the sealing
surface of the oil plug.
xx1300000693

7 Method 2
Rotate axis 5 +77°.
Required oil level is: 0 - 10 mm below the
oil plug hole.
8 Add or drain oil, if required. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
in gearboxes.
Further information about how to drain or
fill with oil is found in section Changing oil,
axis-6 gearbox on page 184.
9 Refit the oil plug. Tightening torque: 24 Nm.
10
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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3 Maintenance
3.3.8 Inspecting the balancing device

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.

Continues on next page

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 3 Maintenance
3.3.8 Inspecting the balancing device
Continued

Required material
Equipment Article number Note
Maintenance kit, link ear 3HAC045815-001 The maintenance kit contains:
• End cover
• Radial sealing with dust
lip, 50x68x8 (2 pcs)
• O-ring 85x3
• Spherical roller bearing
• Washer
Maintenance kit, cradle 3HAC045822-001 Includes:
• bearings and seals
• VK cover.

Check for dissonance

The check points are shown in the figure Inspection points, balancing device on
page 136.

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 443 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 461. This section also
specifies the spare part number.
3 Check for dissonance from If dissonance is detected, perform maintenance accord-
the piston rod (squeaking ing to given instructions in Maintenance kit, complete.
may indicate worn plain
bearings, internal contamin-
ation or insufficient lubrica-
tion).

Check for damage

Check for damages, such as scratches, general wear, uneven surfaces or incorrect
positions.
The check points are shown in the figure Inspection points, balancing device on
page 136.

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.

Continues on next page

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3 Maintenance
3.3.8 Inspecting the balancing device
Continued

Check for leakage

The front ear of the balancing device is lubricated with grease.
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:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.

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 137.
Replacement of the complete bearing
is described in section Replacing the
balancing device on page 461.

Continues on next page

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 3 Maintenance
3.3.8 Inspecting the balancing device
Continued

Check for contamination / lack of free space

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 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

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3 Maintenance
3.3.9 Inspecting the cable harness

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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 3 Maintenance
3.3.9 Inspecting the cable harness
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, velcro

straps and attachments are properly se-
cured, by following the cable harness from
the base to the wrist.
4 Check the motor cables visually for any
damage.
5 Check the connectors at the base visually
for any damage.
6 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

7 Replace the cable harness if wear, cracks See Removing the cable harness on
or damage is detected. page 231.

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3 Maintenance
3.3.10 Inspecting the information labels

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 product labels on page 40.

Illustration 1
E E

K M B

N E

J
E
F

F
F

Continues on next page

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 3 Maintenance
3.3.10 Inspecting the information labels
Continued

Illustration 2
J

N
S

P J N

R
C A
E N
T
J

G
L

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

Continues on next page

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3 Maintenance
3.3.10 Inspecting the information labels
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

Continues on next page

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 3 Maintenance
3.3.10 Inspecting the information labels
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

Required tools and equipment

Visual inspection, no tools are required.

Inspecting, labels

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

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 837.

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3 Maintenance
3.3.11 Inspecting the axis-1 mechanical stop pin

3.3.11 Inspecting the axis-1 mechanical stop pin

Location of mechanical stop pin

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

xx1200001073

Required equipment
Visual inspection, no tools are required.

Inspecting, mechanical stop pin

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

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Continues on next page

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 3 Maintenance
3.3.11 Inspecting the axis-1 mechanical stop pin
Continued

Action Note
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.

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3 Maintenance
3.3.12 Inspecting the additional mechanical stops

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

Required equipment

Equipment etc. Article number Note

Movable mechanical stop 3HAC055744-001 IRB6700 235/2.65, 205/2.80, 175/3.05,
axis 1 150/3.20, 200/2.60, 155/2.85
Limits the robot working range by 15°.
Includes attachment screws and an as-
sembly drawing.
• Mechanical stop
• Attachment screws M12x70 quality
12.9 Gleitmo 603 and washers
• Document for mechanical stop

Continues on next page

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 3 Maintenance
3.3.12 Inspecting the additional mechanical stops
Continued

Equipment etc. Article number Note

Movable mechanical stop 3HAC048533-003 IRB6700 300/2.70, 245/3.00
axis 1 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
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Inspecting, mechanical stops

Use this procedure to inspect the additional mechanical stops.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2 Make sure no additional stops are damaged. Shown in figure Location of

mechanical stops on page 148.
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 148.
Correct attachment screws:
• M12x70 quality 12.9 Gleitmo 603 (2 pcs per
additional mechanical stop)

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3 Maintenance
3.3.13 Inspecting the fork lift accessory

3.3.13 Inspecting the fork lift accessory

Introduction
The installation and use of the Fork lift accessories is described in:
• Directions for use - Fork lift accessory for IRB 6700
The fork lift accessories are supposed to be removed after use.

Location of fork lift accessory

The fork lift accessory is fitted to the robot as shown in the figure.

B
A Fork lift pocket (4 pcs)
B Hex socket head cap screw M20x60 quality steel 8.8-A3F (2 pcs per fork lift
device)

Required equipment

Equipment Article number Note

Fork lift accessory set 3HAC047054-003
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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 3 Maintenance
3.3.13 Inspecting the fork lift accessory
Continued

Inspecting, fork lift device set

Use this procedure to inspect the fork lift device set.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2 Check the fork lift device set for damage.

3 Check attachment screws for deformation and other
type of damage.
4 Make sure fork lift device set is properly attached.
Correct tightening torque, fork lift devices:
• 280 Nm
5 If any damage is detected, the fork lift device and Article number is specified in
attachment screws must be replaced. Required equipment on page 148.
Correct attachment screws:
• M20x60 quality steel 8.8-A3F (2 pcs per addi-
tional mechanical stop)

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3 Maintenance
3.3.14 Inspecting the dampers

3.3.14 Inspecting the dampers

Location of dampers
The figure below shows the location of all the dampers to be inspected.

A Axis-2 damper, 2 pcs

B Axis-3 damper, 2 pcs

Required equipment
Visual inspection, no tools are required.

Inspecting, dampers
The procedure below details how to inspect the dampers.

Note

A damaged damper must be replaced.

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.

Continues on next page

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 3 Maintenance
3.3.14 Inspecting the dampers
Continued

Action Note
2 Check all dampers for damage, cracks or exist-
ing impressions larger than 1 mm.
3 Check attachment screws for deformation.

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.

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3 Maintenance
3.3.15 Inspecting the signal lamp (option)

3.3.15 Inspecting the signal lamp (option)

Location of signal lamp

The signal lamp is located as shown in this figure.

xx1600002089

Required tools and equipment

Equipment Article number Note

Signal lamp kit See Spare parts on To be replaced if damage is detected.
page 837.
Standard toolkit - Content is defined in section Stand-
ard toolkit on page 829.

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").

Continues on next page

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 3 Maintenance
3.3.15 Inspecting the signal lamp (option)
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

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 154.
• 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.

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3 Maintenance
3.4.1 Type of lubrication in gearboxes

3.4 Replacement/changing activities

3.4.1 Type of lubrication in gearboxes

Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with 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.mypo-
rtal.abb.com.
Before starting any inspection, maintenance, or changing activities of lubrication,
always contact the local ABB Service organization for more information.
For ABB personnel: Always check ABB Library for the latest revision of the manual
Technical reference manual - Lubrication in gearboxes, in order to always get the
latest information of updates about lubrication in gearboxes. A new revision will
be published on ABB Library immediately after updates.

Continues on next page

156 Product manual - IRB 6700
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 3 Maintenance
3.4.1 Type of lubrication in gearboxes
Continued

Location of gearboxes
The figure shows the location of the gearboxes.

xx1400000189

A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 4
E Gearbox, axis 5
F Gearbox, axis 6

Equipment

Equipment Note
Oil dispenser Includes pump with outlet pipe.
Use the suggested dispenser or a similar one:
• Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring

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3 Maintenance
3.4.2 Changing oil, axis-1 gearbox

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 (300/2.70, 245/3.00) • IRB 6700 - 235/2.65, IRB 6700 -
205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20
• IRB 6700 - 200/2.60, IRB 6700 -
155/2.85
Used for ventilation on manipulator types:
• IRB 6700 - 300/2.70, IRB 6700 -
245/3.00
Tightening torque: 24 Nm. Tightening torque: 24 Nm.

Consumables

Material Note
Lubricating oil Information about the oil is found in Technical refer-
ence manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on page 156.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.

Continues on next page

158 Product manual - IRB 6700
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 3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

3
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.

Continues on next page

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3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
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 813 for more in-
formation.

8 Remove the oil dispenser.

Refit the protective cap on the nipple.
9 Refit the vent hole plug. Tightening torque: 24 Nm.

Continues on next page

160 Product manual - IRB 6700
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 3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued

Filling oil into the axis-1 gearbox

Use this procedure to refill the gearbox with oil.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

3 Remove the protective cap from the nipple

of the oil hole and connect the oil dis-
penser.

xx1200000948

Continues on next page

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3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued

Action Note
4 Remove the plug from the vent hole.

Note

The vent hole is opened to let out air during

the filling process.

xx1200000950

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.

Continues on next page

162 Product manual - IRB 6700
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 3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued

Action Note
6 Inspect the oil level. IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

xx1200000950

Required oil level: 58 mm ± 5 mm below

the sealing surface of the oil plug.

xx1300000692

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

xx1500001655

Continues on next page

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3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Continued

Action Note
Required oil level: 0 - 10 mm below the oil
plug hole.
7 Remove the oil dispenser and refit the
protective cap to the nipple.
8 Refit the vent hole plug. Tightening torque: 24 Nm
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

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

164 Product manual - IRB 6700

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 3 Maintenance
3.4.3 Changing oil, axis-2 gearbox

3.4.3 Changing oil, axis-2 gearbox

Usage of oil dispenser

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

Location of oil plugs

The oil plugs of the gearbox are located as shown in the figure.

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.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Required consumable

Material Note
Lubricating oil Information about the oil is found in Technical refer-
ence manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on page 156.

Continues on next page

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3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

Draining the axis-2 gearbox

Use this procedure to drain the gearbox.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

3
CAUTION

The gearbox can contain an excess pres-

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

4 Remove the protective cap from the nipple

of the oil hole and connect the oil dis-
penser.

xx1200000951

Continues on next page

166 Product manual - IRB 6700
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 3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued

Action Note
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.

xx1200000952

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 813 for more in-
formation.

8 Refill oil or: Vent hole plug, tightening torque: 24 Nm.

1 Remove the oil dispenser
2 Refit the protective cap on the
nipple.
3 Refit the vent hole plug.

Filling oil into the axis-2 gearbox

Use this procedure to refill the gearbox with oil.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

Product manual - IRB 6700 167
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3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
Continued

Action Note
2
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

3 Remove the protective cap from the nipple

of the oil hole and connect the oil dis-
penser.

xx1200000951

4 Remove the plug from the vent hole.

Note

The vent hole is opened to let air out during

the filling process.

xx1200000952

5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.

The amount of oil to be filled depends on

the amount previously being drained.

Continues on next page

168 Product manual - IRB 6700
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 3 Maintenance
3.4.3 Changing oil, axis-2 gearbox
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 124.
7 Remove the oil dispenser.
Refit the protective cap on the nipple.
8 Refit the level plug. Tightening torque: 24 Nm
9
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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3 Maintenance
3.4.4 Changing oil, axis-3 gearbox

3.4.4 Changing oil, axis-3 gearbox

Usage of oil dispenser

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

Location of oil plugs

The oil plugs of the gearbox are located as shown in the figure.
IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB
6700 - 175/3.05, IRB 6700 - 150/3.20, IRB
6700 - 200/2.60, IRB 6700 - 155/2.85

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

xx1500001645

Oil hole with nipple Level/vent plug

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

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

170 Product manual - IRB 6700
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 3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued

Consumable

Material Note
Lubricating oil Information about the oil is found in Technical refer-
ence manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on page 156.

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

Draining the axis-3 gearbox

Use this procedure to drain the gearbox.
Action Note
1 Run the robot to calibration position.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4
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.

Continues on next page

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3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued

Action Note
5 Remove the protective cap from the nipple
of the oil hole and connect the oil dis-
penser.

xx1200000954

6 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.

xx1200000955

IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,

IRB 6700 - 175/3.05, IRB 6700 - 150/3.20,
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

xx1500001645

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

7 Suck out the oil with the oil dispenser.

Note

There will be some oil left in the gear after

draining.

Continues on next page

172 Product manual - IRB 6700
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 3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued

Action Note
8
WARNING

Used oil is hazardous material and must

be disposed of in a safe way. SeeDecom-
missioning on page 813 for more informa-
tion.

9 Remove the oil dispenser.

Refit the protective cap on the nipple.
10 Refit the vent hole plug. Tightening torque: 24 Nm.

Filling oil into the axis-3 gearbox

Use this procedure to refill the gearbox with oil.
Action Note
1 Run the robot to calibration position.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4 Remove the protective cap from the nipple

of the oil hole and connect the oil dis-
penser.

xx1200000954

Continues on next page

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3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued

Action Note
5 Remove the plug from the vent hole.

Note

The vent hole is opened to let air out during

the filling process.

xx1200000955

IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,

IRB 6700 - 175/3.05, IRB 6700 - 150/3.20,
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

xx1500001645

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

6 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.

The amount of oil to be filled depends on

the amount previously being drained.

Continues on next page

174 Product manual - IRB 6700
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 3 Maintenance
3.4.4 Changing oil, axis-3 gearbox
Continued

Action Note
7 Inspect the oil level at the vent hole (level
plug).

xx1200000955

IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,

IRB 6700 - 175/3.05, IRB 6700 - 150/3.20,
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

xx1500001645

IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Required oil level is: 0 - 20 mm below the
oil plug hole.
More information is found in Inspecting the
oil level in axis-3 gearbox on page 127.
8 Remove the oil dispenser.
Refit the protective cap on the nipple.
9 Refit the level plug. Tightening torque: 24 Nm
10
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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© Copyright 2013 - 2018 ABB. All rights reserved.
3 Maintenance
3.4.5 Changing oil, axis-4 gearbox

3.4.5 Changing oil, axis-4 gearbox

Location of oil plugs

The oil plugs of the gearbox are located as shown in the figure.

xx1200000957
xx1200000956

Oil drain plug Oil fill plug/level plug

Tightening torque: 24 Nm. Tightening torque: 24 Nm.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Consumable

Material Note
Lubricating oil Information about the oil is found in Technical refer-
ence manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on page 156.

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

Draining the axis-4 gearbox

Use this procedure to drain the gearbox.
Action Note
1 Run the robot to calibration position.

Continues on next page

176 Product manual - IRB 6700
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 3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4
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.

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

7 Remove the oil plug from the fill/level hole.

Note

The level hole is opened to speed up the

drainage.

xx1200000957

Continues on next page

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3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued

Action Note
8
WARNING

Used oil is hazardous material and must

be disposed of in a safe way. See Decom-
missioning on page 813 for more informa-
tion.

9 Refill oil or refit the oil plugs. Tightening torque: 24 Nm.

Filling oil into the axis-4 gearbox

Use this procedure to refill the gearbox with oil.
Action Note
1 Run the robot to calibration position.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4 Open the fill/level plug.

xx1200000957

5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.

The amount of oil to be filled depends on

the amount previously being drained.

Continues on next page

178 Product manual - IRB 6700
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 3 Maintenance
3.4.5 Changing oil, axis-4 gearbox
Continued

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

xx1200000957

Required oil level is: 0 - 10 mm below the

oil plug hole.
See Inspecting the oil level in axis-4 gear-
box on page 129.
7 Refit the oil plug. Tightening torque: 24 Nm
8
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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© Copyright 2013 - 2018 ABB. All rights reserved.
3 Maintenance
3.4.6 Changing oil, axis-5 gearbox

3.4.6 Changing oil, axis-5 gearbox

Location of oil plugs

The oil plugs of the gearbox are located as shown in the figure.

xx1200000958 xx1200000959

Oil drain plug Oil fill plug/level plug

Tightening torque: 24 Nm. Tightening torque: 24 Nm.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Consumable

Material Note
Lubricating oil Information about the oil is found in Technical refer-
ence manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on page 156.

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

Draining the axis-5 gearbox

Use this procedure to drain the gearbox.
Action Note
1 Run the robot to calibration position.

Continues on next page

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© Copyright 2013 - 2018 ABB. All rights reserved.
 3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4
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.

5 Remove the oil plug from the drain hole

and let the oil run into the vessel.

xx1200000958

6 Place the oil collecting vessel underneath

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

Used oil is hazardous material and must

be disposed of in a safe way. See section
Decommissioning on page 813 for more in-
formation.

Continues on next page

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3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued

Action Note
9 Refill oil or refit the oil plug. Tightening torque: 24 Nm.

Filling oil into the axis-5 gearbox

Use this procedure to refill the gearbox with oil.
Action Note
1 Run the robot to calibration position.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4 Open the fill/level plug.

xx1200000959

5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.

The amount of oil to be filled depends on

the amount previously being drained.

Continues on next page

182 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 3 Maintenance
3.4.6 Changing oil, axis-5 gearbox
Continued

Action Note
6 Inspect the oil level at the oil fill/level hole
(level plug).

xx1200000959

Required oil level is: 0 - 10 mm below the

oil plug hole.
More information is found in Inspecting the
oil level in axis-5 gearbox on page 131.
7 Refit the oil plug. Tightening torque: 24 Nm
8
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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3 Maintenance
3.4.7 Changing oil, axis-6 gearbox

3.4.7 Changing oil, axis-6 gearbox

Location of oil plugs

The oil plugs of the gearbox are located as shown in the figure.

xx1200000963
xx1200000962

Oil drain plug Oil fill plug

Tightening torque: 24 Nm. Tightening torque: 24 Nm.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Consumable

Material Note
Lubricating oil Information about the oil is found in Technical refer-
ence manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on page 156.

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

Draining the axis-6 gearbox

Use this procedure to drain the gearbox.
Action Note
1 Jog the robot to calibration position.

Continues on next page

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 3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4
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.

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.

xx1200000962

7 Remove the oil plug from the fill hole.

Note

The fill hole is opened to speed up the

drainage.

xx1200000963

Continues on next page

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3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued

Action Note
8
WARNING

Used oil is hazardous material and must

be disposed of in a safe way. See section
Decommissioning on page 813 for more in-
formation.

9 Refill oil or refit the oil plugs. Tightening torque: 24 Nm.

Filling oil into the axis-6 gearbox

Use this procedure to refill the gearbox with oil.
Action Note
1 Jog axis 5 to horizontal position.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
WARNING

Handling gearbox oil involves several

safety risks. Before proceeding, please
read the safety information in the section
Safety risks during work with gearbox lub-
ricants (oil or grease) on page 36.

4 Open the fill plug.

xx1200000963

5 Refill the gearbox with oil. Type of oil and total amount is detailed in
Technical reference manual - Lubrication
Note in gearboxes.

The amount of oil to be filled depends on

the amount previously being drained.

Continues on next page

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 3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
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, IRB 6700 -

205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20
50 mm ± 5 mm below the sealing
surface of the oil plug.
• IRB 6700 - 200/2.60, IRB 6700 -
155/2.85
50 mm ± 5 mm below the sealing
surface of the oil plug.
• IRB 6700 - 300/2.70, IRB 6700 -
245/3.00
45 mm ± 5 mm below the sealing
surface of the oil plug.

xx1300000693

More information is found in Inspecting the

oil level in axis-6 gearbox on page 134.
Method 2:
Rotate axis 5 +77°.
Required oil level is: 0 - 10 mm below the
oil plug hole.
7 Refit the oil plug. Tightening torque: 24 Nm

Continues on next page

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3 Maintenance
3.4.7 Changing oil, axis-6 gearbox
Continued

Action Note
8
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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 3 Maintenance
3.4.8 Replacing the SMB battery

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 instructions for batteries, Safety risks during handling of batteries on page 35.

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

Equipment Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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3 Maintenance
3.4.8 Replacing the SMB battery
Continued

Required spare parts

Spare part Article number Note

Battery unit See Product manual, spare Battery includes protection
parts - IRB 6700/IRB 6700Inv. circuits. Only replace with the
Product manual, spare specified spare part or an
parts - IRB 6790 ABB-approved equivalent.

Removing the battery

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

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

3
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 31

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.

Continues on next page

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 3 Maintenance
3.4.8 Replacing the SMB battery
Continued

Refitting the battery

Use this procedure to refit the SMB battery.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 31

3 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 page 794.
6
DANGER

Make sure all safety requirements are met when

performing the first test run. These are further
described in the section First test run may cause
injury or damage on page 26.

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3 Maintenance
3.5.1 Lubricating the spherical roller bearing, balancing device

3.5 Lubrication activities

3.5.1 Lubricating the spherical roller bearing, balancing device

Location of spherical roller bearing

The spherical roller bearing is located in the link ear of the balancing device.

xx1300000773

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

Equipment, etc. Article number Note

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

Continues on next page

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 3 Maintenance
3.5.1 Lubricating the spherical roller bearing, balancing device
Continued

Lubricating the spherical roller bearing

Use this procedure to lubricate the spherical roller bearing.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

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 204.

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.

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3 Maintenance
3.6.1 Cleaning the IRB 6700

3.6 Cleaning activities

3.6.1 Cleaning the IRB 6700

WARNING

Turn off all electrical power supplies to the manipulator before entering its work
space.

General
To secure high uptime it is important that the 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 116.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all 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.

Continues on next page

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 3 Maintenance
3.6.1 Cleaning the IRB 6700
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 195.

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 195 for exceptions.
2 See Cleaning methods on page 195 for exceptions.

Continues on next page

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3 Maintenance
3.6.1 Cleaning the IRB 6700
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.

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 4 Repair
4.1 Introduction

4 Repair
4.1 Introduction

Structure of this chapter

This chapter describes all repair activities recommended for the IRB 6700 and any
external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the 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.
Otherwise damage to the mechanics and electronics may occur.

Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information on page 821.

Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 17
before commencing any service work.

Note

If the IRB 6700 is connected to power, always make sure that the IRB 6700 is
connected to earth before starting any repair work.
For more information see:
• Product manual - IRC5

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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.

Required equipment

Equipment, etc. Article number Note

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.
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.

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 4 Repair
4.2.2 Mounting instructions for bearings

4.2.2 Mounting instructions for bearings

General
This section describes how to mount and grease different types of bearings on the
robot.

Equipment

Equipment, etc. Article number Note

Grease 3HAB3537-1 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.

Continues on next page

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4 Repair
4.2.2 Mounting instructions for bearings
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.

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 4 Repair
4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals

General
This section describes how to mount different types of seals.

Equipment

Equipment, etc. Article number Note

Grease 3HAB3537-1 Used to lubricate the seals.

Rotating seals
The procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual
mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding
over threads, keyways, etc.

Action Note
1 Check the seal to ensure that:
• The seal is of the correct type (provided with cutting
edge).
• There is no damage to the sealing edge (feel with a
fingernail).
2 Inspect the sealing surface before mounting. If scratches
or damage are found, the seal must be replaced since it
may result in future leakage.
3 Lubricate the seal with grease just before fitting. (Not too Article number is specified
early - there is a risk of dirt and foreign particles adhering in Equipment on page 201.
to the seal.)
Fill 2/3 of the space between the dust tongue and sealing
lip with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4 Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
Make sure no grease left on the robot surface.

Continues on next page

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4 Repair
4.2.3 Mounting instructions for seals
Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.
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, preferably with a brush.
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.
3 Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
Make sure that no grease is left on the robot
surface.

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 4 Repair
4.2.4 Dismantle and mounting tool, 3HAC028920-001

4.2.4 Dismantle and mounting tool, 3HAC028920-001

Dismantle and mounting tool

The dismantle and mounting tool is used to replace shafts and replace bearings
and sealings in several of the following instructions. Only some of the tool parts
are needed in each procedure. The procedure specifies which tool part to be used.
The complete tool set (3HAC028920-001), as follows.

xx1700000383

Part A (hydraulic cylinder) is ordered separately, 3HAC11731-1.

Hydraulic pump is ordered separately, 3HAC13086-1.

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4 Repair
4.2.5 Cut the paint or surface on the robot before replacing parts

4.2.5 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 3HAC037052-001
Plus, ABB Orange

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.

xx0900000121

2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

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 4 Repair
4.2.6 The brake release buttons may be jammed after service work

4.2.6 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.

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4 Repair
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)

4.3 Lifting associated procedures

4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65,

-205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85)

Validity of this section - IRB 6700 -235/2.65, -205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85

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, -205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85
How to attach lifting accessories to variants IRB 6700 -300/2.70, -245/3.00 see
section 4.3.2 Attaching lifting accessories to complete arm system.

Definition of the complete arm system

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

Continues on next page

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 4 Repair
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
Continued

Attachment points of lifting accessory

Required tools

Equipment, etc. Article number Note

Lifting eye 3HAC16131-1 M12
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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4 Repair
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
Continued

Attaching the lifting accessories

Robot position
Use this procedure to jog the robot into position.
Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
Action Note
1 Jog the robot into position:
• Axis 1: no significance as long as the robot
is secured to the foundation.
• Axis 2: -40°
• Axis 3: +65° (approximately)
• Axis 4: calibration position (0°)
• Axis 5. +90°
• Axis 6: calibration position (0°)

xx1200001132

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Attaching lifting accessories to the arm system

Use this procedure to attach the lifting accessories.
Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

2
CAUTION

The complete arm system weigh (according to

variants) 1100 kg.
All lifting accessories used must be sized accord-
ingly.

Continues on next page

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 4 Repair
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
Continued

Action Note
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

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

Continues on next page

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4 Repair
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -205/2.80, -175/3.05,
-150/3.20, -200/2.60, -155/2.85)
Continued

Action Note
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

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 4 Repair
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70, -245/3.00)

4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70,
-245/3.00)

Validity of this section - IRB 6700 -300/2.70, -245/3.00

Note

Some sections have similar titles. Make sure to use the correct section, to find
information about a certain IRB 6700 variant.
This section describes how to attach lifting accessories to variants IRB 6700
-300/2.70, -245/3.00
How to attach lifting accessories to variants IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85 see section 4.3.1 Attaching lifting
accessories to complete arm system.

Definition of the complete arm system

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

Continues on next page

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4 Repair
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70, -245/3.00)
Continued

Attachment points of lifting accessory

Required tools

Equipment, etc. Article number Note

Lifting eye 3HAC16131-1 M12
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

Continues on next page

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 4 Repair
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70, -245/3.00)
Continued

Equipment, etc. Article number Note

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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Attaching the lifting accessories

Robot position

Action Note
1 Jog the robot into position:
• Axis 1: no significance (as long as the robot
is secured to the foundation)
• Axis 2: -45°
• Axis 3: +65°
• Axis 4: 0°
• Axis 5: +90°
• Axis 6: calibration position (0°)
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Attaching the lifting accessories to the arm system

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

2
CAUTION

The complete arm system weighs 1300 Kg.

All lifting accessories used must be sized accord-
ingly!

Continues on next page

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4 Repair
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70, -245/3.00)
Continued

Action Note
3 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

4 Fit a lifting eye to the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer. Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.

Continues on next page

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 4 Repair
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70, -245/3.00)
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.

A Upper arm
B Shackle
C Roundsling
D Hole in frame

2 Connect the roundsling with a shackle. Lifting shackle SA-10-8-NA1

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.

Continues on next page

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4 Repair
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70, -245/3.00)
Continued

Action Note
4 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 the lifting eye in the wrist.

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 4 Repair
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)

4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700-235/2.65, -205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85)

Validity of this section - IRB 6700 -235/2.65, -205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85

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, -205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85
How to attach lifting accessories to variants IRB 6700 -300/2.70, -245/3.00 see
section 4.3.4 Attaching lifting accessories to an unseparated lower and upper
arm.

Attachment points of lifting accessory

xx1200001254

Continues on next page

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4 Repair
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
Continued

Required tools

Equipment, etc. Article number Note

Lifting eye 3HAC16131-1 M12
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Attaching lifting accessories to the lower and upper arm

Robot position
Use this procedure to jog the robot into position.
Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
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!

2 Jog the robot into position:

• 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

Continues on next page

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 4 Repair
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
Continued

Action Note
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Attaching lifting accessories to the lower and upper arm

Use this procedure to attach the lifting accessories.
Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
Action Note
1
CAUTION

The lower and upper arms together weigh (accord-

ing to variants) 510 kg.
All lifting accessories used must be sized accord-
ingly!

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

xx1200001133

3 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1

xx1200001234

Continues on next page

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4 Repair
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
Continued

Action Note
4 Insert a M12x50 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

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.
This will prevent the roundsling from gliding.
7 Attach the roundsling to the shackle on the wrist.

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Continues on next page

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 4 Repair
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
Continued

Action Note
10 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer: Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.

xx1400002196

xx1200001134

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.
13 Attach the Lifting accessory (chain) to an over- Lifting accessory (chain):
head crane (or similar), then to the lifting eye in 3HAC15556-1
the arm house and to a roundsling run through Roundsling, 1 m: Length: 1 m, lift-
the wrist. ing capacity: 1,000 kg.

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.

Continues on next page

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4 Repair
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
Continued

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

222 Product manual - IRB 6700

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 4 Repair
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700 -300/2.70, -245/3.00)

4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700 -300/2.70, -245/3.00)

Validity of this section - IRB 6700 -300/2.70, -245/3.00

Note

Some sections have similar titles. Make sure to use the correct section, to find
information about a certain IRB 6700 variant.
This section describes how to attach lifting accessories to variants IRB 6700
-300/2.70, -245/3.00
How to attach lifting accessories to variants IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85 see section 4.3.3 Attaching lifting
accessories to an unseparated lower and upper arm.

Attachment points of lifting accessory

xx1400002104

Continues on next page

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4 Repair
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700 -300/2.70, -245/3.00)
Continued

Required tools

Equipment, etc. Article number Note

Lifting eye 3HAC16131-1 M12
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Attaching lifting accessories to the lower and upper arm

Robot position

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!

2 Jog the robot into position:

• Axis 1: position the axis 1 to be able
to put down the arm system after
removal
• Axis 2: -60°
• Axis 3: +70° (approximately)
• Axis 4: +90°
• Axis 5: 0° (-90° if DressPack is in-
stalled)
• Axis 6: 0° (+90° if DressPack is in-
stalled)

xx1200001250

Continues on next page

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 4 Repair
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700 -300/2.70, -245/3.00)
Continued

Action Note
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Attaching lifting accessories to the lower and upper arm

Use this procedure to attach the lifting accessories.
Action Note
1
CAUTION

The lower and upper arms together weigh (accord-

ing to variants) 650 kg.
All lifting accessories used must be sized accord-
ingly!

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

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

Continues on next page

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4 Repair
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700 -300/2.70, -245/3.00)
Continued

Action Note
4 Run a roundsling around the lower arm, place it Roundsling, 2.5 m: Length: 2.5 m.
accordingly: Lifting capacity: 2,000 kg.
• With no DressPack cable package installed:
Place the roundsling beneath the securing
screw.
• With DressPack cable package installed:
Place the roundsling beneath the ball joint
housing on the outside of the lower arm.

xx1400002105

5 Run the roundsling up and over the upper arm.

6 Connect both ends of the roundsling with a
shackle.

xx1400000729

7 Stretch the roundsling between the upper and the

lower arm by slowly jogging the axis-3.

Note

Make sure the roundsling is stretched, in order to

carry the weight of the lower arm.

8
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Continues on next page

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 4 Repair
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700 -300/2.70, -245/3.00)
Continued

Action Note
9 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer: Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.

xx1400002196

xx1200001134

10 Attach the Lifting accessory (chain) to an over- Lifting accessory (chain):

head crane (or similar), then to the lifting eye in 3HAC15556-1
the arm house and to the lifting eye in the wrist.

xx1400002104

11 Raise the overhead crane to stretch the chains

and roundslings.
Verify that the roundsling between the wrist and
the lower arm is stretched.
12 To release the brake, connect the 24 VDC power
supply.
Connect to connector R2.MP2, axis-2 motor:
• + = pin 2
• - = pin 5

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4 Repair
4.3.5 Attaching lifting accessories to the upper arm

4.3.5 Attaching lifting accessories to the upper arm

Attachment points of lifting accessory

xx1200001308

Required equipment

Equipment, etc. Article number Note

Lifting eye 3HAC16131-1 M12
Lifting eye 3HAC16131-1 M12
Fender washer - Outer diameter: minimum 26 mm,
maximum 30 mm, hole diameter: 13
mm, thickness: 3 mm.
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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 4 Repair
4.3.5 Attaching lifting accessories to the upper arm
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°
• Axis-5: no significance
• Axis-6: no significance

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

xx1200001133

Continues on next page

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4 Repair
4.3.5 Attaching lifting accessories to the upper arm
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

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 4 Repair
4.4.1 Removing the cable harness

4.4 Complete robot

4.4.1 Removing the cable harness

Location of the cable harness

The cable harness is located as shown in the figure.

xx1300001096

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
Continued

Preparations before removing the cable harness

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
Note

If only the manipulator harness shall be

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

xx1400000208

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

Disconnecting the axis-5 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

4 Disconnect the motor cables.

xx1200001066

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Unscrew the attachment screws and

washers and remove the motor cover.

xx1200001135

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
Continued

Action Note
3 Make sure the o-ring is present.

xx1200001070

4 Disconnect the motor cables.

xx1200001066

5 Remove the cable gland cover.

Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

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 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, -245/3.00)
xx1400002561

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
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

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

Disconnecting the axis-1 and axis-2 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

4 Disconnect the motor cables.

xx1200001066

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

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
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 31

3 Open the small cover on the SMB cover, disconnect

the battery cable and remove the battery.

xx1300000829

4 Remove the SMB cover.

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.

xx1300000669

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
Continued

Disconnecting the brake release unit

Action Note
1
DANGER

Make sure that all supplies for electrical power, hy-

draulic pressure, and air pressure are turned off.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 31

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.

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
Continued

Removing the cable harness in the frame

Action Note
1 Unscrew the attachment screws that hold
the metal clamp frame.

xx1300000542

2 Cut the cable tie inside the frame recess.

xx1200001237

3 Disconnect connectors on the SMB unit.

xx1300001114

Continues on next page

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 4 Repair
4.4.1 Removing the cable harness
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

5 Unscrew the attachment screws that hold

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

Continues on next page

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4 Repair
4.4.1 Removing the cable harness
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

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 4 Repair
4.4.2 Refitting the cable harness

4.4.2 Refitting the cable harness

Location of the cable harness

The cable harness is located as shown in the figure.

xx1300001096

Spare part

Spare part Spare part number Note

Cable harness See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790
Cover insert 3HAC048520-001 Replace if damaged.
Cable protection, PU rubber 3HAC055411-001 Replace if damaged.

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Consumables

Consumable Article number Note

Grease 3HAB3537-1 Used to lubricate o-rings.
O-ring D=84.5x3
21522012-429
Used on the SMB/BU cover.

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
Continued

Consumable Article number Note

O-ring i 3HAB3772-111 (circular pro- 169.5x3 / 169.5x4.8x2.65
file) / 3HAC054692-002
(hexagon profile) Used on axis-1 motor cover.

3HAB3772-111 (circular pro- D=169.5x3

file) / 3HAC054692-002
(hexagon profile) Used on axis-2 motor cover.

3HAB3772-111 (circular pro- D=169.5x3

file) / 3HAC054692-002
(hexagon profile) Used on axis-3 motor cover

3HAB3772-110 (circular pro- D=119x3

file) / 3HAC054692-001
(hexagon profile) Used on axis-4 motor cover.

3HAB3772-110 (circular pro- D=119x3

file) / 3HAC054692-001
(hexagon profile) Used on axis-5 motor cover.

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 232.

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

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
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.
This will also make it easier to run the cable
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

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
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 • 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

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
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
the protection tube in the base.
Make sure that the hoses are running cor-
rectly and are not twisted!
8 If used, fit the bracket that hold the
DressPack to the frame.

xx1400000078

9 If used, connect the DressPack cable

package on the base plate.

xx1200000052

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
10 Refit the base cover.

xx1300000561

Refitting the cable harness in the frame

Action Note
1 Check the o-ring located on the SMB/BU O-ring, 21522012-429
cover. Replace if damaged.

xx1300000737

The figure shows the position of the o-ring.

2 Wipe clean the contact surfaces of the
cover as well as the hole it shall fit in.
3 Apply Sikaflex on the o-ring before as-
sembly.
4 Run the SMB/BU cables into the SMB re-
cess.

xx1300000560

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
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 attach- Screws: 3 pcs.

ment screws from inside the SMB/BU re-
cess.

xx1300000655

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
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

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit please read the safety information in the
section The unit is sensitive to ESD on page 31

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
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 in 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

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4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
7 Pull out the battery cable through the recess for
the battery.

xx1300000834

8 Secure the SMB cover with its 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

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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4 Repair
4.4.2 Refitting the cable harness
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 its 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

Use tape and tie the axis-5 and axis-6

connectors and carrier into a bundle (if not
already done). This is done to facilitate the
procedure and to avoid damaging the parts
during the procedure.
This will also make it easier to run the cable
harness through the inside of the robot.
xx1300000668

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
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

The screws are reached from the outside

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

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
5 Refit the axis-3 lower arm metal clamp
located on the inside of the lower arm.

Note

The screws are reached from the outside

of the lower arm.

xx1300000558

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.

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
4
Tip

Use tape and tie the axis-5 and axis-6

connectors and carrier into a bundle (if not
already done). This is done to facilitate the
procedure and to avoid damaging the parts
during the procedure.
This will also make it easier to run the cable
harness through the inside of the robot.
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

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
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

This step is best performed by two persons

working together:
• Person 1: Put one hand inside the
side hole of the arm tube and take
a hold of the cable harness.
• Person 2: Take a hold on the cable 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

Do not run the cable harness into the

DressPack tube, if one is fitted!

xx1400000356

xx1300000820

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
Continued

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

Tip

This step is best performed by two persons

working together:
• Person 1: Put one hand inside the
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

• Together: Move the cable harness Person 2, working at the wrist:

past the axis-5 motor and into the
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

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4 Repair
4.4.2 Refitting the cable harness
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

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
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:
• Make sure the gasket is fitted cor-
rectly
• Use attachment screws made of
stainless steel to fit the cover.

xx1200000045

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4 Repair
4.4.2 Refitting the cable harness
Continued

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

Note

If DressPack is fitted, the cable fixing

bracket is replaced by the cable guide.

xx1300001973

xx1300000544

Connecting the axis-3 and axis-4 motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

2 Refit the cable gland cover.

Note

Replace the gasket if damaged.

xx1200001067

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
8 Refit the motor cover with its 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.

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

Replace the gasket if damaged.

xx1200001016

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
3 Connect the connectors.
Connect in accordance with the markings
on the connectors.

xx1200001015

4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).

xx1200001021

5
CAUTION

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
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

Do not reuse the self-threading attachment

screws, it will damage the threads. Replace
with standard attachment screws.

Note

Make sure the o-ring is undamaged and 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 819.

xx1500001029

xx1300000489

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 4 Repair
4.4.2 Refitting the cable harness
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

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
Continued

Connecting the axis-6 motor cables

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

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
4 Push the carrier carefully into position.

xx1300001113

5 Secure the carrier with the M4 screw.

Note

The screw is located at the bottom of the

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

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4 Repair
4.4.2 Refitting the cable harness
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

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

10 Refit the motor cover.

xx1200001080

Continues on next page

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 4 Repair
4.4.2 Refitting the cable harness
Continued

Concluding procedure

Action Note
1 Make sure that the cable harness is placed
in a way that it will not be damaged when
the wrist cover is fitted.

xx1600002061

xx1300000596

Cable layout in the wrist with Type A mo-

tors.
2 Inspect the gasket. Replace if damaged.
Foundry Plus and Foundry Prime :
• Make sure that the gasket is undam-
aged on the cover. Replace if dam-
aged!
• Put washers in the holes of the gas-
ket.
• Use attachment screws made of
stainless steel to fit the wrist cover.

xx1400000383

A Protection plugs (2 on wrist cover

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

Continues on next page

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4 Repair
4.4.2 Refitting the cable harness
Continued

Action Note
3 Refit the wrist cover. In order not to dam- Tightening torque: 10 Nm.
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
screws. xx1300000772

4 Foundry Plus: See figure above!

Refit protection plugs.
5 If used, refit the DressPack cable package
on the wrist.
6 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
7
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

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 4 Repair
4.4.3 Replacing the SMB

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

Equipment, etc. Article number Note

SMB unit (DSQC633C) See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790
Battery pack See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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4 Repair
4.4.3 Replacing the SMB
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

Make sure that all supplies for electrical power, hy-

draulic pressure, and air pressure are turned off.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 31

3 Open the small cover on the SMB cover, disconnect

the battery cable and remove the battery.

xx1300000829

4 Remove the SMB cover.

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.

xx1300000669

Disconnecting and removing 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
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 31

Continues on next page

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 4 Repair
4.4.3 Replacing the SMB
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:
• R1.SMB1-3, R1.SMB4-6 and R2.SMB
• Battery cable connector R2.G.
Disconnect the battery cable by pressing down
the upper lip of the R2.G connector to release
the lock while pulling the connector upwards.

xx1300000728

xx1700000993

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

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

Continues on next page

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4 Repair
4.4.3 Replacing the SMB
Continued

Action Note
2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit please read the safety information in the
section The unit is sensitive to ESD on page 31

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 in 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

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 4 Repair
4.4.3 Replacing the SMB
Continued

Action Note
7 Pull out the battery cable through the recess for
the battery.

xx1300000834

8 Secure the SMB cover with its 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
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit please read the safety information in the
section The unit is sensitive to ESD on page 31

2 Reconnect the battery cable.

3 Place the battery in the recess.

xx1300000829

4 Refit the battery cover.

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4 Repair
4.4.3 Replacing the SMB
Continued

Concluding procedures

Action Note
1 Update the revolution counters. See Updating revolution counters on
page 794.
2
DANGER

Make sure all safety requirements are met when

performing the first test run. These are further
described in First test run may cause injury or
damage on page 26.

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 4 Repair
4.4.4 Replacing the brake release unit

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

Equipment, etc. Article number Note

Brake release unit See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790
Battery pack See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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4 Repair
4.4.4 Replacing the brake release unit
Continued

Removing the brake release unit

Preparations before removing the brake release unit

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 31

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

4 Remove the SMB cover.

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.

Continues on next page

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 4 Repair
4.4.4 Replacing the brake release unit
Continued

Disconnecting the brake release unit

Action Note
1
DANGER

Make sure that all supplies for electrical power, hy-

draulic pressure, and air pressure are turned off.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 31

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 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.

Continues on next page

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4 Repair
4.4.4 Replacing the brake release unit
Continued

Refitting the brake release unit

Use this procedure to refit the brake release unit.
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit

please read the safety information in the section The
unit is sensitive to ESD on page 31

2 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.
Be careful not to damage the sockets or pins.
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
brake release board.

6 Refit the SMB cover with its attachment screws.

Note

Do not refit the push button guard at this point!

xx1300000742

Continues on next page

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 4 Repair
4.4.4 Replacing the brake release unit
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 205!

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 page 794.
12
DANGER

Make sure all safety requirements are met when

performing the first test run. These are further de-
scribed in First test run may cause injury or damage
on page 26.

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4 Repair
4.5.1 Replacing the upper arm

4.5 Upper and lower arms

4.5.1 Replacing the upper arm

Location of the upper arm

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

xx1300000483

Spare part

Spare part Spare part number Note

Upper arm See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Consumables
Parts needed to be replaced after removal.
Equipment, etc. Article number Note
Grease 3HAB3537-1 Used to lubricate o-rings.

Continues on next page

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Equipment, etc. Article number Note

3HAB3772-111 (circular pro- D=169.5x3
file) / 3HAC054692-002 Used on axis-3 motor cover.
(hexagon profile)
3HAB3772-110 (circular pro- D=119x3
O-ring file) / 3HAC054692-001 Used on axis-4 motor cover.
(hexagon profile)
3HAB3772-110 (circular pro- D=119x3
file) / 3HAC054692-001 Used on axis-5 motor cover.
(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.

Required tools and equipment

Equipment, etc. Article number Note

Lifting eye 3HAC16131-1 M12
Lifting eye 3HAC16131-1 M12
Fender washer - Outer diameter: minimum 26 mm,
maximum 30 mm, hole diameter: 13
mm, thickness: 3 mm.
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Pallet Used for putting down removed parts
from robot.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
Guide pin, M12x200 3HAC13056-4 Always use guide pins in pairs.
Guide pin, M16x150 3HAC13120-2 Always use guide pins in pairs.
Guide pin, M16x200 3HAC13120-3 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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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4 Repair
4.5.1 Replacing the upper arm
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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the 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 738.

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.

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove 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
1 Jog the robot into position:
• Axis 1: No significance (as long as
the robot is secured to the founda-
tion)
• Axis 2: -60°
• Axis 3: +60°
• Axis 4: +90°
• Axis 5: +90°
• Axis 6: No significance
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

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.

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.

xx1400000355

3 If used, open the ball joint housing on the

arm tube and remove the DressPack cable
package.

xx1400000206

4 Remove the wrist cover.

xx1300002247

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.

xx1500001030

xx1300000490

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4 Repair
4.5.1 Replacing the upper arm
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

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.

Disconnecting the axis-5 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

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 4 Repair
4.5.1 Replacing the upper arm
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

4 Disconnect the motor cables.

xx1200001066

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4 Repair
4.5.1 Replacing the upper arm
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-6 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Unscrew the attachment screws and re-

move the motor cover.

xx1200001080

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
3 Disconnect the motor cables.

xx1300000488

4 Unscrew the attachment screws that hold

the cable bracket.

xx1300000484

5 Unscrew the M4 screw that holds the carri-

er.

Note

The screw is located at the bottom of the

carrier.

xx1300000485

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
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

Disconnecting the axis-3 and axis-4 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Unscrew the attachment screws and

washers and remove the motor cover.

xx1200001135

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 4 Repair
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Continued

Action Note
3 Make sure the o-ring is present.

xx1200001070

4 Disconnect the motor cables.

xx1200001066

5 Remove the cable gland cover.

Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

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4 Repair
4.5.1 Replacing the upper arm
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

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 4 Repair
4.5.1 Replacing the upper arm
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

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4 Repair
4.5.1 Replacing the upper arm
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

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 4 Repair
4.5.1 Replacing the upper arm
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

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4 Repair
4.5.1 Replacing the upper arm
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

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 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, -245/3.00)
xx1400002561

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Attaching the lifting accessories

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

xx1200001133

3 Fit a lifting eye in the arm house, with a Lifting eye: 3HAC16131-1
fender washer underneath. Fender washer: Outer diameter: minimum
26 mm, maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.

xx1400002196

xx1200001134

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

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
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

Preparations before removing the upper arm - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 -
175/3.05, IRB 6700 - 150/3.20

Action Note
1 Remove two attachment screws (M12) in Guide pin, M12x150: 3HAC13056-2
opposite holes and replace them with guide Guide pin, M12x200: 3HAC13056-4
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

2 Leave one of the remaining attachment

screws fitted, remove the other screws.

xx1300000747

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Preparations before removing the upper arm - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-4
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.

xx1300002245

2 Leave one of the remaining attachment

screws fitted, remove the other screws.

xx1300002246

Preparations before removing the upper arm - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Note

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.

xx1400002563

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
2 Leave one of the remaining attachment
screws fitted, remove the other screws.

xx1400002564

Removing the upper arm

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

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
2 Remove the remaining attachment screw IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
and let the upper arm slide out from the IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
lower arm with support from the guide pins.

xx1300001610

IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

TBD
IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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.

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4 Repair
4.5.1 Replacing the upper arm
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, IRB 6700 - 205/2.80, Guide pin, M12x150: 3HAC13056-2
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20 Guide pin, M12x200: 3HAC13056-4
Fit two guide pins in opposite M12 holes Always use guide pins in pairs.
in the axis-3 gearbox.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1700000058

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
4 IRB 6700 - 200/2.60, IRB 6700 - 155/2.85 Guide pin, M12x150: 3HAC13056-2
Fit two guide pins in opposite M12 holes Guide pin, M12x200: 3HAC13056-4
in the axis-3 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1400000361

5 IRB 6700 - 300/2.70, IRB 6700 - 245/3.00 Guide pin, M16x150: 3HAC13120-2
Fit two guide pins in opposite M16 holes Guide pin, M16x200: 3HAC13120-3
in the axis-3 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1700000056

Securing the upper arm - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 -
150/3.20

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
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

7 Remove the guide pins and fit the two re-

maining M12 screws.

xx1300000659

8 Secure the upper arm by tightening the at- Tightening torque depends on screw dimen-
tachment screws. sion.
Tightening torque, M16: 300 Nm
Tightening torque, M12: 120 Nm
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Securing the upper arm - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.
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 22 of the 24 M12 screws and wash-

ers.

xx1300002246

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
7 Remove the guide pins and fit the two re-
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, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Securing the upper arm - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.
3 Lift the upper arm and bring it towards the
lower arm.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
Connect the 24 VDC power supply, to re-
lease the brakes.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
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

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
6 Insert and tighten 20 of the 22 M16 screws.

xx1700000057

7 Remove the guide pins and fit the two re-

maining screws.
8 Secure the upper arm by tightening the at- M16, tightening torque: 300 Nm
tachment screws.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Refitting the cable harness - upper arm

Action Note
1 Refit the metal clamp on top of the arm
house.

xx1300000541

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
2 Refit the arm house metal clamp.

xx1300000543

3 Arrange the cables between the cable

clamps in the upper arm.
4
Tip

Use tape and tie the axis-5 and axis-6

connectors and carrier into a bundle (if not
already done). This is done to facilitate the
procedure and to avoid damaging the parts
during the procedure.
This will also make it easier to run the cable
harness through the inside of the robot.
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

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 4 Repair
4.5.1 Replacing the upper arm
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

This step is best performed by two persons

working together:
• Person 1: Put one hand inside the
side hole of the arm tube and take
a hold of the cable harness.
• Person 2: Take a hold on the cable 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

Do not run the cable harness into the

DressPack tube, if one is fitted!

xx1400000356

xx1300000820

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4 Repair
4.5.1 Replacing the upper arm
Continued

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

Tip

This step is best performed by two persons

working together:
• Person 1: Put one hand inside the
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

• Together: Move the cable harness Person 2, working at the wrist:

past the axis-5 motor and into the
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

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 4 Repair
4.5.1 Replacing the upper arm
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

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4 Repair
4.5.1 Replacing the upper arm
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:
• Make sure the gasket is fitted cor-
rectly
• Use attachment screws made of
stainless steel to fit the cover.

xx1200000045

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 4 Repair
4.5.1 Replacing the upper arm
Continued

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

Note

If DressPack is fitted, the cable fixing

bracket is replaced by the cable guide.

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.

Connecting the axis-3 and axis-4 motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

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4 Repair
4.5.1 Replacing the upper arm
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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 4 Repair
4.5.1 Replacing the upper arm
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 its 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.

Connecting the axis-5 motor cables

Action Note
1 Push the motor cables in through the cable
gland opening.

xx1300000738

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
2 Refit the cable gland cover by performing
the following steps:
• Slide the cable gland cover onto the
inner screw.
• Refit and tighten the outer screw.
• Tighten the inner screw. Make sure
that the gasket is not damaged.

Note

Replace the gasket if damaged.

xx1200001016

3 Connect the connectors.

Connect in accordance with the markings
on the connectors.

xx1200001015

4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).

xx1200001021

5
CAUTION

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

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 4 Repair
4.5.1 Replacing the upper arm
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

Do not reuse the self-threading attachment

screws, it will damage the threads. Replace
with standard attachment screws.

Note

Make sure the o-ring is undamaged and 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 819.

xx1500001029

xx1300000489

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4 Repair
4.5.1 Replacing the upper arm
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

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Connecting the axis-6 motor cables

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

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4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
4 Push the carrier carefully into position.

xx1300001113

5 Secure the carrier with the M4 screw.

Note

The screw is located at the bottom of the

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

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 4 Repair
4.5.1 Replacing the upper arm
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

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

10 Refit the motor cover.

xx1200001080

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4 Repair
4.5.1 Replacing the upper arm
Continued

Refitting the wrist cover

Action Note
1 Inspect the gasket. Replace if damaged.
Foundry Plus and Foundr Prime:
• Make sure that the gasket is undam-
aged on the cover. Replace if dam-
aged.
• Put washers in the holes of the gas-
ket.
• Use attachment screws made of
stainless steel to fit the wrist cover.

xx1400000383

A Protection plugs (2 on wrist cover

and 2 on cover axis-5 gearbox)
B Washers (10 pcs) in gasket holes
2 Refit the wrist cover. In order not to dam- Tightening torque: 10 Nm.
age the cable harness when the wrist cover
is refitted, use this method:
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.
4 Move the upper part of the cover into
position.
5 Secure the cover with its attachment
screws.
xx1300000772

3 Remove the lifting accessories.

Concluding procedure

Action Note
1 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.

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 4 Repair
4.5.1 Replacing the upper arm
Continued

Action Note
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

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4 Repair
4.5.2 Replacing the wrist

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

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 4 Repair
4.5.2 Replacing the wrist
Continued

Spare part

Spare part Spare part number Note

Wrist See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Consumables

Equipment, etc. Article number Note

Cable tie -
Grease 3HAB3537-1 Used to lubricate o-rings.
O-ring 3HAB3772-110 (circular pro- D=119x3
file) / 3HAC054692-001 Used on axis-5 motor cover.
(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.

Required tools and equipment

Equipment, etc. Article number Note

Roundsling, 1 m - Length: 1 m, lifting capacity: 1,000 kg.
Pallet Used for putting down removed parts
from robot.
Cardboard Used for protection.
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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4 Repair
4.5.2 Replacing the wrist
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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the wrist

These procedures describes how to remove the wrist.

Preparations before removing the wrist

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Remove tools and other equipment fitted
to the wrist.

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 4 Repair
4.5.2 Replacing the wrist
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
4 Jog the robot into position:
• Axis 1: no significance (as long as
the robot is secured to the founda-
tion)
• Axis 2: -60°
• Axis 3: +60°
• Axis 4: +90°
• Axis 5: +90°
• Axis 6: no significance
5
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

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.

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.

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4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.

xx1400000355

3 If used, open the ball joint housing on the

arm tube and remove the DressPack cable
package.

xx1400000206

4 Remove the wrist cover.

xx1300002247

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 4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.

xx1500001030

xx1300000490

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4 Repair
4.5.2 Replacing the wrist
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

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

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 4 Repair
4.5.2 Replacing the wrist
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

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4 Repair
4.5.2 Replacing the wrist
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

Disconnecting the axis-5 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

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 4 Repair
4.5.2 Replacing the wrist
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

4 Disconnect the motor cables.

xx1200001066

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4 Repair
4.5.2 Replacing the wrist
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.

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, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
140 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

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.

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 4 Repair
4.5.2 Replacing the wrist
Continued

Removing the wrist

Action Note
1 If used, remove the bracket with the part
of the ball joint housing still fitted.

xx1700000691

2 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2

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

Tip

Lubricate the guide pins with some grease

to make the wrist slide better.

xx1300000748

3 Remove the remaining attachment screws.

xx1300000749

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

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4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
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

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Wipe clean all contact surfaces.

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 4 Repair
4.5.2 Replacing the wrist
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

Lubricate the guide pins with some grease

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.
Connect to R2.MP5-connector:
• + = 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, -205/2.80, -
175/3.05, -150/3.20, -200/2.60, -155/2.85)
140 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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4 Repair
4.5.2 Replacing the wrist
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

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 4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
3 Slide the wrist into fitting position.

xx1300000771

4 Fit 10 of the 12 attachment screws and Screws: M12x50.

washers.

xx1300000749

5 Remove the guide pins and replace them

with the remaining attachment screws and
washers.

xx1300000748

6 Tighten the attachment screws. Tightening torque: 120 Nm.

Continues on next page

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4 Repair
4.5.2 Replacing the wrist
Continued

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

Replace the gasket if damaged.

xx1200001016

3 Connect the connectors.

Connect in accordance with the markings
on the connectors.

xx1200001015

Continues on next page

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 4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).

xx1200001021

5
CAUTION

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

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

Do not reuse the self-threading attachment

screws, it will damage the threads. Replace
with standard attachment screws.

Note

Make sure the o-ring is undamaged and xx1200001013

properly fitted.

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4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
7 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
Note is installed on the robot.

If replacing a type A motor with a type B

motor, the heat protection plate must be
replaced with plates suited for the type B
motor. See Type A vs type B motors on
page 819.

xx1500001029

xx1300000489

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 4 Repair
4.5.2 Replacing the wrist
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

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4 Repair
4.5.2 Replacing the wrist
Continued

Connecting the axis-6 motor cables

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

Continues on next page

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 4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
4 Push the carrier carefully into position.

xx1300001113

5 Secure the carrier with the M4 screw.

Note

The screw is located at the bottom of the

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

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4 Repair
4.5.2 Replacing the wrist
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

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

10 Refit the motor cover.

xx1200001080

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 4 Repair
4.5.2 Replacing the wrist
Continued

Concluding procedure

Action Note
1 Make sure that the cable harness is placed There are two versions of the heat protec-
in a way so it will not be damaged when tion plates.
the wrist cover is fitted. Choose figure depending on which plate
is installed on the robot.

xx1500001672

xx1300000596

Cable layout in the wrist with Type A mo-

tors.
2 Inspect the gasket. Replace if damaged.
Foundry Plus and Foundry Prime:
• Make sure that the gasket is undam-
aged on the cover. Replace if dam-
aged.
• Put washers in the holes of the gas-
ket.
• Use attachment screws made of
stainless steel to fit the wrist cover.

xx1400000383

A Protection plugs (2 on wrist cover

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

Continues on next page

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4 Repair
4.5.2 Replacing the wrist
Continued

Action Note
3 Refit the wrist cover. Use this method not Tightening torque: 10 Nm.
to damage the cable harness:
1 Hold the cover tilted. See figure!
2 Catch any part of the cable harness
hanging down.
3 Lift the cover, still held tilted.
4 Move the upper part of the cover into
position.
5 Secure the cover with its attachment
screws.

xx1300000772

4 Foundry Plus:
Refit protection plugs.
5 If used, refit the DressPack cable package
on the wrist.
6 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
7
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

364 Product manual - IRB 6700

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 4 Repair
4.5.3 Replacing the turning disc

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

Spare part Spare part number Note

Turning disc See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Consumables

Equipment, etc. Article number Note

Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat. Re-
commended drying time is
24h.
Used on Foundry Plus.

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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4 Repair
4.5.3 Replacing the turning disc
Continued

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.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Remove any equipment fitted to the turning

disc.

Removing the turning disc

Action Note
1 - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
Remove the screws and washers, that se-
cure the turning disc.

xx1300000492

2 - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Remove the screws and washers, that se-
cure the turning disc.

xx1300002302

Continues on next page

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 4 Repair
4.5.3 Replacing the turning disc
Continued

Action Note
3 - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
Remove the screws and washers, that se-
cure the turning disc.

xx1400002195

4 Remove the turning disc.

xx1300000493

Continues on next page

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4 Repair
4.5.3 Replacing the turning disc
Continued

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.

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, IRB 6700 - 205/2.80, IRB IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
6700 - 175/3.05, IRB 6700 - 150/3.20, IRB
6700 - 200/2.60, IRB 6700 - 155/2.85

xx1500000877 xx1500000878

Use the holes closest to the synchronization Use the holes at the back end of the synchron-
mark. ization plate.

Continues on next page

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 4 Repair
4.5.3 Replacing the turning disc
Continued

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 - 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 turning disc

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 368.
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, IRB 6700 - 205/2.80, Tightening torque: 35 Nm.

IRB 6700 - 175/3.05, IRB 6700 - 150/3.20 Attachment screws: M8x25, Steel 12.9
Secure the turning disc with its attachment Gleitmo 603 (24 pcs)
screws and washers. Washers: Steel 8.4x13x1.5 (24 pcs)

xx1300000492

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4 Repair
4.5.3 Replacing the turning disc
Continued

Action Note
5 IRB 6700 - 200/2.60, IRB 6700 - 155/2.85 Tightening torque: 70 Nm
Secure the turning disc with its attachment Attachment screws: M10x25, Steel 12.9
screws and washers. Gleitmo 603, (9 pcs)
Washers: (3 pcs)

xx1300002302

6 IRB 6700 - 300/2.70, IRB 6700 - 245/3.00 Tightening torque: 70 Nm

Secure the turning disc with its attachment Attachment screws: M10x25, Steel 12.9
screws and washers. Gleitmo 603, (21 pcs)
Washers: Steel 11x17x25 (21 pcs)

xx1400002195

Concluding procedure

Action Note
1
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

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 4 Repair
4.5.4 Replacing the process turning disc

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.

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Consumables

Equipment, etc. Article number Note

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.

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4 Repair
4.5.4 Replacing the process turning disc
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Remove any equipment fitted to the pro-

cess turning disc.

Removing the process turning disc

Action Note
1 IRB 6700 - 235/2.65, - 205/2.80, - 175/3.05,
- 150/3.20.
Remove the 24 M8 screws and washers,
that secure the process turning disc.

2 IRB 6700 - 200/2.60, - 155/2.85.

Remove the nine M10 screws and three
washers, that secure the process turning
disc.

Continues on next page

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 4 Repair
4.5.4 Replacing the process turning disc
Continued

Action Note
3 IRB 6700 -300/2.70, -245/3.00.
Remove the 21 M10 screws and washers,
that secure the process turning disc.

4 Remove the process turning disc.

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.

Continues on next page

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4 Repair
4.5.4 Replacing the process turning disc
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, IRB 6700 - 205/2.80, IRB IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
6700 - 175/3.05, IRB 6700 - 150/3.20, IRB
6700 - 200/2.60, IRB 6700 - 155/2.85

xx1500000877 xx1500000878

Use the holes closest to the synchronization Use the holes at the back end of the synchron-
mark. ization plate.

Continues on next page

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 4 Repair
4.5.4 Replacing the process turning disc
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
1 If new turning disc spare part is installed: See Replacing the synchronization mark
verify that the correct synchronization mark plate on page 373.
plate for axis-6 is installed on the wrist.
2 Wipe clean the contacts surfaces.
3 Foundry Plus: A B
Apply Mercasol on the surfaces on the
process turning disc and axis-6 gearbox
as shown in the figure.

The figure show standard turning disc.

Surfaces to apply Mercasol on are the
same with process turning disc.
4 IRB 6700 -235/2.65, -205/2.80, -175/3.05, - Tightening torque: 35 Nm.
150/3.20. Attachment screws: M8x25, Steel 12.9
Secure the process turning disc with its Gleitmo 603 (24 pcs)
attachment screws and washers. Washers: Steel 8.4x13x1.5 (24 pcs)

Continues on next page

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4 Repair
4.5.4 Replacing the process turning disc
Continued

Action Note
5 IRB 6700 -200/2.60, -155/2.85. Tightening torque: 70 Nm
Secure the process turning disc with its Attachment screws: M10x25, Steel 12.9
attachment screws and washers. Gleitmo 603, (9 pcs)
Washers: (3 pcs)

6 IRB 6700 -300/2.70, -245/3.00. Tightening torque: 70 Nm

Secure the process turning disc with its Attachment screws: M10x25, Steel 12.9
attachment screws and washers. Gleitmo 603, (21 pcs)
Washers: Steel 11x17x25 (21 pcs)

Concluding procedure

Action Note
1
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

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 4 Repair
4.5.5 Replacing the lower arm

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

Spare part Spare part number Note

Lower arm See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

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4 Repair
4.5.5 Replacing the lower arm
Continued

Consumables

Equipment Article number Note

Grease 3HAA1001-294 Tribol GR 100-0 PD, 50 ml
For lubrication of the front
bearing of the balancing
device.
Grease 3HAB3537-1 Used to lubricate o-rings.
O-ring 3HAB3772-111 (circular pro- D=169.5x3
file) / 3HAC054692-002 Used on axis-3 motor cover.
(hexagon profile)
3HAB3772-110 (circular pro- D=119x3
file) / 3HAC054692-001 Used on axis-4 motor cover.
(hexagon profile)
3HAB3772-110 (circular pro- D=119x3
file) / 3HAC054692-001 Used on axis-5 motor cover.
(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.

Required tools and equipment

Equipment Article number Note

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!

Lifting shackle - SA-10-8-NA1

Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Dismantle and mounting tool 3HAC028920-001 Used for removing and fitting shaft and
bearings.
Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.
Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Lifting eye 3HAC16131-1 M12
Lifting eye 3HAC16131-1 M12
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
Guide pin, M12x200 3HAC13056-4 Always use guide pins in pairs.

Continues on next page

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Equipment Article number Note

Pallet Used for putting down removed parts
from robot.
Guide pin, M16x150 3HAC13120-2 Always use guide pins in pairs.
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Anvil 3HAC047273-001 Included in the tool kit Dismantle and
mounting tool (3HAC028920-001).
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

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4 Repair
4.5.5 Replacing the lower arm
Continued

Removing the lower arm

Use these procedures to remove the lower arm.

Preparations before removing the lower arm

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Remove 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°.
Connect to R2.MP5-connector:
• + = pin 2
• - = pin 5

xx1200001081

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Unloading or locking the balancing device springs

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 tool,
balancing device (3HAC020902-001).

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
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

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4 Repair
4.5.5 Replacing the lower arm
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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
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).

Continues on next page

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Remove any equipment, if fitted, on or

close to the balancing device.
4
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
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.

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4 Repair
4.5.5 Replacing the lower arm
Continued

Removing the shaft in the front (link ear)

Action Note
1 Remove the VK cover. It is possible to drive a screwdriver (or
similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.

xx1200001278

2 Unscrew the attachment screw and washer.

xx1200001279

• M16x70 quality steel 8.8-A3F

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
3 Use the dismantle and mounting tool and Dismantle and mounting tool:
pull the shaft out. 3HAC028920-001
F Hydraulic pump 80 MPa: 3HAC13086-1
1
L A Hydraulic cylinder: 3HAC11731-1

xx1200001280

xx1700000378

The numbers in the figure refers to the

marked tool pieces respectively.
4 Put down the balancing device and let it
rest on the frame.

xx1200001281

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.

Continues on next page

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
2 If DressPack is installed:
• Remove the bracket with the com-
plete ball joint housing still fitted, as
shown in the figure.
This is done to be able to reach the two
hidden screws that secure the wrist cover.

xx1400000355

3 If used, open the ball joint housing on the

arm tube and remove the DressPack cable
package.

xx1400000206

4 Remove the wrist cover.

xx1300002247

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.

xx1500001030

xx1300000490

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4 Repair
4.5.5 Replacing the lower arm
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

Removing cable brackets

Action Note
1 Unscrew the screws that hold the bracket
and let it hang free.

xx1200001184

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 4 Repair
4.5.5 Replacing the lower arm
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

Disconnecting the axis-3 and axis-4 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

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4 Repair
4.5.5 Replacing the lower arm
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

4 Disconnect the motor cables.

xx1200001066

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Disconnecting the axis-5 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Unscrew the attachment screws and

washers and remove the motor cover.

xx1200001135

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
3 Make sure the o-ring is present.

xx1200001070

4 Disconnect the motor cables.

xx1200001066

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.

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Disconnecting the 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 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

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4 Repair
4.5.5 Replacing the lower arm
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

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 4 Repair
4.5.5 Replacing the lower arm
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

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4 Repair
4.5.5 Replacing the lower arm
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

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 4 Repair
4.5.5 Replacing the lower arm
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

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4 Repair
4.5.5 Replacing the lower arm
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

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 4 Repair
4.5.5 Replacing the lower arm
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

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 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, -245/3.00)
xx1400002561

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4 Repair
4.5.5 Replacing the lower arm
Continued

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

xx1200001133

3 Fit a lifting eye in the arm house, with a Lifting eye: 3HAC16131-1
fender washer underneath. Fender washer: Outer diameter: minimum
26 mm, maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.

xx1400002196

xx1200001134

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

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
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

Preparations before removing the upper arm - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 -
175/3.05, IRB 6700 - 150/3.20

Action Note
1 Remove two attachment screws (M12) in Guide pin, M12x150: 3HAC13056-2
opposite holes and replace them with guide Guide pin, M12x200: 3HAC13056-4
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

2 Leave one of the remaining attachment

screws fitted, remove the other screws.

xx1300000747

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4 Repair
4.5.5 Replacing the lower arm
Continued

Preparations before removing the upper arm - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-4
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.

xx1300002245

2 Leave one of the remaining attachment

screws fitted, remove the other screws.

xx1300002246

Preparations before removing the upper arm - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Note

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.

xx1400002563

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
2 Leave one of the remaining attachment
screws fitted, remove the other screws.

xx1400002564

Removing the upper arm

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

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
2 Remove the remaining attachment screw IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
and let the upper arm slide out from the IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
lower arm with support from the guide pins.

xx1300001610

IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

TBD
IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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.

Continues on next page

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 4 Repair
4.5.5 Replacing the lower arm
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

Preparations before removing the lower arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
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

The screws are reached from outside the

lower arm!

xx1300000540

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4 Repair
4.5.5 Replacing the lower arm
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, - 205/2.80, -
175/3.05, - 150/3.20, - 200/2.60, - 155/2.85)
160 kg (IRB 6700 - 300/2.70, - 245/3.00)
All lifting accessories used must be sized
accordingly!

6 Apply the lifting accessory to the lower arm.

Removing the lower arm - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 -
150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Action Note
1 Raise the lifting accessory to unload the
lower arm.
2 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1300000788

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 4 Repair
4.5.5 Replacing the lower arm
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, IRB 6700 - 245/3.00

Action Note
1 Raise the lifting accessory to unload the
lower arm.
2 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1400002181

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
3 Remove all but one of the remaining attach-
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

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
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

Keep the sealing surfaces clean from Mer-

casol.

xx1700001879

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
3 Valid for variants: IRB 6700 - 235/2.65, IRB Guide pin, M16x150: 3HAC13120-2
6700 - 205/2.80, IRB 6700 - 175/3.05, IRB Always use guide pins in pairs.
6700 - 150/3.20.
Valid for variants: IRB 6700 - 200/2.60, IRB
6700 - 155/2.85.
Fit two guide pins in opposite holes in the
axis-2 gearbox.

Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1700000055

4 Valid for variants: IRB 6700 - 300/2.70, IRB Guide pin, M16x150: 3HAC13120-2
6700 - 245/3.00. Always use guide pins in pairs.
Fit two guide pins in opposite holes in the
axis-2 gearbox.

Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1400002189

5
CAUTION

The lower arm weighs .

145 kg (IRB 6700 - 235/2.65, - 205/2.80, -
175/3.05, - 150/3.20, - 200/2.60, - 155/2.85)
160 kg (IRB 6700 - 300/2.70, - 245/3.00)
All lifting accessories used must be sized
accordingly.

6 Attach the lifting accessory to the lower

arm.
7 Wipe clean all contact surfaces.

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4 Repair
4.5.5 Replacing the lower arm
Continued

Securing the lower arm to the axis-2 gearbox - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 -
175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Action Note
1
CAUTION

The lower arm weighs .

145 kg (IRB 6700 - 235/2.65, - 205/2.80, -
175/3.05, - 150/3.20, - 200/2.60, - 155/2.85)
160 kg (IRB 6700 - 300/2.70, - 245/3.00)
All lifting accessories used must be sized
accordingly.

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

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 4 Repair
4.5.5 Replacing the lower arm
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).
7 Remove the guide pins and replace them
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, IRB 6700 - 245/3.00

Action Note
1 Lift the lower arm onto the guide pins and
slide it into position.

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4 Repair
4.5.5 Replacing the lower arm
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

3 Fit one attachment screw in one of the up-

per holes using it for security and lower the
lifting accessory a little.
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).
6 Remove the guide pins and replace them
with the remaining attachment screws.

xx1400002181

7 Secure the remaining attachment screws. Tightening torque M16: 300 Nm

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
8 Remove the lifting accessory from the
lower 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, IRB 6700 - 205/2.80, Guide pin, M12x150: 3HAC13056-2
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20 Guide pin, M12x200: 3HAC13056-4
Fit two guide pins in opposite M12 holes Always use guide pins in pairs.
in the axis-3 gearbox.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1700000058

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
4 IRB 6700 - 200/2.60, IRB 6700 - 155/2.85 Guide pin, M12x150: 3HAC13056-2
Fit two guide pins in opposite M12 holes Guide pin, M12x200: 3HAC13056-4
in the axis-3 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1400000361

5 IRB 6700 - 300/2.70, IRB 6700 - 245/3.00 Guide pin, M16x150: 3HAC13120-2
Fit two guide pins in opposite M16 holes Guide pin, M16x200: 3HAC13120-3
in the axis-3 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1700000056

Securing the upper arm - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 -
150/3.20

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
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

7 Remove the guide pins and fit the two re-

maining M12 screws.

xx1300000659

8 Secure the upper arm by tightening the at- Tightening torque depends on screw dimen-
tachment screws. sion.
Tightening torque, M16: 300 Nm
Tightening torque, M12: 120 Nm
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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4 Repair
4.5.5 Replacing the lower arm
Continued

Securing the upper arm - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.
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 22 of the 24 M12 screws and wash-

ers.

xx1300002246

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
7 Remove the guide pins and fit the two re-
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, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Securing the upper arm - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.
3 Lift the upper arm and bring it towards the
lower arm.
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
Connect the 24 VDC power supply, to re-
lease the brakes.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
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

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
6 Insert and tighten 20 of the 22 M16 screws.

xx1700000057

7 Remove the guide pins and fit the two re-

maining screws.
8 Secure the upper arm by tightening the at- M16, tightening torque: 300 Nm
tachment screws.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Refitting the cable harness - lower arm

Action Note
1
Tip

Use tape and tie the axis-5 and axis-6

connectors and carrier into a bundle (if not
already done). This is done to facilitate the
procedure and to avoid damaging the parts
during the procedure.
This will also make it easier to run the cable
harness through the inside of the robot.
xx1300000668

2 Run the upper end of the cable harness up

through the lower arm.

xx1300000733

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
3 Refit the axis-2 lower arm metal clamp
located on the inside of the lower arm.

Note

The screws are reached from the outside

of the lower arm.

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

5 Refit the axis-3 lower arm metal clamp

located on the inside of the lower arm.

Note

The screws are reached from the outside

of the lower arm.

xx1300000558

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4 Repair
4.5.5 Replacing the lower arm
Continued

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
Tip

Use tape and tie the axis-5 and axis-6

connectors and carrier into a bundle (if not
already done). This is done to facilitate the
procedure and to avoid damaging the parts
during the procedure.
This will also make it easier to run the cable
harness through the inside of the robot.
xx1300000668

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
A B C D
5 Foundry Plus:
Make sure that the gasket underneath the
cover is correctly fitted. Replace if dam-
aged.
The gasket is covered with adhesive on the
side facing the upper arm cover. The three
washers are pressed into the holes in the
gasket. Make sure all three washers are
fitted.

xx1400000382

A Gasket
B Cable guide
C Washer
D Cover
6 Run the cable harness through the cable Person 1, working at the side hole:
guide and then into and through the upper
arm tube.

Tip

This step is best performed by two persons

working together:
• Person 1: Put one hand inside the
side hole of the arm tube and take
a hold of the cable harness.
• Person 2: Take a hold on the cable 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

Do not run the cable harness into the

DressPack tube, if one is fitted!

xx1400000356

xx1300000820

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4 Repair
4.5.5 Replacing the lower arm
Continued

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

Tip

This step is best performed by two persons

working together:
• Person 1: Put one hand inside the
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

• Together: Move the cable harness Person 2, working at the wrist:

past the axis-5 motor and into the
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

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 4 Repair
4.5.5 Replacing the lower arm
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

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4 Repair
4.5.5 Replacing the lower arm
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:
• Make sure the gasket is fitted cor-
rectly
• Use attachment screws made of
stainless steel to fit the cover.

xx1200000045

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 4 Repair
4.5.5 Replacing the lower arm
Continued

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

Note

If DressPack is fitted, the cable fixing

bracket is replaced by the cable guide.

xx1300001973

xx1300000544

Connecting the axis-3 and axis-4 motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

2 Refit the cable gland cover.

Note

Replace the gasket if damaged.

xx1200001067

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
8 Refit the motor cover with its 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.

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

Replace the gasket if damaged.

xx1200001016

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
3 Connect the connectors.
Connect in accordance with the markings
on the connectors.

xx1200001015

4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).

xx1200001021

5
CAUTION

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

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 4 Repair
4.5.5 Replacing the lower arm
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

Do not reuse the self-threading attachment

screws, it will damage the threads. Replace
with standard attachment screws.

Note

Make sure the o-ring is undamaged and 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 819.

xx1500001029

xx1300000489

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4 Repair
4.5.5 Replacing the lower arm
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

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Connecting the axis-6 motor cables

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

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
4 Push the carrier carefully into position.

xx1300001113

5 Secure the carrier with the M4 screw.

Note

The screw is located at the bottom of the

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

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 4 Repair
4.5.5 Replacing the lower arm
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

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

10 Refit the motor cover.

xx1200001080

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4 Repair
4.5.5 Replacing the lower arm
Continued

Concluded refitting of the cable harness

Action Note
1 Secure the cable harness with cable straps There are two versions of the heat protec-
to the heat protection plate. tion plates.
Choose figure depending on which plate
is installed on the robot.

xx1500001029

xx1300000489

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
2 Fit the heat protection plate with the Choose figure depending on which plate
screws. is installed on the robot.

xx1500001030

xx1300000490

3 Make sure that the cable harness is placed

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

xx1600002061

xx1300000596

Cable layout in the wrist with Type A mo-

tors.

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
4 Inspect the gasket. Replace if damaged.
Foundry Plus:
• Make sure that the gasket is undam-
aged on the cover. Replace if dam-
aged.
• Put washers (10 pcs) in the holes of
the gasket.
• Use attachment screws made of
stainless steel to fit the wrist cover.

xx1400000383

A Protection plugs (2 on wrist cover

and 2 on cover axis-5 gearbox)
B Washers (10 pcs) in gasket holes
5 Use caution in order not to damage the Tightening torque: 10 Nm.
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.
3 Lift the cover, still tilted.
4 Move the upper part of the cover into
position.
5 Secure the cover with its attachment
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.

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 4 Repair
4.5.5 Replacing the lower arm
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.

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
2 Use caution and jog the robot to the calibration
position (if not already done).
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
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)

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 4 Repair
4.5.5 Replacing the lower arm
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 the shaft in with the hydraulic press tool. Hydraulic pressure: 250 bar
Hydraulic pump 80 MPa:
3HAC13086-1
Hydraulic cylinder: 3HAC11731-1
Dismantle and mounting tool:
3HAC028920-001

xx1700002238

The item numbers refer to mark-

ings on the tools.
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

Continues on next page

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
13 Fit the VK-cover.

xx1200001278

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

grease.

Concluded refitting of the front shaft

Action Note
1 Remove the lifting accessory from the bal-
ancing device.
2 Refit the cable bracket (if not already refit-
ted).

xx1200001283

Continues on next page

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 4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
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
jogged to -20° or +20°. Fitting and removal
of the tool shall only be done with axis-2 in
this position!
To unload or restore a new balancing
device or if the spring unit of the balancing
device cannot be compressed by jogging
the robot, only use the hydraulic press tool
Dismantle and mounting tool 3HAC028920-
001.

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

6 Remove the distance tool.

xx0800000480

A Distance tool: 3HAC030662-001

Continues on next page

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4 Repair
4.5.5 Replacing the lower arm
Continued

Action Note
7 Refit the cover plate. Attachment screws: M10 quality 12.9 (4
pcs)

xx1300000554

Concluding procedure

Action Note
1 Remove the lifting accessory.
2 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
3
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

442 Product manual - IRB 6700

3HAC044266-001 Revision: N
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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear

4.6 Frame and base

4.6.1 Replacing spherical roller bearing, link ear

Location of spherical roller bearing

The spherical roller bearing is located in the link ear of the balancing device.

xx1300000773

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

Summary of the replacement procedure

This is a brief summary of the replacement procedure, containing the major actions
to be performed.
1 Unload the balancing device.
2 Replace the spherical roller bearing.
3 Restore the balancing device.

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Spare part

Equipment Article number Note

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

Equipment, etc. Article number Note

VK cover, 28x7 3HAA2166-12 Located at the front link ear of the bal-
ancing device. 2 pcs required.
Grease 3HAA1001-294 Tribol GR 100-0 PD, 50 ml
Locking liquid 3HAB7116-1 Loctite 243

Required tools and equipment

Equipment, etc. Article number Note

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!

Hydraulic press tool, balan- 3HAC020902-001 Used to unload or restore a balancing

cing device device.
Dismantle and mounting tool 3HAC028920-001 Used for removing and fitting shaft and
bearings.
Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.
Lock screw, M16x120 - Used to secure lower arm.
Lifting shackle - SA-10-8-NA1
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Dismantle and mounting tool 3HAC028920-001 Used for removing and fitting shaft and
bearings.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

444 Product manual - IRB 6700
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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Dismantle and mounting tool

The following parts of the tool are needed for this replacement.

1
L A

xx1700000378

The numbers in the figure refers to the marked tool pieces respectively.

Removing the spherical roller bearing

Use these procedures to remove the spherical roller bearing in the link ear.

Unloading or locking the balancing device springs

Compression of the balancing device springs to an unloaded position, can be done
in two different methods using two different tools - Distance tool or Hydraulic press
tool, balancing device. The situations when to use which tool are very different.
The method described in this procedure, describes how to use the Distance tool
(3HAC030662-001). The Distance tool can not be used to unload or restore the
pressure of the balancing device spring unit! The Distance tool is only used to
keep the balancing device springs in a locked position, after they have been

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

unloaded with the help of the robot itself (as described in this procedure) and with
the balancing device still being fitted on the robot.

Note

To unload or restore a balancing device which cannot be done with the help of
the robot itself, the Hydraulic press tool, balancing device (3HAC020902-001)
must be used. See Unloading the balancing device on page 492

Illustration Article number Note

3HAC030662-001 Only used to keep the balan-
Distance tool cing device in a locked posi-
tion, after the balancing
device springs has been un-
loaded with the help of the
robot itself.

DANGER
xx1400000726

Never use this tool to unload

or restore a balancing
device!

3HAC020902-001 This tool is used to unload or

Hydraulic press tool, balan- restore a balancing device
cing device which cannot be done with
the help of the robot itself.
This press tool shall also be
used if the tool shall be fitted
xx1300000672 on or be removed from a
balancing device, not fitted
on the robot.
Use this tool:
• if the balancing device
shall be unloaded or
restored after it has
been removed from
the robot
• on a balancing device
not fitted on the robot,
such as a spare part.

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.

Continues on next page

446 Product manual - IRB 6700
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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Locking the balancing device springs with the Distance tool

Use this procedure to unload the balancing device springs with the help of the
robot, and to lock the 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 tool,
balancing device (3HAC020902-001).

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove the cover plate on the back of the

balancing device.

DANGER

DO NOT remove any other screws then the

rear cover attachment screws!

xx1300000554

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
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 temporarily.
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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Preparations before removing the spherical roller bearing

Action Note
1 Jog axis-2 to the calibration position (if not
already in this position).

Continues on next page

448 Product manual - IRB 6700
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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
2 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

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove any equipment, if fitted, on or

close to the balancing device.
5
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
6 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1

xx1300000661

7 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.

Removing the shaft in the front (link ear)

Action Note
1 Remove the VK cover. It is possible to drive a screwdriver (or
similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.

xx1200001278

Continues on next page

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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
2 Unscrew the attachment screw and washer.

xx1200001279

• M16x70 quality steel 8.8-A3F

3 Use the dismantle and mounting tool and Dismantle and mounting tool:
pull the shaft out. 3HAC028920-001
F Hydraulic pump 80 MPa: 3HAC13086-1
1
L A Hydraulic cylinder: 3HAC11731-1

xx1200001280

xx1700000378

The numbers in the figure refers to the

marked tool pieces respectively.
4 Put down the balancing device and let it
rest on the frame.

xx1200001281

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

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

3 Remove the o-ring.

xx1300000775

4 Apply the dismantle and mounting tool and Dismantle and mounting tool:
pull the spherical roller bearing out together 3HAC028920-001
with the radial sealing and washer.

xx1300000840

A Spherical roller bearing

B Radial sealing
C Washer

Continues on next page

452 Product manual - IRB 6700
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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Refitting the spherical roller bearing

Refitting the spherical roller bearing, link ear

Action Note
1 Wipe clean all contact surfaces from resid-
ual grease.
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.

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
6 Apply the dismantle and mounting tool and Dismantle and mounting tool:
press in the spherical roller bearing. 3HAC028920-001
4

F
J

xx1700000379 xx1300000776

7 Refit the o-ring.

xx1300000775

8 Apply Locking liquid on the screws and Loctite 243, 3HAB7116-1

secure the end cover with the radial sealing
ring.

xx1300000774

Continues on next page

454 Product manual - IRB 6700
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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Attaching lifting accessory to the balancing device

Action Note
1
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1

xx1300000661

3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.

Unloading a new spare part, balancing device

Action Note
1
DANGER

Do not use the Distance tool: 3HAC030662-

001 to unload or restore the pressure of
the balancing device spring unit! This tool
is only used to lock the spring unit in a
compressed position, after axis-2 has been
jogged to -30° or +30°. Fitting and removal
of the tool shall only be done with axis-2 in
this position!
To unload or restore a new balancing
device or if the spring unit of the balancing
device cannot be compressed by jogging
the robot, only use the Hydraulic press tool,
balancing device (3HAC020902-001).

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
2 Before a new spare part balancing device How to unload a new balancing device (a
is fitted, the springs must be unloaded us- spare part, not yet fitted to the robot) is
ing the Hydraulic press tool, balancing described in Unloading the balancing
device 3HAC020902-001. device on page 492.

Refitting the front shaft of the balancing device

Action Note
1 Turn the power to the robot on temporarily.
2 Use caution and jog the robot to the calibration
position (if not already done).
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
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

Continues on next page

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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
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)
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 the shaft in with the hydraulic press tool. Hydraulic pressure: 250 bar
Hydraulic pump 80 MPa:
3HAC13086-1
Hydraulic cylinder: 3HAC11731-1
Dismantle and mounting tool:
3HAC028920-001

xx1700002238

The item numbers refer to mark-

ings on the tools.

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
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

13 Fit the VK-cover.

xx1200001278

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

grease.

Continues on next page

458 Product manual - IRB 6700
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 4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Concluded refitting of the front shaft

Action Note
1 Remove the lifting accessory from the bal-
ancing device.
2 Refit the cable bracket (if not already refit-
ted).

xx1200001283

3 Remove the locking screw (M16x120).

xx1200001116

4 Foundry Plus:
Apply Mercasol in the hole for the locking
screw.

xx1400000372

5 Jog axis-2 to:

• -30° or +30°.

Continues on next page

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4 Repair
4.6.1 Replacing spherical roller bearing, link ear
Continued

Action Note
6
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

7 Remove the Distance tool.

8 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
577.

xx1300000554

460 Product manual - IRB 6700

3HAC044266-001 Revision: N
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 4 Repair
4.6.2 Replacing the balancing device

4.6.2 Replacing the balancing device

Location of the balancing device

The balancing device is located as shown in the figure.

xx1300000660

Summary of the replacement procedure

This is a brief summary of the replacement procedure, containing the major actions
to be performed.
1 Unload the balancing device.
2 Replace the balancing device.

Spare part

Spare parts Spare part number Note

Balancing device See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Continues on next page

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4 Repair
4.6.2 Replacing the balancing device
Continued

Consumables

Equipment, etc. Article number Note

Grease 3HAA1001-294 Tribol GR 100-0 PD
VK cover, 28x7 3HAA2166-12 Located at the front link ear of the bal-
ancing device. 2 pcs required.
VK cover, 90x12 3HAA2166-28 Located at the cradle of the balancing
device. 2 pcs required.
Locking liquid 3HAB7116-1 Loctite 243
Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat. Recommen-
ded drying time is 24h.

Required tools and equipment

Equipment, etc. Article number Note

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!

Lock screw, M16x120 - Used to secure lower arm.

Threaded bar, M16x340 -
Anvil 3HAC047273-001 Included in the tool kit Dismantle and
mounting tool (3HAC028920-001).
Hydraulic press tool, balan- 3HAC020902-001 Used to unload or restore a balancing
cing device device.
Dismantle and mounting tool 3HAC028920-001 Used for removing and fitting shaft and
bearings.
Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.
Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Lifting shackle - SA-10-8-NA1
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Removing the balancing device

Use these procedures to remove the balancing device.

Unloading or locking the balancing device springs

Compression of the balancing device springs to an unloaded position, can be done
in two different methods using two different tools - Distance tool or Hydraulic press
tool, balancing device. The situations when to use which tool are very different.

Continues on next page

462 Product manual - IRB 6700
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 4 Repair
4.6.2 Replacing the balancing device
Continued

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.

Note

To unload or restore a balancing device which cannot be done with the help of
the robot itself, the Hydraulic press tool, balancing device (3HAC020902-001)
must be used. See Unloading the balancing device on page 492

Illustration Art. no. Note

3HAC030662-001 Only used to keep the balan-
Distance tool cing device in a locked posi-
tion, after the balancing
device springs has been un-
loaded with the help of the
robot itself.

DANGER
xx1400000726

Never use this tool to unload

or restore a balancing
device!

3HAC020902-001 This tool is used to unload or

Hydraulic press tool, balan- restore a balancing device
cing device which cannot be done with
the help of the robot itself.
This press tool shall also be
used if the tool shall be fitted
xx1300000672 on or be removed from a
balancing device, not fitted
on the robot.
Use this tool:
• if the balancing device
shall be unloaded or
restored after it has
been removed from
the robot
• on a balancing device
not fitted on the robot,
such as a spare part.

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.

Continues on next page

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4 Repair
4.6.2 Replacing the balancing device
Continued

Unloading or locking the balancing device springs

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 tool,
balancing device (3HAC020902-001).

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
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

Continues on next page

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 4 Repair
4.6.2 Replacing the balancing device
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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Preparations before removing the balancing device

Action Note
1 Jog axis-2 to the calibration position (if not
already in this position).

Continues on next page

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4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
2 Fit a locking screw M16x120 through the
hole for the lock screw in the frame and
into the lower arm (or using a lifting access-
ory or similar).
The lock screw is used to secure the weight
of the lower arm, in order to avoid acci-
dents or damage.

xx1200001116

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove any equipment, if fitted, on or

close to the balancing device.

Attaching lifting accessory to the balancing device

Action Note
1
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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 4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
2 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1

xx1300000661

3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.

Continues on next page

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4 Repair
4.6.2 Replacing the balancing device
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.

Continues on next page

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 4 Repair
4.6.2 Replacing the balancing device
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.

Removing the shaft in the front (link ear)

Action Note
1 Remove the VK cover. It is possible to drive a screwdriver (or
similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.

xx1200001278

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4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
2 Unscrew the attachment screw and washer.

xx1200001279

• M16x70 quality steel 8.8-A3F

3 Use the dismantle and mounting tool and Dismantle and mounting tool:
pull the shaft out. 3HAC028920-001
F Hydraulic pump 80 MPa: 3HAC13086-1
1
L A Hydraulic cylinder: 3HAC11731-1

xx1200001280

xx1700000378

The numbers in the figure refers to the

marked tool pieces respectively.
4 Put down the balancing device and let it
rest on the frame.

xx1200001281

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 4 Repair
4.6.2 Replacing the balancing device
Continued

Concluding procedure

Action Note
1 Remove the balancing device.
2 If the same balancing device shall be refit-
ted, the Distance tool 3HAC030662-001
must stay fitted during the time the balan-
cing device is removed from the robot.

DANGER

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.

Attaching lifting accessory to the balancing device

Action Note
1
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1

xx1300000661

Continues on next page

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4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.

Unloading a new spare part, balancing device

Action Note
1
DANGER

Do not use the Distance tool: 3HAC030662-

001 to unload or restore the pressure of
the balancing device spring unit! This tool
is only used to lock the spring unit in a
compressed position, after axis-2 has been
jogged to -30° or +30°. Fitting and removal
of the tool shall only be done with axis-2 in
this position!
To unload or restore a new balancing
device or if the spring unit of the balancing
device cannot be compressed by jogging
the robot, only use the Hydraulic press tool,
balancing device (3HAC020902-001).

2 Before a new spare part balancing device How to unload a new balancing device (a
is fitted, the springs must be unloaded us- spare part, not yet fitted to the robot) is
ing the Hydraulic press tool, balancing described in Unloading the balancing
device 3HAC020902-001. device on page 492.

Refitting the rear shafts

Perform this procedure on both sides.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
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

Continues on next page

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 4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
4 Apply the refitting tool and press the shafts Dismantle and mounting tool:
into position one at a time. 3HAC028920-001
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

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

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4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
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

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

Refitting the front shaft of the balancing device

Action Note
1 Turn the power to the robot on temporarily.
2 Use caution and jog the robot to the calibration
position (if not already done).
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Continues on next page

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 4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
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)
9 Lubricate the shaft and place it to the front ear.

Note

Foundry Plus:
Do not lubricate surfaces where Mercasol is ap-
plied.

xx1200001280

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4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
10 Press the shaft in with the hydraulic press tool. Hydraulic pressure: 250 bar
Hydraulic pump 80 MPa:
3HAC13086-1
Hydraulic cylinder: 3HAC11731-1
Dismantle and mounting tool:
3HAC028920-001

xx1700002238

The item numbers refer to mark-

ings on the tools.
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

13 Fit the VK-cover.

xx1200001278

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 4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
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

grease.

Concluded refitting of the front shaft

Action Note
1 Remove the lifting accessory from the bal-
ancing device.
2 Refit the cable bracket (if not already refit-
ted).

xx1200001283

3 Remove the locking screw (M16x120).

xx1200001116

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4 Repair
4.6.2 Replacing the balancing device
Continued

Action Note
4 Foundry Plus:
Apply Mercasol in the hole for the locking
screw.

xx1400000372

5 Jog axis-2 to:

• -30° or +30°.
6
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

7 Remove the Distance tool.

8 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
577.

xx1300000554

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 4 Repair
4.6.3 Replacing the rear bearings on the balancing device

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

Equipment Article number Note

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

Equipment Article number Note

VK cover, 90x12 3HAA2166-28 Located at the cradle of the balancing
device. 2 pcs required.
Locking liquid 3HAB7116-1 Loctite 243
Grease 3HAB3537-1 Shell Gadus S2V220 AC

Continues on next page

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4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Required tools and equipment

Equipment Article number Note

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!

Lock screw, M16x120 - Used to secure lower arm.

Lifting shackle - SA-10-8-NA1
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Threaded bar, M16x340 -
Dismantle and mounting tool 3HAC028920-001 Used for removing and fitting shaft and
bearings.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Removing the bearing, cradle

Use these procedures to remove the bearing in the cradle.

Unloading or locking the balancing device springs

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 tool,
balancing device (3HAC020902-001).

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.

Continues on next page

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 4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove the cover plate on the back of the

balancing device.

DANGER

DO NOT remove any other screws than the

rear cover attachment screws.

xx1300000554

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.

Continues on next page

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4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
9
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Preparations before removing the rear bearings

Action Note
1 Jog axis-2 to the calibration position (if not
already in this position).
2 Fit a locking screw through the hole for the Lock screw, M16x120
lock screw in the frame and into the lower
arm (or using a lifting accessory or similar).
The lock screw is used to secure the weight
of the lower arm, in order to avoid acci-
dents or damage.

xx1200001116

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove any equipment, if fitted, on or

close to the balancing device.
5
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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 4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
6 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1

xx1300000661

7 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.

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!

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4 Repair
4.6.3 Replacing the rear bearings on the balancing device
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

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 4 Repair
4.6.3 Replacing the rear bearings on the balancing device
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, -

150/3.20, -200/2.60, -155/2.85.
Apply the press tool and pull out the shaft
end with bearing, sealing and distance.
7 IRB 6700 -300/2.70, -245/3.00.
Apply the press tool and pull out the shaft
end with the groove ball bearing.

Refitting the bearing, cradle

Use these procedures to refit the bearing in the cradle.

Refitting the shaft end and rear bearings

Action Note
1 Wipe clean all contact surfaces from resid-
ual grease and other contamination inside
the recess.

Continues on next page

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4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
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
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 Part of tool Dismantle and mounting tool:
balancing device. 3HAC028920-001.

xx1700002296

The item number refers to marking on the

tool.
5 IRB 6700 -235/2.65, -205/2.80, -175/3.05, -
150/3.20, -200/2.60, -155/2.85.
Use caution and put sealing ring, radial
sealing, spacer and groove ball bearing
onto the shaft end manually.

xx1300000830

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 4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
6 IRB 6700 -300/2.70, -245/3.00
Use caution and put radial sealing and
groove ball bearing onto the shaft end
manually.

A B C D

xx1400001996

A Radial sealing with dustlip(2 pcs)

B Retaining ring bore (2 pcs)
C VK-cover (2 pcs)
D Groove ball bearing (2 pcs)

7 Put the shaft end with the fitted parts, on

the threaded bar.
8 Manually press the shaft end into the cradle
a little.

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4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
9 Apply the press tool, hydraulic pump and Hydraulic pump 80 MPa, 3HAC13086-1.
nut on the threaded bar. Do not press yet! Hydraulic cylinder, 3HAC11731-1.
K
4

xx1700000406

The item numbers refer to markings on the

tools.
10 Put a big screwdriver between the cradle
and balancing device and use it as a dis-
tance tool.

xx1300000838

11 Use caution and press the shaft end in po-

sition.
12 Remove the press tool and the threaded
bar.
13 Fit the retaining ring bore.

xx1700000343

14 Apply locking liquid on the attachment Loctite 243, 3HAB7116-1

screw.

Continues on next page

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 4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
15 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

16 Fit a VK cover to protect the bearing.

Remove the lifting accessories

Action Note
1 Remove the lifting accessories.

Concluding procedure

Action Note
1 Refit the retaining ring bore.

xx1300000664

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4 Repair
4.6.3 Replacing the rear bearings on the balancing device
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.

Continues on next page

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 4 Repair
4.6.3 Replacing the rear bearings on the balancing device
Continued

Action Note
7 Apply flange sealant and refit the cover Screws: M10 quality 12.9.
plate on the back of the balancing device. Tightening torque: 50 Nm.
Flange sealant for conical fittings: Loctite
577.

xx1300000554

8
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

Product manual - IRB 6700 491

3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.6.4 Unloading the balancing device

4.6.4 Unloading the balancing device

Prerequisite
This section describes how to unload the balancing device using the Hydraulic
press tool, balancing device: 3HAC020902-001.

DANGER

If the balancing device is fitted on the robot during the procedure, remember to:
• jog axis-2 to calibration position
• lock axis-2 with a M16 lock screw. How to secure the lower arm is described
in the current repair activity, for example removal of the balancing device.

DANGER

There is a high tensioned spring inside the balancing device, incorrect handling
may cause injuries and damage property.

Continues on next page

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 4 Repair
4.6.4 Unloading the balancing device
Continued

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.
The press tool includes two press devices that are used to different models of the
balancing device.

xx0200000174

A Press block
B Hydraulic cylinder
C Press device
D Bolt, press device
E Moving pin with marking
F Bolt (4 pcs)
G Pin, attached to the fix plate

Required equipment

Equipment, etc. Article number Note

Hydraulic press tool, balan- 3HAC020902-001 Used to unload or restore a balancing
cing device device.
Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.

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4 Repair
4.6.4 Unloading the balancing device
Continued

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Unloading the balancing device

The procedure below details how to use the press tool in order to unload the
balancing device. How to remove the press tool, is detailed in section Restoring
the balancing device on page 496.

Action Note
1 Fit the moving pin to the correct press device. Press device: 3HAC12800-1

xx0300000599

The moving pin is shown in the figure

Press tool and hydraulic cylinder on
page 493.
2 Fit the correct press device and moving pin The bolt is shown in the figure Press
to the press tool. Secure with the bolt, press tool and hydraulic cylinder on page 493.
device.

Note

Make sure the bolt is secured properly!

3 Remove the rear cover of the balancing

device, by unscrewing the attachment screws.

DANGER

DO NOT! remove any other screws then the

rear cover attachment screws.

xx1300000554

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 4 Repair
4.6.4 Unloading the balancing device
Continued

Action Note
4 Fit the press tool to the rear of the balancing Hydraulic press tool, balancing device:
device with enclosed bolts. Tighten them with 3HAC020902-001.
45 Nm!
5 Fit the hydraulic cylinder to the press tool.
6 Connect the hydraulic pump to the cylinder.
7 Increase the pressure and press until the
marking on the moving pin indicates the cor-
rect position (in level with the pressure block).
8 Turn the fix plate to position "Closed" in order
to lock the tool in loaded condition.

xx0200000174

A Press block
B Hydraulic cylinder
C Press device
D Bolt, press device
E Moving pin with marking
F Bolt (4 pcs)
G Pin, attached to the fix plate
Hydraulic cylinder: 3HAC11731-1.
Hydraulic pump 80 MPa: 3HAC13086-1.
Do not apply more pressure than neces-
sary, it could damage bearings and
sealings at the shaft.
9 Unload the hydraulic cylinder.
10 The hydraulic cylinder may now be removed
from the tool, when necessary.

CAUTION

Do not remove the press tool!

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4 Repair
4.6.5 Restoring the balancing device

4.6.5 Restoring the balancing device

Overview
This section details how to restore the balancing device and how to remove the
press tool from the device.

DANGER

There is a high tensioned spring inside the balancing device, incorrect handling
may cause injuries and damage property.

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.
The press tool includes two press devices that are used to different models of the
balancing device.

xx0200000174

A Press block
B Hydraulic cylinder
C Press device
D Bolt, press device
E Moving pin with marking

Continues on next page

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 4 Repair
4.6.5 Restoring the balancing device
Continued

F Bolt (4 pcs)
G Pin, attached to the fix plate

Required equipment

Equipment, etc. Article number Note

Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Consumables

Equipment, etc. Art. no. Note

Flange sealant for conical - Loctite 577
fittings Used to secure the attachment screws
of the rear cover at the end of the bal-
ancing device.

Restoring the balancing device

The procedure below details how to restore the balancing device, that is removing
the press tool.
Action Note
1 Refit the hydraulic cylinder to the press
tool, in case it has been removed.
2 Press with the cylinder and the hydraulic
pump until the fix plate is movable again.
Turn the pin on the fix plate to position
"Open".

CAUTION

Do not apply more pressure than neces-

sary, it could damage bearings and seal-
ings at the shaft.

3 Unload the hydraulic cylinder and make xx0200000174

sure the moving pin indicates that the tool
has returned to its starting position.
A Press block
4 Remove the hydraulic cylinder.
B Hydraulic cylinder
5 Remove the press tool by unscrewing the
C Press device
bolts.
D Bolt, press device
E Moving pin with marking
F Bolt (4 pcs)
G Pin, attached to the fix plate

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4 Repair
4.6.5 Restoring the balancing device
Continued

Action Note
6 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
577.

xx1300000554

7
DANGER

The rear cover of the balancing device is

a safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the ro-
bot!

498 Product manual - IRB 6700

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 4 Repair
4.6.6 Replacing the stop pin

4.6.6 Replacing the stop pin

Location of the stop pin

The stop pin is located as shown in the figure.

xx1300000475

Spare part

Equipment Article number Note

Stop pin See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Required consumables

Consumable Article number Note

Locking liquid 3HAB7116-1 Loctite 243
Foundry plus: 3HAC034903-001 Mercasol 3110 Waxcoat. Recom-
Rust preventive mended drying time is 24h.

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4 Repair
4.6.6 Replacing the stop pin
Continued

Removing the stop pin

Action Note
1 IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
Jog the robot to this position:
• axis 1 = -5°

xx1300000479

2 IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,

IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Note

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Hold the mechanical stop pin in a firm grip,

use caution and remove it by unscrewing
the set screw, cup point.

CAUTION

The mechanical stop weighs 5 kg and may

unexpectedly fall down when the set screw
is removed.

xx1300000476

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 4 Repair
4.6.6 Replacing the stop pin
Continued

Action Note
5 Remove the stop pin.

xx1300000477

Refitting the stop pin

Action Note
1 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply Mercasol on the surfaces shown in casol 3110 Waxcoat. Recommended drying
the figure, on stop pin and in the hole as time is 24h.).
shown in the figure.

xx1400000378

2 Fit the stop pin.

xx1300000477

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4 Repair
4.6.6 Replacing the stop pin
Continued

Action Note
3 Apply locking liquid on the set screw, and Loctite 243
secure the stop pin. Set screw: M10x20

xx1300000476

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 4 Repair
4.7.1 Replacing the axis-1 motor

4.7 Motors

4.7.1 Replacing the axis-1 motor

Location of the axis-1 motor

The motor is located as shown in the figure.

xx1200001064

Summary of the replacement procedure

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

Spare part Spare part number Note

Axis-1 motor See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

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4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Consumables

Equipment, etc. Article number Note

Grease 3HAB3537-1 Used to lubricate o-rings, Shell Gadus
S2V220 AC.
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.
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Required tools and equipment

Equipment, etc. Article number Note

Lifting accessory, motor 3HAC14459-1
Roundsling, 1 m - Length: 1 m, lifting capacity: 1,000 kg.
Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
Guide pin, M10x150 3HAC15521-2 Always use guide pins in pairs.
Bits extender 3HAC12342-1 300 mm, bits 1/2"
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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 4 Repair
4.7.1 Replacing the axis-1 motor
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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the axis-1 motor

These procedures describe how to remove the motor.

Preparations before removing the axis-1 motor

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog the robot to the synchronization posi-
tion.
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

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4 Repair
4.7.1 Replacing the axis-1 motor
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

Disconnecting the motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

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 4 Repair
4.7.1 Replacing the axis-1 motor
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

4 Disconnect the motor cables.

xx1200001066

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4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-1 motor

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Attach the lifting accessories. Lifting accessory (chain): 3HAC15556-1

Lifting accessory, motor: 3HAC14459-1.
3 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
Connect to R2.MP1-connector:
• + = pin 2
• - = pin 5
4
CAUTION

The weight of the motor is 25 kg

All lifting accessories used must be sized
accordingly.

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 4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
5 Unscrew the attachment screws and Bits extender: 3HAC12342-1
washers.
Use a bits extender to reach the screws.

xx1200001071

6 Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2

Always use guide pins in pairs.
7
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

8 If needed, use removal tools to help re- Removal tool M12: 3HAC057339-003
move the motor. Removal tool M14: 3HAC057339-004
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
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

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4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
10 Disconnect the 24 VDC power supply.

Refitting the axis-1 motor

These procedures describes how to refit the motor.

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

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

Continues on next page

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 4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
5 If the motor is a new spare part, remove the cover.

xx1200001135

6 Foundry Plus: Tightening torque, transparent

Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-1 motor

Action Note
1 Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2
Always use guide pins in pairs.
2
CAUTION

The motor weighs 25 kg.

All lifting accessories used must be sized
accordingly.

3 Apply the lifting accessory. Lifting accessory, motor: 3HAC14459-1.

4 Fit the rotation tool. Rotation tool: 3HAB7887-1

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4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
5 Connect the 24 VDC power supply to re-
lease the brakes.
To release the brakes, connect the 24 VDC
power supply as described in the list.
Connect to R2.MP1-connector:
• + = pin 2
• - = pin 5
6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
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

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

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 4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
9 Perform a leak-down test (if not already See Performing a leak-down test on
done). page 198.
10 Disconnect the 24 VDC power supply.

Connecting the motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

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

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4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
4 Inspect the o-ring. O-ring, axis-1: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
Note file)
O-ring, axis-2: 3HAB3772-111 (circular
Replace if damaged. profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

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 4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
8 Refit the motor cover with its 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.

Concluding procedure
Use this procedure for the concluding refitting.
Action Note
1 Foundry Plus:
Refit the protection plates with three
M10x30 and two M5x12 attachment screws.

Note

Make sure that the axis-1 and axis-2 motor

cables are run through the hole in the pro-
tection plates correctly.

xx1400000723

2 Foundry Plus:
Secure the axis-1 and axis-2 motor cables
with a cable tie.

xx1400000722

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4 Repair
4.7.1 Replacing the axis-1 motor
Continued

Action Note
3 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
4
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

516 Product manual - IRB 6700

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 4 Repair
4.7.2 Replacing the axis-2 motor

4.7.2 Replacing the axis-2 motor

Location of the motor

The motor is located as shown in the figure.

xx1200001112

Summary of the replacement procedure

This list is a brief summary of the replacement procedure, containing the major
actions to be performed.
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

Spare part Spare part number Note

Axis-2 motor See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Continues on next page

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4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Consumables

Equipment, etc. Article number Note

Grease 3HAB3537-1 Shell Gadus S2V220 AC
Used to lubricate o-rings.
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
Used on motor flange.
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Required tools and equipment

Equipment, etc. Article number Note

Lifting accessory, motor 3HAC15534-1 Lifting instruction 3HAC15640-2 en-
closed.
Roundsling, 1 m - Length: 1 m, lifting capacity: 1,000 kg.
Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
Guide pin, M10x150 3HAC15521-2 Always use guide pins in pairs.
Bits extender 3HAC12342-1 300 mm, bits 1/2"
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Lock screw, M16x120 - Used to secure lower arm.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

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 4 Repair
4.7.2 Replacing the axis-2 motor
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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the motor

These procedures describes how to remove the motor.

Preparations before removing the axis-2 motor

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Drain the oil from the gearbox. See Draining the axis-2 gearbox on
page 166.
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.

Continues on next page

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4 Repair
4.7.2 Replacing the axis-2 motor
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.
The lock screw is used to secure the weight
of the lower arm, in order to avoid acci-
dents or damage.

Note

Tighten the lock screw manually, no tools

needed.

xx1200001116

6
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

7 Remove any equipment hindering access

to the motor.

Disconnecting the motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Unscrew the attachment screws and

washers and remove the motor cover.

xx1200001135

Continues on next page

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 4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Action Note
3 Make sure the o-ring is present.

xx1200001070

4 Disconnect the motor cables.

xx1200001066

5 Remove the cable gland cover.

Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-2 motor

Action Note
1 Before removing the motor, make sure that
the axis-2 gearbox is completely drained.

Continues on next page

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4 Repair
4.7.2 Replacing the axis-2 motor
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

5 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2

Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the motor slide better.

6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

7 If required, press the motor out of its posi- Removal tool M12: 3HAC057339-003
tion by using the removal tool in opposite Removal tool M14: 3HAC057339-004
holes of the motor.
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
8 Disconnect the 24 VDC power supply.
9
CAUTION

The motor weighs 28 kg.

All lifting accessories used must be sized
accordingly.

Continues on next page

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 4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Action Note
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

These procedures describes how to refit the motor.

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

xx1200001019

Continues on next page

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4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Action Note
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

5 If the motor is a new spare part, remove the cover.

xx1200001135

6 Foundry Plus: Tightening torque, transparent

Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-2 motor

Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.

Continues on next page

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 4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Action Note
2
CAUTION

The motor weighs 28 kg.

All lifting accessories used must be sized
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.
7 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
8 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP2, axis-2 mo-
tor:
• + = pin 2
• - = pin 5
9
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
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.
• Make sure that the motor pinion
does not get damaged.
• Make sure that the direction of the
cable exit is facing the correct way.
11 Fit two of the attachment screws and Screws: M10x30 Steel 12.9 Gle
washers. 603+Geo500

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4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Action Note
12 Remove the guide pins and replace with
the remaining attachment screws.
13 Secure the motor with its attachment Bits extender: 3HAC12342-1
screws and washers. Tightening torque: 50 Nm.
Use a bits extender in order to reach the Screw dimension: M10x30 Steel 12.9 Gle
screws. 603+Geo500 (4 pcs)

xx1200001117

14 Perform a leak-down test. See Performing a leak-down test on

page 198.

Connecting the motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

2 Refit the cable gland cover.

Note

Replace the gasket if damaged.

xx1200001067

Continues on next page

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 4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Action Note
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

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4 Repair
4.7.2 Replacing the axis-2 motor
Continued

Action Note
8 Refit the motor cover with its 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.

Concluding procedure

Action Note
1 Use caution and jog axis-2 a little to facilit-
ate the removal of the lock screw.
2 Remove the lock screw securing the lower Lock screw, M16x120
arm.

xx1200001115

Continues on next page

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 4 Repair
4.7.2 Replacing the axis-2 motor
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 167.
5 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
6
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in the section First
test run may cause injury or damage on
page 26.

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4 Repair
4.7.3 Replacing the axis-3 motor

4.7.3 Replacing the axis-3 motor

Location of the axis-3 motor

The axis-3 motor is located as shown in the figure.

xx1200001113

Spare part

Spare part Spare part number Note

Axis-3 motor See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Consumables

Equipment, etc. Article number Note

Grease 3HAB3537-1 Shell Gadus S2V220 AC
Used to lubricate o-rings.
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
Used on motor flange.
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Continues on next page

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 4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Required tools and equipment

Equipment, etc. Article number Note

Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Lifting accessory, motor 3HAC15534-1 Lifting instruction 3HAC15640-2 en-
closed.
Roundsling, 1 m - Length: 1 m, lifting capacity: 1,000 kg.
Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
Guide pin, M10x150 3HAC15521-2 Always use guide pins in pairs.
Bits extender 3HAC12342-1 300 mm, bits 1/2"
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.

Continues on next page

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4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the motor

These procedures describes how to remove the motor.

Preparations before removing the axis-3 motor

Use this procedure to do the necessary preparations before removing the motor.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Drain the axis-3 gearbox. See Draining the axis-3 gearbox on
page 171.
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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

5 Remove any equipment hindering access

to the motor.

Disconnecting the motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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 4 Repair
4.7.3 Replacing the axis-3 motor
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

4 Disconnect the motor cables.

xx1200001066

Continues on next page

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4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-3 motor

Action Note
1 Before removing the motor, make sure that
the axis-3 gearbox is completely drained.
2
DANGER

When releasing the holding brakes of the

motor, the upper arm will be movable and
may fall down if not secured. Verify that
the upper arm is secured as previously
described, before continuing.

3 To release the brakes, connect the 24 VDC

power supply.
Connect to connector R2.MP3:
• + = pin 2
• - = pin 5
4 Unscrew the attachment screws that hold Bits extender: 3HAC12342-1
the motor.
Use a bits extender to reach the screws.

xx1200001126

Continues on next page

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 4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
5 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the motor slide better.

6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

7 If required, press the motor out of position Removal tool M12: 3HAC057339-003
by using the removal tool in the remaining Removal tool M14: 3HAC057339-004
holes for the motor.
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
8 Use caution and lift the motor out on the
guide pins, in order to get the pinion away
from the gear, and let the motor rest on
the guide pins.
9
CAUTION

The motor weighs 26 kg.

All lifting accessories used must be sized
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.

12 Disconnect the 24 VDC power supply.

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4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
13 Remove the motor by lifting it straight out. Make sure the pinion is not damaged.

xx1200001131

Refitting the motor

These procedures describes how to refit the motor.

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

xx1200001019

Continues on next page

536 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
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

5 If the motor is a new spare part, remove the cover.

xx1200001135

6 Foundry Plus: Tightening torque, transparent

Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-3 motor

Use this procedure to secure the motor.
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.

Continues on next page

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4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
2
CAUTION

The motor weighs 26 kg.

All lifting accessories used must be sized
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

5 Remove the lifting accessory and allow the

motor to rest on the guide pins.
6 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
7 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP3:
• + = pin 2
• - = pin 5

Continues on next page

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 4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
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.
15 Perform a leak-down test. See Performing a leak-down test on
page 198.
16 Disconnect the 24 VDC power supply.

Connecting the motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

Continues on next page

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4 Repair
4.7.3 Replacing the axis-3 motor
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

Continues on next page

540 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.3 Replacing the axis-3 motor
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 its 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.

Concluding procedure
Use this procedure for the concluding refitting.
Action Note
1 Remove the equipment used to unload the
upper arm.
2 Refill the gearbox with oil. See Filling oil into the axis-3 gearbox on
page 173.
3 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.

Continues on next page

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3HAC044266-001 Revision: N
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4 Repair
4.7.3 Replacing the axis-3 motor
Continued

Action Note
4
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

542 Product manual - IRB 6700

3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.4 Replacing the axis-4 motor

4.7.4 Replacing the axis-4 motor

Location of the axis-4 motor

The axis-4 motor is located as shown in the figure.

xx1200001114

Spare parts

Spare part Spare part number Note

Axis-4 motor See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Consumables

Equipment, etc. Article number Note

Grease 3HAB3537-1 Shell Gadus S2V220 AC
Used to lubricate o-rings.
O-ring i 3HAB3772-110 (circular pro- D=119x3
file) / 3HAC054692-001 Used on motor cover.
(hexagon profile)
O-ring 3HAB3772-107 D=102x3
Used on motor flange.
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Continues on next page

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4 Repair
4.7.4 Replacing the axis-4 motor
Continued

Required tools and equipment

Equipment, etc. Article number Note

Removal tool M12 3HAC057339-003 Used to push out the motor, if neces-
sary.
Always use removal tools in pairs.
Guide pin, M8x150 3HAC15520-2 Always use guide pins in pairs.
Long AllenKeySocketIN19L - Length: 140 mm.
6-140
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Continues on next page

544 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.4 Replacing the axis-4 motor
Continued

Removing the motor

These procedures describes how to remove the motor.

Preparations before removing the axis-4 motor

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog the robot into position:
• axis 1 = no significance.
• axis 2 = -65°
• axis 3 = upper arm pointing straight
up (if possible).
With the robot in this position, there is no
need to drain oil from the axis-4 gearbox
when the motor is replaced.
3 If there is no space to position the upper
arm pointed straight up, drain the axis-4
gearbox.
4
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Disconnecting the motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.7.4 Replacing the axis-4 motor
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

4 Disconnect the motor cables.

xx1200001066

Continues on next page

546 Product manual - IRB 6700
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 4 Repair
4.7.4 Replacing the axis-4 motor
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-4 motor

Action Note
1
CAUTION

Use caution when releasing the brakes!

Axis-4 can move unexpectedly!

2 To release the brakes, connect the 24 VDC

power supply.
Connect to connector R2.MP4:
• + = pin 2
• - = pin 5
3 Unscrew the attachment screws that secure
the motor.

xx1200001137

4 Apply two guide pins in opposite holes. Guide pin, M8x150: 3HAC15520-2
Always use guide pins in pairs.
5
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

6 Press the motor out of position by fitting Removal tool M12: 3HAC057339-003
the removal tool in the remaining attach- Always use removal tools in pairs.
ment holes for the motor.

Continues on next page

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4 Repair
4.7.4 Replacing the axis-4 motor
Continued

Action Note
7
CAUTION

The motor weighs 13 kg.

All lifting accessories used must be sized
accordingly.

8 Disconnect the 24 VDC power supply.

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

Refitting the motor

These procedures describes how to refit the motor.

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

xx1200001019

Continues on next page

548 Product manual - IRB 6700
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 4 Repair
4.7.4 Replacing the axis-4 motor
Continued

Action Note
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

5 If the motor is a new spare part, remove the cover.

xx1200001135

6 Foundry Plus: Tightening torque, transparent

Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-4 motor

Action Note
1 Apply two guide pins in opposite holes. Guide pin, M8x150: 3HAC15520-2
Always use guide pins in pairs.

Continues on next page

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4 Repair
4.7.4 Replacing the axis-4 motor
Continued

Action Note
2 Put the motor onto the guide pins.

xx1700000291

3
Note

Make sure the cable gland opening is

turned the correct way.

xx1200001130

4
CAUTION

The motor weighs 13 kg.

All lifting accessories used must be sized
accordingly.

5 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
This requires two persons co-operating, if
the motor is installed from above (if the
upper arm is pointing upwards).
6 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP2:
• + = pin 2
• - = pin 5

Continues on next page

550 Product manual - IRB 6700
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 4 Repair
4.7.4 Replacing the axis-4 motor
Continued

Action Note
7
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

8 Push the motor carefully in position 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.
• Make sure that the motor pinion
does not get damaged.
• Make sure that the direction of the
cable gland is facing the correct
way.
9 Remove the guide pins.
10 Secure the motor with its attachment Tightening torque: 35 Nm.
screws and washers. Screws: M8x30 quality 12.9 Gleitmo (4 pcs)

xx1200001137

11 Perform a leak-down test. See Performing a leak-down test on

page 198.
12 Disconnect the 24 VDC power supply.

Connecting the motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

Continues on next page

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4 Repair
4.7.4 Replacing the axis-4 motor
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

Continues on next page

552 Product manual - IRB 6700
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 4 Repair
4.7.4 Replacing the axis-4 motor
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 its 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.

Concluding procedure

Action Note
1 Refill the gearbox with oil, if gearbox has See Filling oil into the axis-4 gearbox on
been drained. page 178.
2 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
3
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

Product manual - IRB 6700 553

3HAC044266-001 Revision: N
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4 Repair
4.7.5 Replacing the axis-5 motor

4.7.5 Replacing the axis-5 motor

Location of the axis-5 motor

The axis-5 motor is located inside the wrist, as shown in the figure.

xx1500001899

Spare part

Spare part Spare part number Note

Axis-5 motor See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790
Heat protection plate See Product manual, spare Required, if replacing a type
parts - IRB 6700/IRB 6700Inv. A motor with a type B motor.
Product manual, spare 2 plates required.
parts - IRB 6790 See Type A vs type B motors
on page 819.

Consumables

Equipment, etc. Article number Note

Grease 3HAB3537-1 Shell Gadus S2V220 AC
Used to lubricate o-rings.
O-ring i 3HAB3772-110 (circular pro- D=119x3
file) / 3HAC054692-001 Used on motor cover.
(hexagon profile)
O-ring 3HAB3772-107 D=102x3
Used on motor flange.
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Required tools

Equipment, etc. Article number Note

Removal tool M12 3HAC057339-003 Used to push out the motor, if neces-
sary.
Always use removal tools in pairs.

Continues on next page

554 Product manual - IRB 6700
3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Equipment, etc. Article number Note

Long AllenKeySocketIN19L - Length: 140 mm.
6-140
Guide pin, M8x100 3HAC15520-1 Always use guide pins in pairs.
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Continues on next page

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© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Removing the axis-5 motor

Use these procedures to remove the motor.

Preparations before removing the axis-5 motor

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 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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

556 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.5 Replacing the axis-5 motor
Continued

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 Remove the wrist cover.

xx1300002247

Continues on next page

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4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Action Note
5 Remove the heat protection plate/plates There are two versions of the heat protec-
from the motor with the cabling still at- tion plates.
tached to the plate. Choose figure depending on which plate
Remove the heat protection plates from the is installed on the robot.
motor with the cabling still attached to the
plate.

xx1500001030

xx1300000490

Continues on next page

558 Product manual - IRB 6700
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 4 Repair
4.7.5 Replacing the axis-5 motor
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 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.7.5 Replacing the axis-5 motor
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

4 Disconnect the motor cables.

xx1200001066

Continues on next page

560 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.5 Replacing the axis-5 motor
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.

Removing the axis-5 motor

Action Note
1 Unscrew the attachment screws that secure Bits extender: 3HAC12342-1
the motor, using a bits extender.

xx1200001017

2
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

3 If needed, fit removal tools in opposite Removal tool M12: 3HAC057339-003

holes. Always use removal tools in pairs.

Continues on next page

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4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Action Note
4
CAUTION

The motor weighs 12 kg.

All lifting accessories used must be sized
accordingly.

5 Use caution and lift the motor out. Be

careful not to damage the pinion.

xx1200001018

Refitting the axis-5 motor

The procedures describe how to refit the motor.

Preparations before refitting the axis-5 motor

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

562 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.7.5 Replacing the axis-5 motor
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

6 Apply two guide pins in opposite holes. Guide pin, M8x100: 3HAC15520-1

Securing the axis-5 motor

Action Note
1
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

Continues on next page

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3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Action Note
2 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
3 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
Connect to connector R2.MP5:
• + = pin 2
• - = pin 5
4
CAUTION

The motor weighs 12 kg.

All lifting accessories used must be sized
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

6 Remove the guide pins.

Continues on next page

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 4 Repair
4.7.5 Replacing the axis-5 motor
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

8 Perform a leak-down test. See Performing a leak-down test on

page 198.
9 Disconnect the 24 VDC power supply.

Connecting the motor cables

Action Note
1 Push the motor cables in through the cable
gland opening.

xx1300000738

Continues on next page

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4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Action Note
2 Refit the cable gland cover by performing
the following steps:
• Slide the cable gland cover onto the
inner screw.
• Refit and tighten the outer screw.
• Tighten the inner screw. Make sure
that the gasket is not damaged.

Note

Replace the gasket if damaged.

xx1200001016

3 Connect the connectors.

Connect in accordance with the markings
on the connectors.

xx1200001015

4 Make sure the o-ring on the motor is undam- O-ring, axis 5: 3HAB3772-110 (circular
aged. profile) / 3HAC054692-001 (hexagon pro-
Replace if damaged. file).

xx1200001021

5
CAUTION

When fitting the motor cover, make sure

that none of the cables inside will be dam-
aged.

Continues on next page

566 Product manual - IRB 6700
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 4 Repair
4.7.5 Replacing the axis-5 motor
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

Do not reuse the self-threading attachment

screws, it will damage the threads. Replace
with standard attachment screws.

Note

Make sure the o-ring is undamaged and 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 819.

xx1500001029

xx1300000489

Continues on next page

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4 Repair
4.7.5 Replacing the axis-5 motor
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

Continues on next page

568 Product manual - IRB 6700
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 4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Concluding procedure

Action Note
1 Make sure that the cable harness is placed There are two versions of the heat protec-
in a way that it will not be damaged when tion plates.
the wrist cover is fitted. Choose figure depending on which plate
is installed on the robot.

xx1500001672

xx1300000596

Cable layout in the wrist with Type A mo-

tors.
2 Inspect the gasket. Replace if damaged.
Foundry Plus and Foundry Prime:
• Make sure that the gasket is undam-
aged on the cover. Replace if dam-
aged.
• Put washers in the holes of the gas-
ket.
• Use attachment screws made of
stainless steel to fit the wrist cover.

xx1400000383

A Protection plugs (2 on wrist cover

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

Continues on next page

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4 Repair
4.7.5 Replacing the axis-5 motor
Continued

Action Note
3 Refit the wrist cover. In order not to dam- Tightening torque: 10 Nm
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
screws. xx1300000772

4 Foundry Plus:
Refit protection plugs.
5 If used, refit the DressPack cable package
on the wrist.
6 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
7
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

570 Product manual - IRB 6700

3HAC044266-001 Revision: N
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 4 Repair
4.7.6 Replacing the axis-6 motor

4.7.6 Replacing the axis-6 motor

Location of axis-6 motor

The axis-6 motor is located as shown in the figure.

xx1200001080

Spare part

Spare part Spare part number Note

Axis-6 motor See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Consumables

Equipment, etc. Article number Note

Grease 3HAB3537-1 Shell Gadus S2V220 AC
Used to lubricate o-rings.
Gasket i 3HAC033489-001/ Used on motor cover.
3HAC044252-001
O-ring 3HAB3772-107 D=102x3
Used on motor flange.
i Information about which of the two types of gasket to choose is found in Product manual, spare
parts - IRB 6700/IRB 6700Inv.

Continues on next page

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4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Required tools and equipment

Equipment, etc. Article number Note

Removal tool M12 3HAC057339-003 Used to push out the motor, if neces-
sary.
Always use removal tools in pairs.
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Continues on next page

572 Product manual - IRB 6700
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 4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Removing the axis-6 motor

Use these procedures to remove the motor.

Preparations before removing the axis-6 motor

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog the robot to a position where axis 5
can be positioned with the motor pointing
straight up at an acceptable working posi-
tion.
With axis 5 in this position it is possible to
replace the motor without draining the oil
from the axis-6 gearbox.

xx1200001081

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove the wrist cover.

xx1300002247

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4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Disconnecting the 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 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

Continues on next page

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 4 Repair
4.7.6 Replacing the axis-6 motor
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

Removing the axis-6 motor

Action Note
1 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
Connect to R2.MP6-connector:
• + = pin 2
• - = pin 5

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4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Action Note
2 Unscrew the motor attachment screws.

xx1200001090

3
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

4 If required, press the motor out of position Removal tool M12: 3HAC057339-003
by fitting the removal tool, motor to the at- Always use removal tools in pairs.
tachment holes of the motor.
5
CAUTION

The motor weighs 9 kg.

All lifting accessories used must be sized
accordingly.

Continues on next page

576 Product manual - IRB 6700
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 4 Repair
4.7.6 Replacing the axis-6 motor
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

7 Disconnect the 24 VDC power supply.

Refitting the axis-6 motor

Use this procedure to refit the motor.

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

Continues on next page

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4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Action Note
2 Remove any old paint residues or other contam-
ination from the contact surfaces on both the
motor and the mating parts.
Wipe clean the contact surfaces and the o-ring
groove.
3 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

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

5 If the motor is a new spare part, remove the cover.

xx1200001135

Continues on next page

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 4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Action Note
6 Foundry Plus: Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-6 motor

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 To release the brakes, connect the 24 VDC

power supply.
Connect to connector R2.MP6:
• + = pin 2
• - = pin 5
3
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

Continues on next page

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4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Action Note
4 Check the gasket.
Replace if damaged.

xx1200001094

5
CAUTION

The motor weighs 9 kg.

All lifting accessories used must be sized
accordingly.

Continues on next page

580 Product manual - IRB 6700
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 4 Repair
4.7.6 Replacing the axis-6 motor
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

Continues on next page

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4 Repair
4.7.6 Replacing the axis-6 motor
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

The screw is located at the bottom of the

carrier.

xx1300000485

10 Refit the cable bracket.

xx1300000484

11 Perform a leak-down test. See Performing a leak-down test on

page 198.
12 Disconnect the 24 V DC power supply.

Continues on next page

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 4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Action Note
13 Reconnect the connectors.

xx1200001084

14 Check the gasket. Gasket: 3HAC033489-001/ 3HAC044252-

Replace if damaged. 001
Information about which of the two types
of gasket to choose is found in Product
manual, spare parts - IRB 6700/IRB
6700Inv.

xx1200001095

15 Refit the motor cover.

xx1200001082

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4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Concluding procedure

Action Note
1 Make sure that the cable harness is placed There are two versions of the heat protec-
in a way that it will not be damaged when tion plates.
the wrist cover is fitted. Choose figure depending on which plate
is installed on the robot.

xx1500001672

xx1300000596

Cable layout in the wrist with Type A mo-

tors.
2 Inspect the gasket. Replace if damaged.
Foundry Plus and Foundry Prime:
• Make sure that the gasket is undam-
aged on the cover. Replace if dam-
aged.
• Put washers in the holes of the gas-
ket.
• Use attachment screws made of
stainless steel to fit the wrist cover.

xx1400000383

A Protection plugs (2 on wrist cover

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

Continues on next page

584 Product manual - IRB 6700
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 4 Repair
4.7.6 Replacing the axis-6 motor
Continued

Action Note
3 Refit the wrist cover. In order not to dam- Tightening torque: 10 Nm
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
screws. xx1300000772

4 Foundry Plus:
Refit protection plugs.
5 If used, refit the DressPack cable package
on the wrist.
6 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
7
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

Product manual - IRB 6700 585

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)

4.8 Gearboxes

4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB
6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)

Validity of this section

Note

This section describes how to replace the gearbox on variants IRB 6700 - 235/2.65,
IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60,
IRB 6700 - 155/2.85.
How to replace the gearbox on variants IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
see Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00) on
page 626.

Location of the axis-1 gearbox

The axis-1 gearbox is located as shown in the figure.

xx1200001183

Continues on next page

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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Summary of the replacement procedure

This list is a brief summary of the replacement procedure, containing the major
actions to be performed.
1 Drain the axis-1 gearbox.
2 Remove the cabling from the base.
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
parts - IRB 6700/IRB 6700Inv.

Consumables

Equipment, etc. Article number Note

Locking liquid 3HAB7116-1 Loctite 243
Flange sealant 12340011-116 Loctite 574
Grease 3HAB3537-1 Shell Gadus S2V220 AC
O-ring, nitrile rubber 3HAB3772-93 380.59x3.53
O-ring, nitrile rubber 3HAB3772-164 or
3HAC061327-002 (de-
pends on gearbox vari-
ant, see Product manual,
spare parts - IRB 6700)
O-ring i 3HAB3772-111 (circular 169.5x3 / 169.5x4.8x2.65
profile) / 3HAC054692-
002 (hexagon profile)
O-ring, nitrile rubber 3HAB3772-107 102x3
Cable straps -
Sealing ring -
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Equipment, etc. Article number Note

Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
Bits extender 3HAC12342-1 300 mm, bits 1/2"
Lifting eye 3HAC16131-1 M12
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.
Lifting eye 3HAC14457-4 M16
Lifting accessory, motor 3HAC14459-1
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
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.
24 VDC power supply - Used to release the motor brakes.
Guide for reduction gear 3HAC043870-009 Used to guide axis-1 gear and frame
during refitting.
Valid for IRB 6700 - 235/2.65, IRB 6700
- 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60,
IRB 6700 - 155/2.85.
Guide pin, M10x150 3HAC15521-2 Always use guide pins in pairs.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
Guide pin, M16x150 3HAC13120-2 Always use guide pins in pairs.
Guide pin, M16x200 3HAC13120-3 Always use guide pins in pairs.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Continues on next page

588 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the axis-1 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 159.

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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
pin.

xx1300000478

5
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

6 Hold the mechanical stop pin in a firm grip,

and remove it by unscrewing the set screw.

CAUTION

The mechanical stop pin weighs 5 kg and

may fall down when the set screw is removed.

xx1300000476

7 Unscrew the attachment screws that secure

the cable bracket.

xx1200001184

Continues on next page

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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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
Use this procedure to jog the robot into position.
Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
Action Note
1 Jog the robot into position:
• Axis 1: no significance as long as the robot
is secured to the foundation.
• Axis 2: -40°
• Axis 3: +65° (approximately)
• Axis 4: calibration position (0°)
• Axis 5. +90°
• Axis 6: calibration position (0°)

xx1200001132

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Attaching the lifting accessories

Use this procedure to attach the lifting accessories.

Continues on next page

592 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

2
CAUTION

The complete arm system weigh (according to

variants) 1100 kg.
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

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

Continues on next page

594 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

Disconnecting the axis-1 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 6700 595
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© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.

xx1200001135

3 Make sure the o-ring is present.

xx1200001070

4 Disconnect the motor cables.

xx1200001066

Continues on next page

596 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-1 motor

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Attach the lifting accessories. Lifting accessory (chain): 3HAC15556-1

Lifting accessory, motor: 3HAC14459-1.
3 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
Connect to R2.MP1-connector:
• + = pin 2
• - = pin 5
4
CAUTION

The weight of the motor is 25 kg

All lifting accessories used must be sized
accordingly.

Continues on next page

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© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
5 Unscrew the attachment screws and Bits extender: 3HAC12342-1
washers.
Use a bits extender to reach the screws.

xx1200001071

6 Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2

Always use guide pins in pairs.
7
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

8 If needed, use removal tools to help re- Removal tool M12: 3HAC057339-003
move the motor. Removal tool M14: 3HAC057339-004
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
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

Continues on next page

598 Product manual - IRB 6700
3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
10 Disconnect the 24 VDC power supply.

Preparations before removing the cable harness in the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
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

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

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.

Continues on next page

600 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
2 Pull out the robot cable harness through
the protection tube.

xx1300000732

3 Place the cable harness over the balancing

device.

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.
2 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins.

Tip

Lubricate the guide pins with some grease

to make the frame slide better.

xx1700001635

Guide pin, M16x200: 3HAC13120-3

xx1700001636

Always use guide pins in pairs.

Continues on next page
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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
3 Remove the remaining attachment screws,
that hold the frame to the axis-1 gearbox.
4
CAUTION

The complete arm system weighs: 1100

kg.
All lifting accessories used must be sized
accordingly.

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

Continues on next page

602 Product manual - IRB 6700
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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
2 Fit two guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2
Guide pin, M12x200: 3HAC13056-4
Tip

Lubricate the guide pins with some grease

to make the gearbox slide better.

xx1700001653

Always use guide pins in pairs.

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, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
140 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

Continues on next page

604 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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
Guide pin, M12x200: 3HAC13056-4
Tip Always use guide pins in pairs.

Lubricate the guide pins with some grease

to make the gearbox slide better.

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.

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

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.

xx1700002190

2 Attach the lifting accessory (chain). Lifting accessory (chain): 3HAC15556-1

xx1700002191

3
CAUTION

The weight of the gearbox is

92 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
140 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

606 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
4 Wipe clean the contact surfaces from any
contamination.
Also wipe clean the o-ring groove.

xx1200001245

5 Wipe clean and put some grease on a new O-ring, nitrile rubber: 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

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

3 Remove the guide pins.

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)

Continues on next page

608 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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.
2 Wipe clean the contact surfaces from any
remaining contamination.
3 Apply flange sealant on the contact surface Flange sealant: 12340011-116 (Loctite 574)
of the gearbox.

xx1700002198

Continues on next page

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© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
4 Wipe clean the o-ring groove in the gearbox O-ring, nitrile rubber: 3HAB3772-164 or
and the new o-ring. 3HAC061327-002 (depends on gearbox
variant, see Product manual, spare parts -
5 Lubricate the new o-ring with grease and IRB 6700).
fit it to the gearbox.
Grease: 3HAB3537-1.

xx1700001658

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

Lubricate the guide pins with some grease

to make the frame slide better.

xx1300000823

Guide pin, M16x150: 3HAC13120-2

xx1300000822

Always use guide pins in pairs.

Continues on next page

610 Product manual - IRB 6700
3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
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

Refitting the arm system

Action Note
1
CAUTION

The arm system weighs 1100 kg.

All lifting accessories used must be sized
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 592.
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.
6 Wipe clean the contact surfaces from any
remaining contamination.
Also wipe clean the o-ring groove.

Continues on next page

Product manual - IRB 6700 611
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© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
7 Apply grease on the o-ring groove in the
frame.

xx1500001955

8 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

Continues on next page

612 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
9 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

10 Lower the arm system to align the other Position of Guide pin, M16x150:
guide pin into the hole.

xx1300000822

Continues on next page

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© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
11 Visually verify through the axis-1 motor
hole that the hole is aligned with the pinion
hole in the gearbox.

xx1700002040

xx1700002041

B
12 Fit the aligning tool according to figure. A

xx1300001118

A Aligning tool
B Attachment screws (2 pcs)
C Correct fitting of the aligning tool.
Tightening torque: 50 Nm.

Continues on next page

614 Product manual - IRB 6700
3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
13 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.

14 When the arm system is almost in position, This is done to be sure that all screws will
fit the accessible attachment screws enter the gears correctly.
manually (no tools). Attachment screws: M16x110 (16 pcs)
15 Use caution and lower the complete arm
system into position on top of the gearbox.
16 Secure the complete arm system to the Tightening torque: 300 Nm.
axis-1 gearbox with its attachment screws.
17 Remove the two guide pins and replace Tightening torque: 300 Nm.
with attachment screws.
Tighten the remaining, accessible attach-
ment screws.
18 Perform a leak-down test. See Performing a leak-down test on
page 198.
19 Remove the aligning tool, after the leak-
down test is completed successfully.
20 Remove the lifting accessories.

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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.

Continues on next page

Product manual - IRB 6700 615
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© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
3 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

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

5 If the motor is a new spare part, remove the cover.

xx1200001135

Continues on next page

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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
6 Foundry Plus: Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-1 motor

Action Note
1 Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2
Always use guide pins in pairs.
2
CAUTION

The motor weighs 25 kg.

All lifting accessories used must be sized
accordingly.

3 Apply the lifting accessory. Lifting accessory, motor: 3HAC14459-1.

4 Fit the rotation tool. Rotation tool: 3HAB7887-1
5 Connect the 24 VDC power supply to re-
lease the brakes.
To release the brakes, connect the 24 VDC
power supply as described in the list.
Connect to R2.MP1-connector:
• + = pin 2
• - = pin 5
6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
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

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 198.
10 Disconnect the 24 VDC power supply.

Continues on next page

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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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 • 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

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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
the protection tube in the base.
Make sure that the hoses are running cor-
rectly and are not twisted!
8 If used, fit the bracket that hold the
DressPack to the frame.

xx1400000078

9 If used, connect the DressPack cable

package on the base plate.

xx1200000052

Continues on next page

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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
10 Refit the base cover.

xx1300000561

Connecting the axis-1 motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

2 Refit the cable gland cover.

Note

Replace the gasket if damaged.

xx1200001067

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

622 Product manual - IRB 6700
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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
8 Refit the motor cover with its 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.

Concluding procedure

Action Note
1 Turn on the power to the robot and jog to:
• axis 1 = -5°
• axis 2 = +10°
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Refill oil in the gearbox. See Filling oil into the axis-1 gearbox on
page 161.
4 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply Mercasol on the surfaces shown in casol 3110 Waxcoat. Recommended drying
the figure, on stop pin and in the hole as time is 24h.).
shown in the figure.

xx1400000378

Continues on next page

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4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
5 Refit the mechanical stop pin and secure Locking liquid: 3HAB7116-1 (Loctite 243).
it with the attachment screw. Tightening torque: 24 Nm
Apply locking liquid on the screw.

xx1300000476

6 Secure the cable harness inside the frame

recess with a cable strap.

xx1200001237

7 Refit the cable bracket on the frame.

xx1200001246

8 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 798.
General calibration information is included
in section Calibration on page 787.

Continues on next page

624 Product manual - IRB 6700
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 4 Repair
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
9
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

Product manual - IRB 6700 625

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)

4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)

Validity of this section - variant

Note

This section describes how to replace the gearbox on variants IRB 6700 - 300/2.70,
IRB 6700 - 245/3.00.
How to replace the gearbox on variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
see Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB
6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
on page 586.

Location of the axis-1 gearbox

The axis-1 gearbox is located as shown in the figure.

xx1200001183

Summary of the replacement procedure

This is a brief summary of the replacement procedure, containing the major actions
to be performed.
1 Drain the axis-1 gearbox.
2 Remove the cabling from the base.
Continues on next page
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

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
parts - IRB 6700/IRB 6700Inv.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
Bits extender 3HAC12342-1 300 mm, bits 1/2"
Lifting eye 3HAC16131-1 M12
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.
Lifting eye 3HAC14457-4 M16
Lifting eye 3HAC14457-4 M16
Lifting accessory, motor 3HAC14459-1
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
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.
24 VDC power supply - Used to release the motor brakes.
Guide pin, M10x150 3HAC15521-2 Always use guide pins in pairs.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Equipment, etc. Article number Note

Guide pin, M16x120 3HAC062397-001 Always use guide pins in pairs.
Guide pin, M20x180 3HAC048814-002 Always use guide pins in pairs.
Support legs 3HAC15535-1
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

Consumables

Equipment, etc Article number Note

Flange sealant 12340011-116 Loctite 574
Grease 3HAB3537-1 Used to lubricate o-rings.
Locking liquid 3HAB7116-1 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.
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
Used on motor flange.
Sealing ring 3HAC047474-001 Located in the frame, on top
of the protection tube.
O-ring 3HAB3772-57 Located on the sealing ring.
Radial sealing with dust lip 3HAB3701-51 Located in the frame, under-
neath the sealing ring.
Cable straps -
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Required documents

Document name Document number Note

Technical reference manual - Lubrication in 3HAC042927-001
gearboxes

Continues on next page

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the axis-1 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 gearbox.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
4 Remove tools and other equipment fitted on This is done to achieve the best stability
the turning disc. of the complete arm system, when it is
DressPack can stay fitted for the time being. resting by itself, after it has been re-
moved.
5 Hold the mechanical stop pin in a firm grip,
and remove it by unscrewing the attachment
screw.

CAUTION

The mechanical stop weighs 5 kg.

xx1400002179

6 Begin draining the axis-1 gearbox. See Draining the axis-1 gearbox on
page 159.
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.

8 Foundry Plus.
Cut the cable tie that hold the axis-1 and axis-
2 motor cables on the protection plates.

xx1400000722

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
9 Foundry Plus.
Disassemble the protection plates by remov-
ing five of the attachment screws (three
M10x30 and two of the M5x12 screws).

xx1400000723

10 Foundry Plus.
Remove the two protection plates.

xx1400000724

Robot position
Action Note
1 Jog the robot into position:
• Axis 1: no significance (as long as the robot
is secured to the foundation)
• Axis 2: -45°
• Axis 3: +65°
• Axis 4: 0°
• Axis 5: +80°
• Axis 6: no significance

xx1200001132

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

Attaching the lifting accessories to the arm system

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.

2
CAUTION

The complete arm system weighs 1300 Kg.

All lifting accessories used must be sized accord-
ingly!

3 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

4 Fit a lifting eye to the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer. Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.

Continues on next page

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.

A Upper arm
B Shackle
C Roundsling
D Hole in frame

2 Connect the roundsling with a shackle. Lifting shackle SA-10-8-NA1

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.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
4 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 the lifting eye in the wrist.

Disconnecting the axis-1 motor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Unscrew the attachment screws and

washers and remove the motor cover.

xx1200001135

3 Make sure the o-ring is present.

xx1200001070

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
4 Disconnect the motor cables.

xx1200001066

5 Remove the cable gland cover.

Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-1 motor

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Attach the lifting accessories. Lifting accessory (chain): 3HAC15556-1

Lifting accessory, motor: 3HAC14459-1.
3 To release the brakes, connect the 24 VDC 24 VDC power supply
power supply.
Connect to R2.MP1-connector:
• + = pin 2
• - = pin 5
4
CAUTION

The weight of the motor is 25 kg

All lifting accessories used must be sized
accordingly.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
5 Unscrew the attachment screws and Bits extender: 3HAC12342-1
washers.
Use a bits extender to reach the screws.

xx1200001071

6 Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2

Always use guide pins in pairs.
7
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

8 If needed, use removal tools to help re- Removal tool M12: 3HAC057339-003
move the motor. Removal tool M14: 3HAC057339-004
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
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

Continues on next page

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
10 Disconnect the 24 VDC power supply.

Preparations before removing the cable harness in the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
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

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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

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.

Continues on next page

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
2 Pull out the robot cable harness through
the protection tube.

xx1300000732

3 Place the cable harness over the balancing

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

Lubricate the guide pins with some grease

to make the frame slide better.

xx1700000320

xx1700000321

Guide pin, M16x120: 3HAC062397-001

Always use guide pins in pairs.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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: 1300 Kg.

All lifting accessories used must be sized
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.

Continues on next page

640 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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

between the lug and the surface of the gear-
box. This is done in order not to damage the
surface of the gearbox which is a sealing
surface.

xx1700000323

3
CAUTION

The weight of the gearbox and base together

is
240 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
305 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.

Continues on next page

642 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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

10 Fit two guide pins in opposite holes. Guide pin, M20x180: 3HAC048814-002
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the gearbox slide better.

xx1700000337

11
CAUTION

The weight of the gearbox is

92 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
140 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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

Continues on next page

644 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Refitting the axis-1 gearbox

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

Leave a couple of millimeters of space

between the lug and the surface of the gear-
box. This is done in order not to damage the
surface of the gearbox which is a sealing
surface.

xx1700000325

3
CAUTION

The weight of the gearbox is

92 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
140 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.

Continues on next page

646 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
8 Apply flange sealant to the mounting interface Flange sealant: Loctite 574 (12340011-
on the gearbox. 116).

xx1700001384

9 Fit guide pins in opposite holes in the gear- Guide pin, M20x180: 3HAC048814-002
box. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the gearbox slide better.

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

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.

Continues on next page

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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 243 (3HAB7116-1).

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, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
305 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

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)

Continues on next page

650 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.
3 Wipe clean the contact surfaces from any
remaining contamination.
4 Wipe clean the o-ring groove in the gearbox Grease, Shell Gadus S2V220 AC:
and apply some grease to the groove. 3HAB3537-1.
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 S2V220 AC:
and frame with a new. 3HAB3537-1.
Install the new o-ring in the groove.

Note

A new o-ring also needs to be cleaned!

xx1700000336

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
6 Apply flange sealant in two strings according Flange sealant, Loctite 574: 12340011-
to the figure. 116.

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).
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the frame slide better.

xx1700000329

Refitting the arm system

Action Note
1
CAUTION

The arm system weighs 1300 Kg.

All lifting accessories used must be sized
accordingly!

2 Make sure that all lifting accessories still is See Attachment points of lifting accessory
fitted correctly on the arm system. on page 212.

Continues on next page

652 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.
5 Wipe clean the contact surfaces from any
remaining contamination.
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.

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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.

Tightening torque: 300 Nm
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

Continues on next page

654 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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

Securing the axis-1 motor

Action Note
1 Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2
Always use guide pins in pairs.
2
CAUTION

The motor weighs 25 kg.

All lifting accessories used must be sized
accordingly.

3 Apply the lifting accessory. Lifting accessory, motor: 3HAC14459-1.

4 Fit the rotation tool. Rotation tool: 3HAB7887-1
5 Connect the 24 VDC power supply to re-
lease the brakes.
To release the brakes, connect the 24 VDC
power supply as described in the list.
Connect to R2.MP1-connector:
• + = pin 2
• - = pin 5

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
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

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 198.
10 Disconnect the 24 VDC power supply.

Continues on next page

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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Connecting the axis-1 motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

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

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
4 Inspect the o-ring. O-ring, axis-1: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
Note file)
O-ring, axis-2: 3HAB3772-111 (circular
Replace if damaged. profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

658 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
8 Refit the motor cover with its 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.

Refilling oil in the gearbox

Action Note
1 Refill oil in the gearbox. See Changing oil, axis-1 gearbox
on page 158.

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

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
2 • 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

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
the protection tube in the base.
Make sure that the hoses are running cor-
rectly and are not twisted!

Continues on next page

660 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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

10 Refit the base cover.

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

Continues on next page

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4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
2 Refit the mechanical stop pin and secure it Tightening torque: 24 Nm
with the attachment screw.
Locking liquid (Loctite 243) on screw.

xx1400002179

3 Secure the cable harness inside the frame

hole with a cable strap.

xx1200001237

4 Refit the cable bracket on the frame.

xx1200001246

Continues on next page

662 Product manual - IRB 6700
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 4 Repair
4.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Concluding procedure

Action Note
1 Re-calibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 798.
General calibration information is included
in section Calibration on page 787.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These are
further described in First test run may cause
injury or damage on page 26.

Product manual - IRB 6700 663

3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)

4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB
6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)

Validity of this section

Note

This section describes how to replace the gearbox on variants IRB 6700 - 235/2.65,
IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60,
IRB 6700 - 155/2.85.
How to replace the gearbox on variants IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
see Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00) on
page 701.

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.

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Location of the axis-2 gearbox

The axis-2 gearbox is located as shown in the figure.

xx1200001276

Spare parts

Spare parts Article number Note

Axis-2 gearbox See Product manual, spare
parts - IRB 6700/IRB 6700Inv.
Product manual, spare
parts - IRB 6790

Consumables

Equipment, etc Article number Note

Grease 3HAB3537-1 Used to lubricate o-rings.
O-ring 3HAB3772-107 D=102x3
Used on motor flange.
O-ring i 3HAB3772-111 (circular pro- D=169.5x3
file) / 3HAC054692-002 Used on motor cover.
(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) -

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Equipment, etc Article number Note

Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat. Re-
commended drying time is
24h.
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Lifting eye 3HAC16131-1 M12
Lifting eye 3HAC14457-4 M16
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.
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
Pallet Used for putting down removed parts
from robot.
Guide pin, M16x150 3HAC13120-2 Always use guide pins in pairs.
Guide pin, M16x200 3HAC13120-3 Always use guide pins in pairs.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
Guide pin, M12x200 3HAC13056-4 Always use guide pins in pairs.
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 pin, M10x150 3HAC15521-2 Always use guide pins in pairs.
Lifting accessory, gearbox 3HAC046112-001 i
3HAC046128-001 ii
Hydraulic cylinder 3HAC11731-1 To be used with the press tool.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Equipment, etc. Article number Note

Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85, IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the axis-2 gearbox

Use these procedures to remove the gearbox.

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Begin draining the gearbox. See Draining the axis-2 gearbox on

page 166.

Unloading or locking the balancing device springs

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 tool,
balancing device (3HAC020902-001).

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.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove the cover plate on the back of the

balancing device.

DANGER

DO NOT remove any other screws than the

rear cover attachment screws.

xx1300000554

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.

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
9
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Attaching lifting accessory to the balancing device

Action Note
1
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1

xx1300000661

3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Removing the shaft in the front (link ear)

Action Note
1 Remove the VK cover. It is possible to drive a screwdriver (or
similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.

xx1200001278

2 Unscrew the attachment screw and washer.

xx1200001279

• M16x70 quality steel 8.8-A3F

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
3 Use the dismantle and mounting tool and Dismantle and mounting tool:
pull the shaft out. 3HAC028920-001
F Hydraulic pump 80 MPa: 3HAC13086-1
1
L A Hydraulic cylinder: 3HAC11731-1

xx1200001280

xx1700000378

The numbers in the figure refers to the

marked tool pieces respectively.
4 Put down the balancing device and let it
rest on the frame.

xx1200001281

Robot position
Use this procedure to jog the robot into position.
Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
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!

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
2 Jog the robot into position:
• 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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Attaching lifting accessories to the lower and upper arm

Use this procedure to attach the lifting accessories.
Valid for variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05,
IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85.
Action Note
1
CAUTION

The lower and upper arms together weigh (accord-

ing to variants) 510 kg.
All lifting accessories used must be sized accord-
ingly!

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

xx1200001133

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
3 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1

xx1200001234

4 Insert a M12x50 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

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.
This will prevent the roundsling from gliding.
7 Attach the roundsling to the shackle on the wrist.

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.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
9
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

10 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer: Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.

xx1400002196

xx1200001134

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.

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
13 Attach the Lifting accessory (chain) to an over- Lifting accessory (chain):
head crane (or similar), then to the lifting eye in 3HAC15556-1
the arm house and to a roundsling run through Roundsling, 1 m: Length: 1 m, lift-
the wrist. ing capacity: 1,000 kg.

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.
15 To release the brake, connect the 24 VDC power
supply.
Connect to connector R2.MP2, axis-2 motor:
• + = pin 2
• - = pin 5

Disconnecting the axis-2 motor cables

Use this procedure to disconnect the motor cables.
Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
2 Unscrew the attachment screws and
washers and remove the motor cover.

xx1200001135

3 Make sure the o-ring is present.

xx1200001070

4 Disconnect the motor cables.

xx1200001066

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-2 motor

Action Note
1 Before removing the motor, make sure that
the axis-2 gearbox is completely drained.
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

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
5 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the motor slide better.

6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

7 If required, press the motor out of its posi- Removal tool M12: 3HAC057339-003
tion by using the removal tool in opposite Removal tool M14: 3HAC057339-004
holes of the motor.
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
8 Disconnect the 24 VDC power supply.
9
CAUTION

The motor weighs 28 kg.

All lifting accessories used must be sized
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

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

2 Unscrew the attachment screws that secure

the axis-2 lower arm metal clamp and the
axis-3 lower arm metal clamp located on
the inside of the lower arm by removing the
attachment screws.

Note

The screws are reached from outside the

lower arm!

xx1300000540

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
3 Unscrew the attachment screws of the
cable bracket on the frame and let it hang
loose.

xx1200001283

Removing and lifting away the lower and upper arms un-separated (Step 1)
Use this procedure for the first step of removing and lifting away the lower and
upper arm un-separated.
Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1300000788

2 Remove all but one of the remaining attach-

ment screws that secure the lower arm to
the axis-2 gearbox.

xx1300000789

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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.
All lifting accessories used must be sized
accordingly!

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.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Removing the axis-2 gearbox

Use the procedure to remove gearbox.
Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-4
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the gearbox slide better.

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.

All lifting accessories used must be sized
accordingly.

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 i
3HAC046128-001 ii
7 Use caution and let the gearbox slide out
on the guide pins.
8 Remove the gearbox.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85, IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Refitting the axis-2 gearbox

Use these procedures to refit the gearbox.

Continues on next page

684 Product manual - IRB 6700
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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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!

Refitting the gearbox

Use this procedure to refit the gearbox.
Action Note
1
CAUTION

The gearbox weighs 83 kg.

All lifting accessories used must be sized
accordingly!

2 Apply the lifting accessory to the gearbox. Lifting accessory, gearbox:

3HAC046112-001 i
3HAC046128-001 ii
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.

5 Wipe clean the contact surfaces from any

contamination.

Note

Also wipe clean the o-ring groove.

6 Check the condition of the o-ring. O-ring: 3HAB3772-144 (D=309.3x3.1) /

Replace if damaged. 3HAB3772-48 (D=319.3x5.7)
Located between the gearbox and the
frame.
Size depends on gearbox model. Measure
the groove to see dimension of the o-ring.
7 Lubricate the o-ring with some grease, for
a better fitting in the groove.
8 Fit the o-ring in the groove.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
9 Foundry Plus: Rust preventive: 3HAC034903-001 (Mer-
Apply rust preventive to the gearbox sur- casol 3110 Waxcoat. Recommended drying
faces shown in the figures. time is 24h.)

xx1400000374

10 Fit two guide pins in opposite holes (M12). Guide pin, M12x150: 3HAC13056-2
Guide pin, M12x200: 3HAC13056-4
Tip Always use guide pins in pairs.

Lubricate the guide pins with some grease

to make the gearbox slide better.

xx1700000445

11 Lift the gearbox and let it rest on the guide

pins.
12 Slide the gearbox into position.

Continues on next page

686 Product manual - IRB 6700
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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
13 Fit the attachment screws and washers
now accessible.

xx1400002188

Attachment screws: M12x90 12.9 Gleitmo

(30 pcs).
14 Remove the lifting accessory.
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.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85, IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
3 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

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

5 If the motor is a new spare part, remove the cover.

xx1200001135

Continues on next page

688 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
6 Foundry Plus: Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-2 motor

Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION

The motor weighs 28 kg.

All lifting accessories used must be sized
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.

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
7 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
8 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP2, axis-2 mo-
tor:
• + = pin 2
• - = pin 5
9
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
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.
• Make sure that the motor pinion
does not get damaged.
• Make sure that the direction of the
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.
13 Secure the motor with its attachment Bits extender: 3HAC12342-1
screws and washers. Tightening torque: 50 Nm.
Use a bits extender in order to reach the Screw dimension: M10x30 Steel 12.9 Gle
screws. 603+Geo500 (4 pcs)

xx1200001117

14 Perform a leak-down test. See Performing a leak-down test on

page 198.

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.

Continues on next page

690 Product manual - IRB 6700
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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
2 Fit the rotation tool, if not already fitted. Rotation tool: 3HAB7887-1
3 Fit two guide pins in opposite holes in the Guide pin, M16x150: 3HAC13120-2
axis-2 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1400000360

4
CAUTION

The lower and upper arms together weigh

510 kg.
All lifting accessories used must be sized
accordingly!

5 Attach the lifting accessories, if not already

fitted.
6 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.
7 Before putting the arms on the guide pins,
make sure that the hole pattern is matched
and in the correct position for all screws.
8 If the hole pattern is not matching, use the Rotation tool: 3HAB7887-1
rotation tool and adjust.

xx1300000819

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
9 Slide the lower arm on to the guide pins.
10 Use caution and move the arms into posi-
tion at the axis-2 gearbox on the guide pins.
11 Fit all now accessible attachment screws Screws: M16x50 quality steel 12.9 Gleitmo
and washers.

xx1300000789

12 Remove the two guide pins and replace Screws: M16x50 quality steel 12.9 Gleitmo
with the remaining attachment screws and
washers.
13 Secure the lower arm to the axis-2 gearbox Tightening torque M16: 300 Nm
with its attachment screws.
14 Disconnect the 24 VDC power supply.
15 Remove the lifting accessories.

Connecting the axis-2 motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

Continues on next page

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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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 its 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 cabling

Use this procedure to refit the cabling.
Action Note
1 Use caution and push the cable harness
into the lower arm.

Continues on next page

694 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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

The screws are reached from the outside

of the lower arm!

xx1200001282

3 Refit the cable bracket on the frame.

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

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Refitting the front shaft of the balancing device

Action Note
1 Turn the power to the robot on temporarily.
2 Use caution and jog the robot to the calibration
position (if not already done).
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
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)

Continues on next page

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 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

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 the shaft in with the hydraulic press tool. Hydraulic pressure: 250 bar
Hydraulic pump 80 MPa:
3HAC13086-1
Hydraulic cylinder: 3HAC11731-1
Dismantle and mounting tool:
3HAC028920-001

xx1700002238

The item numbers refer to mark-

ings on the tools.
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

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
13 Fit the VK-cover.

xx1200001278

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

grease.

Concluded refitting of the front shaft

Action Note
1 Remove the lifting accessory from the bal-
ancing device.
2 Refit the cable bracket (if not already refit-
ted).

xx1200001283

Continues on next page

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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
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
jogged to -20° or +20°. Fitting and removal
of the tool shall only be done with axis-2 in
this position!
To unload or restore a new balancing
device or if the spring unit of the balancing
device cannot be compressed by jogging
the robot, only use the hydraulic press tool
Dismantle and mounting tool 3HAC028920-
001.

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

6 Remove the distance tool.

xx0800000480

A Distance tool: 3HAC030662-001

Continues on next page

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4 Repair
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB
6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
Continued

Action Note
7 Refit the cover plate. Attachment screws: M10 quality 12.9 (4
pcs)

xx1300000554

Concluding procedure

Action Note
1 If the robot is equipped with DressPack,
refit the brackets of the ball joint housings
on the wrist.
2 Refill oil to the axis-2 gearbox. See Filling oil into the axis-2 gearbox on
page 167.
3 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
4
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

700 Product manual - IRB 6700

3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)

4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)

Validity of this section

Note

This section describes how to replace the gearbox on variants IRB 6700 - 300/2.70,
IRB 6700 - 245/3.00.
How to replace the gearbox on variants IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
see Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB
6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85)
on page 664.

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 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.

Continues on next page

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Location of the axis-2 gearbox

The axis-2 gearbox is located as shown in the figure.

xx1200001276

Summary of the replacement procedure

This is a brief summary of the replacement procedure, containing the major actions
to be performed.
1 Remove the upper and lower arm together, as a package.
2 Replace the axis-2 gearbox.

Spare parts

Spare parts Article number Note

Axis-2 gearbox See Product manual, spare
parts - IRB 6700/IRB 6700Inv.

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Lifting eye 3HAC16131-1 M12
Lifting eye 3HAC14457-4 M16

Continues on next page

702 Product manual - IRB 6700
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© Copyright 2013 - 2018 ABB. All rights reserved.
 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Equipment, etc. Article number Note

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.
Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
Pallet Used for putting down removed parts
from robot.
Guide pin, M16x150 3HAC13120-2 Always use guide pins in pairs.
Guide pin, M16x200 3HAC13120-3 Always use guide pins in pairs.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
Guide pin, M12x200 3HAC13056-4 Always use guide pins in pairs.
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 pin, M10x150 3HAC15521-2 Always use guide pins in pairs.
Lifting accessory, gearbox 3HAC046112-001 i
3HAC046128-001 ii
Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Hydraulic pump 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85, IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Consumables

Equipment, etc Article number Note

Grease 3HAB3537-1 Used to lubricate o-rings.

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Equipment, etc Article number Note

O-ring 3HAB3772-107 D=102x3
Used on motor flange.
O-ring i 3HAB3772-111 (circular pro- D=169.5x3
file) / 3HAC054692-002 Used on motor cover.
(hexagon profile)
O-ring 3HAB3772-144 D=309.3x3.1
Used on gearbox.
VK cover 3HAA2166-28 VK 28x7
Locking liquid (Loctite 2701) -
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Required documents

Document name Document number Note

Technical reference manu- 3HAC042927-001
al - Lubrication in gearboxes

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the axis-2 gearbox

Use these procedures to remove the gearbox.

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Follow the order of the separate procedures according to the order they are
presented.

CAUTION

When performing these procedures, the cable harness will still be fitted or partly
fitted to the robot. Use extreme caution not to cause any damage to the cable
harness!

Preparations before replacing the axis-2 gearbox

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Begin draining the gearbox. See Draining the axis-2 gearbox on

page 166.

Unloading or locking the balancing device springs

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 tool,
balancing device (3HAC020902-001).

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.

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

4 Remove the cover plate on the back of the

balancing device.

DANGER

DO NOT remove any other screws than the

rear cover attachment screws.

xx1300000554

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.

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
9
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Attaching lifting accessory to the balancing device

Action Note
1
CAUTION

The weight of the balancing device (exclud-

ing cradle) is
140 kg (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85)
185 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1

xx1300000661

3 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1
raise to unload the weight.

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Removing the shaft in the front (link ear)

Action Note
1 Remove the VK cover. It is possible to drive a screwdriver (or
similar) through the VK cover, as close as
possible to the center of the VK cover and
pull it out.

xx1200001278

2 Unscrew the attachment screw and washer.

xx1200001279

• M16x70 quality steel 8.8-A3F

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
3 Use the dismantle and mounting tool and Dismantle and mounting tool:
pull the shaft out. 3HAC028920-001
F Hydraulic pump 80 MPa: 3HAC13086-1
1
L A Hydraulic cylinder: 3HAC11731-1

xx1200001280

xx1700000378

The numbers in the figure refers to the

marked tool pieces respectively.
4 Put down the balancing device and let it
rest on the frame.

xx1200001281

Robot position

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!

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
2 Jog the robot into position:
• Axis 1: position the axis 1 to be able
to put down the arm system after
removal
• Axis 2: -60°
• Axis 3: +70° (approximately)
• Axis 4: +90°
• Axis 5: 0° (-90° if DressPack is in-
stalled)
• Axis 6: 0° (+90° if DressPack is in-
stalled)

xx1200001250

3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Attaching lifting accessories to the lower and upper arm

Use this procedure to attach the lifting accessories.
Action Note
1
CAUTION

The lower and upper arms together weigh (accord-

ing to variants) 650 kg.
All lifting accessories used must be sized accord-
ingly!

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

xx1400002106

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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.
• With no DressPack cable package installed:
Place the roundsling beneath the securing
screw.
• With DressPack cable package installed:
Place the roundsling beneath the ball joint
housing on the outside of the lower arm.

xx1400002105

5 Run the roundsling up and over the upper arm.

6 Connect both ends of the roundsling with a
shackle.

xx1400000729

7 Stretch the roundsling between the upper and the

lower arm by slowly jogging the axis-3.

Note

Make sure the roundsling is stretched, in order to

carry the weight of the lower arm.

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
8
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

9 Fit a lifting eye in the arm house, with a fender Lifting eye: 3HAC16131-1
washer underneath. Fender washer: Outer diameter:
minimum 26 mm, maximum 30 mm,
hole diameter: 13 mm, thickness:
3 mm.

xx1400002196

xx1200001134

10 Attach the Lifting accessory (chain) to an over- Lifting accessory (chain):

head crane (or similar), then to the lifting eye in 3HAC15556-1
the arm house and to the lifting eye in the wrist.

xx1400002104

11 Raise the overhead crane to stretch the chains

and roundslings.
Verify that the roundsling between the wrist and
the lower arm is stretched.
12 To release the brake, connect the 24 VDC power
supply.
Connect to connector R2.MP2, axis-2 motor:
• + = pin 2
• - = pin 5

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

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

2 Unscrew the attachment screws that secure

the axis-2 lower arm metal clamp and the
axis-3 lower arm metal clamp located on
the inside of the lower arm by removing the
attachment screws.

Note

The screws are reached from outside the

lower arm.

xx1300000540

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1400002181

2 Remove all but one of the remaining attach-

ment screws that secure the lower arm to
the axis-2 gearbox.

xx1400002182

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

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

The lower and upper arms together weigh

650 kg.
All lifting accessories used must be sized
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 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.

Disconnecting the axis-2 motor cables

Use this procedure to disconnect the motor cables.
Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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

4 Disconnect the motor cables.

xx1200001066

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-2 motor

Action Note
1 Before removing the motor, make sure that
the axis-2 gearbox is completely drained.
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

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
5 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the motor slide better.

6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

7 If required, press the motor out of its posi- Removal tool M12: 3HAC057339-003
tion by using the removal tool in opposite Removal tool M14: 3HAC057339-004
holes of the motor.
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
8 Disconnect the 24 VDC power supply.
9
CAUTION

The motor weighs 28 kg.

All lifting accessories used must be sized
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

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Removing the axis-2 gearbox

Use the procedure to remove gearbox.
Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-4
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the gearbox slide better.

xx1700000443

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

The gearbox weighs 110 kg.

All lifting accessories used must be sized
accordingly!

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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 i
3HAC046128-001 ii
7 Let the gearbox slide out on the guide pins.
8 Remove the gearbox.

xx1400002186

i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85, IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Refitting the axis-2 gearbox

Use these procedures to refit the gearbox.
Follow the order of the separate procedures according to the order they are
presented.

CAUTION

When performing these procedures, the cable harness will still be fitted or partly
fitted to the robot. Use the utmost caution not to cause any damage to the cable
harness!

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Refitting the gearbox

Use this procedure to refit the gearbox.
Action Note
1
CAUTION

The gearbox weighs according to vari-

ant110 kg.
All lifting accessories used must be sized
accordingly!

2 Apply the lifting accessory to the gearbox. Lifting accessory, gearbox:

3HAC046112-001 i
3HAC046128-001 ii
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!

5 Wipe clean the contact surfaces from any

contamination.

Note

Also wipe clean the o-ring groove.

6 Check the condition of the o-ring.

Replace if damaged.
7 Lubricate the o-ring with some grease, for
a better fitting in the groove.
8 Fit the o-ring in the groove.
9 Foundry Plus:
Apply Mercasol on the surfaces shown in
the figure.

xx1400000374

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
10 Fit two guide pins in opposite holes (M12). Guide pin, M12x150: 3HAC13056-2
Guide pin, M12x200: 3HAC13056-4
Tip Always use guide pins in pairs.

Lubricate the guide pins with some grease

to make the gearbox slide better.

xx1700000445

11 Lift the gearbox and let it rest on the guide

pins.
12 Slide the gearbox into position.

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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

14 Remove the lifting accessory.

15 Remove the guide pins and fit the remain-
ing attachment screws.
16 Secure the gearbox with its attachment Tightening torque: 120 Nm.
screws.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85, IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Continues on next page

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

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

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
5 If the motor is a new spare part, remove the cover.

xx1200001135

6 Foundry Plus: Tightening torque, transparent

Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-2 motor

Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION

The motor weighs 28 kg.

All lifting accessories used must be sized
accordingly.

3 Apply the lifting accessory. Lifting accessory, motor: 3HAC15534-1

Lifting accessory (chain): 3HAC15556-1

Continues on next page

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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.
7 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
8 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP2, axis-2 mo-
tor:
• + = pin 2
• - = pin 5
9
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
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.
• Make sure that the motor pinion
does not get damaged.
• Make sure that the direction of the
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.

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
13 Secure the motor with its attachment Bits extender: 3HAC12342-1
screws and washers. Tightening torque: 50 Nm.
Use a bits extender in order to reach the Screw dimension: M10x30 Steel 12.9 Gle
screws. 603+Geo500 (4 pcs)

xx1200001117

14 Perform a leak-down test. See Performing a leak-down test on

page 198.

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
3 Fit two guide pins in opposite holes in the Guide pin, M16x150: 3HAC13120-2
axis-2 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the lower arm slide better.

xx1400002189

4
CAUTION

The lower and upper arms together weigh

650 kg.
All lifting accessories used must be sized
accordingly!

5 Apply the lifting accessories, if not already

fitted.

Continues on next page

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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

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.
12 Fit one attachment screw in one of the up-
per holes using it for security and lower the
lifting accessory a little.

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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.
16 Disconnect the 24 VDC power supply.
17 Remove the lifting accessories.

Connecting the axis-2 motor cables

Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

2 Refit the cable gland cover.

Note

Replace the gasket if damaged.

xx1200001067

Continues on next page

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

730 Product manual - IRB 6700
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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
8 Refit the motor cover with its 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 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
on the inside of the lower arm.

Note

The screws are reached from the outside

of the lower arm!

xx1200001282

3 Refit the cable bracket on the frame.

xx1200001283

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
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

Refitting the front shaft of the balancing device

Action Note
1 Turn the power to the robot on temporarily.
2 Use caution and jog the robot to the calibration
position (if not already done).
3
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
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.

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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)
9 Lubricate the shaft and place it to the front ear.

Note

Foundry Plus:
Do not lubricate surfaces where Mercasol is ap-
plied.

xx1200001280

Continues on next page

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
10 Press the shaft in with the hydraulic press tool. Hydraulic pressure: 250 bar
Hydraulic pump 80 MPa:
3HAC13086-1
Hydraulic cylinder: 3HAC11731-1
Dismantle and mounting tool:
3HAC028920-001

xx1700002238

The item numbers refer to mark-

ings on the tools.
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

13 Fit the VK-cover.

xx1200001278

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
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

grease.

Concluded refitting of the front shaft

Action Note
1 Remove the lifting accessory from the bal-
ancing device.
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
jogged to -20° or +20°. Fitting and removal
of the tool shall only be done with axis-2 in
this position!
To unload or restore a new balancing
device or if the spring unit of the balancing
device cannot be compressed by jogging
the robot, only use the hydraulic press tool
Dismantle and mounting tool 3HAC028920-
001.

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.

Continues on next page

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4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
5
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

6 Remove the distance tool.

xx0800000480

A Distance tool: 3HAC030662-001

7 Refit the cover plate. Attachment screws: M10 quality 12.9 (4
pcs)

xx1300000554

Concluding procedure

Action Note
1 If the robot is equipped with DressPack,
refit the brackets of the ball joint housings
on the wrist.

Continues on next page

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 4 Repair
4.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)
Continued

Action Note
2 Refill oil to the axis-2 gearbox. See Filling oil into the axis-2 gearbox on
page 167.
3 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
4
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

Product manual - IRB 6700 737

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4 Repair
4.8.5 Replacing the axis-3 gearbox

4.8.5 Replacing the axis-3 gearbox

Space required beside

This section describes how to replace the gearbox without needing to remove the
cable harness and DressPack cable package (if installed) from the robot.
The described procedure requires free space on the floor, at the right-hand side
of the 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.

Location of the axis-3 gearbox

The axis-3 gearbox is located as shown in the figure.

xx1300000515

Continues on next page

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Summary of the replacement procedure

This list is a brief summary of the replacement procedure, containing the major
actions to be performed.
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.
2 Replace the axis-3 gearbox.

Spare parts

Spare parts Spare part number Note

Axis-3 gearbox See Product manu-
al, spare parts - IRB
6700/IRB 6700Inv.
Product manual,
spare parts - IRB
6790
.

Consumables

Equipment, etc Article number Note

Grease 3HAB3537-1 Used to lubricate o-rings.
Rust preventive 3HAC034903-001 Mercasol 3110 Waxcoat. Re-
commended drying time is
24h.
O-ring 3HAB3772-107 D=102x3
Used on motor flange.
O-ring i 3HAB3772-111 (circular pro- D=169.5x3
file) / 3HAC054692-002 Used on motor cover.
(hexagon profile)
Oring 3HAB3772-145 D=266.3x3.5
Used on gearbox.
i The cross-section profile is either circular or hexagon. If only ordering the o-ring, order the same
profile that is currently installed in the connection box.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Required tools and equipment

Equipment, etc. Article number Note

Oil collecting vessel - The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Oil dispenser - One example of oil dispenser can be
found in section Type of lubrication in
gearboxes on page 156.
Lifting eye 3HAC16131-1 M12
Lifting eye 3HAC14457-4 M16
Fender washer - Outer diameter: minimum 26 mm,
maximum 30 mm, hole diameter: 13
mm, thickness: 3 mm.
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en-
closed.
Pallet Used for putting down removed parts
from robot.
Lifting accessory, gearbox 3HAC046128-001 i
3HACxx ii
3HAC046112-001 iii
Removal tool 3HAC057339-003 Used to push out the motor, if neces-
3HAC057339-004 sary.
Always use removal tools in pairs.
Size depending on motor type, see
Type A vs type B motors on page 819.
ScrewsM8x75, fully threaded - Used to push out the gearbox, if neces-
sary.
Pallet Used for putting down removed parts
from robot.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
Guide pin, M16x200 3HAC13120-3 Always use guide pins in pairs.
Pinion 3HAC067546-001 iv Used for rotating the axis-3 gearbox
3HAC067547-001 v when refitting upper arm.
3HAC067545-001 vi
24 VDC power supply - Used to release the motor brakes.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
iv IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
v IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Continues on next page

740 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

vi IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the axis-3 gearbox

Use these procedures to remove the axis-3 gearbox.
Follow the order of the separate procedure according to the order they are
presented.

Preparations before removing the axis-3 gearbox

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
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

When releasing the holding brakes of the

motor, the upper arm will be movable and
may fall down if not secured. Verify that the
upper arm is secured as previously de-
scribed, before continuing.

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:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
6 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
7 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

8 Begin draining the gearbox. See Draining the axis-3 gearbox on

page 171.
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.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Disconnecting the axis-3 and axis-4 motor cables

Use this procedure to disconnect the motor cables on the axis-3 and axis-4 motors.
Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Unscrew the attachment screws and

washers and remove the motor cover.

xx1200001135

3 Make sure the o-ring is present.

xx1200001070

4 Disconnect the motor cables.

xx1200001066

Continues on next page

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
5 Remove the cable gland cover.
Make sure the gasket is not damaged.

Tip

Make a note in which direction the cable

gland hole is facing, if the motor will be re-
moved too. The motor shall be refitted in
the same position.

xx1200001067

6 Use caution and pull out the motor cables.

Removing the axis-3 motor

Action Note
1 Before removing the motor, make sure that
the axis-3 gearbox is completely drained.
2
DANGER

When releasing the holding brakes of the

motor, the upper arm will be movable and
may fall down if not secured. Verify that
the upper arm is secured as previously
described, before continuing.

3 To release the brakes, connect the 24 VDC

power supply.
Connect to connector R2.MP3:
• + = pin 2
• - = pin 5
4 Unscrew the attachment screws that hold Bits extender: 3HAC12342-1
the motor.
Use a bits extender to reach the screws.

xx1200001126

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
5 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the motor slide better.

6
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

7 If required, press the motor out of position Removal tool M12: 3HAC057339-003
by using the removal tool in the remaining Removal tool M14: 3HAC057339-004
holes for the motor.
Depending on motor type A or B, see
Identifying the motor by article number on
page 819
Always use removal tools in pairs.
8 Use caution and lift the motor out on the
guide pins, in order to get the pinion away
from the gear, and let the motor rest on
the guide pins.
9
CAUTION

The motor weighs 26 kg.

All lifting accessories used must be sized
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.

12 Disconnect the 24 VDC power supply.

Continues on next page

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
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 233.
Use this procedure to loosen required cable brackets of the robot cable harness,
in order to get the longest possible length of the cable harness between the lower
and upper arm.
Action Note
1 Unscrew the attachment screws that hold
the axis-3 lower arm metal clamp (the one
closest to the axis-3 gearbox) located on
the inside of the lower arm.

Note

The screw is reached from the outside of

the lower arm!

xx1800000042

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
2 Unscrew the attachment screws that hold
the cable bracket on top of the arm house.

xx1300000541

3 Unscrew the attachment screws that hold

the cable bracket under the arm house.

xx1300000543

4 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

xx1300000544

Continues on next page

748 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
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.

Continues on next page

Product manual - IRB 6700 749
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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1

xx1200001133

3 Fit a lifting eye in the arm house, with a Lifting eye: 3HAC16131-1
fender washer underneath. Fender washer: Outer diameter: minimum
26 mm, maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.

xx1400002196

xx1200001134

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

Continues on next page

750 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
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

Preparations before removing the upper arm - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 -
175/3.05, IRB 6700 - 150/3.20

Action Note
1 Remove two attachment screws (M12) in Guide pin, M12x150: 3HAC13056-2
opposite holes and replace them with guide Guide pin, M12x200: 3HAC13056-4
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

2 Leave one of the remaining attachment

screws fitted, remove the other screws.

xx1300000747

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Preparations before removing the upper arm - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Guide pin, M12x200: 3HAC13056-4
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.

xx1300002245

2 Leave one of the remaining attachment

screws fitted, remove the other screws.

xx1300002246

Preparations before removing the upper arm - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Action Note
1 Remove two attachment screws in opposite Guide pin, M16x150: 3HAC13120-2
holes and replace them with guide pins. Guide pin, M16x200: 3HAC13120-3
Always use guide pins in pairs.
Note

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.

xx1400002563

Continues on next page

752 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
2 Leave one of the remaining attachment
screws fitted, remove the other screws.

xx1400002564

Removing the upper arm

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

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
2 Remove the remaining attachment screw IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
and let the upper arm slide out from the IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
lower arm with support from the guide pins.

xx1300001610

IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

TBD
IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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.

Continues on next page

754 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
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

Removing the axis-3 gearbox

Use this procedure to remove the gearbox.
Action Note
1 Remove two attachment screws in opposite Guide pin, M12x150: 3HAC13056-2
holes and replace them with guide pins. Always use guide pins in pairs.
IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
Tip IRB 6700 - 175/3.05, IRB 6700 - 150/3.20

Lubricate the guide pins with some grease

to make the gearbox slide better.

xx1300001969

IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

TBD
IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

xx1700000370

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
2 Remove all but one of the remaining attach- IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
ment screws. IRB 6700 - 175/3.05, IRB 6700 - 150/3.20

xx1300001970

IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

TBD
IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

xx1700000371

3 Fit two fully threaded screws and use them ScrewsM8x75, fully threaded: Used to push
as removal tools. out the gearbox, 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.

Continues on next page

756 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
6
CAUTION

The axis-3 gearbox weighs .

• 56 kg (IRB 6700 - 235/2.65, -
205/2.80, - 175/3.05, - 150/3.20, -
200/2.60, - 155/2.85)
• 85 kg (IRB 6700 - 300/2.70, -
245/3.00)
All lifting accessories used must be sized
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.
10 Remove the gearbox.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Refitting the axis-3 gearbox

Use these procedures to refit the axis-3 gearbox.
Follow the order of the separate procedures according to the order they are
presented.

Preparations before refitting the axis-3 gearbox

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
2
CAUTION

The axis-3 gearbox weighs .

• 56 kg (IRB 6700 - 235/2.65, -
205/2.80, - 175/3.05, - 150/3.20, -
200/2.60, - 155/2.85)
• 85 kg (IRB 6700 - 300/2.70, -
245/3.00)
All lifting accessories used must be sized
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.
5 Remove the o-ring and wipe it clean.

Note

This shall also be done on a new spare

part.

6 Check the condition of the o-ring. Oring: 3HAB3772-145.

Replace if damaged.
7 Wipe clean the contact surfaces, both on
the gearbox and in the upper arm.
Also wipe clean the o-ring groove.
8 Lubricate the o-ring with some grease.
9 Fit the o-ring in the groove.
10 Fit two guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2
Always use guide pins in pairs.
Tip

Lubricate the guide pins with some grease

to make the gearbox slide better.

11 Lift the gearbox to the upper arm and let it

rest on the guide pins.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Continues on next page

758 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Securing the axis-3 gearbox - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 -
150/3.20

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 Remove the lifting accessory.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Securing the axis-3 gearbox - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Action Note
1 Secure the gearbox with 13 of the 15 attach- Tightening torque: 120 Nm
ment screws. M12x70.

xx1300001970

2 Remove the guide pins and replace with

the remaining attachment screws.

xx1300001969

3 Secure the remaining attachment screws. Tightening torque: 120 Nm.

M12x70.
4 Remove the lifting accessory.

Securing the axis-3 gearbox - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Action Note
1 Secure the gearbox with 28 of the 30 attach- Tightening torque: 120 Nm
ment screws. M12x70.

xx1400002193

Continues on next page

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
2 Remove the guide pins and replace with
the remaining attachment screws.

xx1400002194

3 Secure the remaining attachment screws. Tightening torque: 120 Nm.

M12x70.
4 Remove the lifting accessory.

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

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
3 IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, Guide pin, M12x150: 3HAC13056-2
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20 Guide pin, M12x200: 3HAC13056-4
Fit two guide pins in opposite M12 holes Always use guide pins in pairs.
in the axis-3 gearbox.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1700000058

4 IRB 6700 - 200/2.60, IRB 6700 - 155/2.85 Guide pin, M12x150: 3HAC13056-2
Fit two guide pins in opposite M12 holes Guide pin, M12x200: 3HAC13056-4
in the axis-3 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1400000361

5 IRB 6700 - 300/2.70, IRB 6700 - 245/3.00 Guide pin, M16x150: 3HAC13120-2
Fit two guide pins in opposite M16 holes Guide pin, M16x200: 3HAC13120-3
in the axis-3 gearbox. Always use guide pins in pairs.

Tip

Lubricate the guide pins with some grease

to make the upper arm slide better.

xx1700000056

Continues on next page

762 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Securing the upper arm - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 -
150/3.20

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.
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

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
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
Tightening torque, M12: 120 Nm
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Securing the upper arm - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.
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

Continues on next page

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
6 Insert 22 of the 24 M12 screws and wash-
ers.

xx1300002246

7 Remove the guide pins and fit the two re-

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, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Securing the upper arm - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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)
465 kg (IRB 6700 -300/2.70, -245/3.00)
All lifting accessories used must be sized
accordingly.

2 Attach the lifting accessories, if not already See Attaching lifting accessories to the
fitted. upper arm on page 228.
3 Lift the upper arm and bring it towards the
lower arm.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
4 If the axis-3 motor is installed to the upper 24 VDC power supply
arm: Rotation tool
Connect the 24 VDC power supply, to re-
lease the brakes.
Connect to R2.MP3-connector:
• + = pin 2
• - = pin 5
Use the rotation tool and rotate the axis-3
motor to find the correct position for the
guide pins in the lower arm.
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 and tighten 20 of the 22 M16 screws.

xx1700000057

7 Remove the guide pins and fit the two re-

maining screws.
8 Secure the upper arm by tightening the at- M16, tightening torque: 300 Nm
tachment screws.
i IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
ii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
iii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

Preparations prior to refitting motor

Action Note
1
DANGER

Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
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.

Continues on next page

766 Product manual - IRB 6700
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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
3 Check the o-ring. O-ring, 3HAB3772-107
Replace if damaged.

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

5 If the motor is a new spare part, remove the cover.

xx1200001135

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
6 Foundry Plus: Tightening torque, transparent
Valid for axis-2, axis-3, axis-4 and axis-6 motors. plug: 25 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 xx1800000102

Protection filter (Stand- Transparent plug

ard). (Foundry Plus).

Securing the axis-3 motor

Use this procedure to secure the motor.
Action Note
1 Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2
Always use guide pins in pairs.
2
CAUTION

The motor weighs 26 kg.

All lifting accessories used must be sized
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

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
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

5 Remove the lifting accessory and allow the

motor to rest on the guide pins.
6 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1
the pinion when mating it into the gear.
7 To release the brakes, connect the 24 VDC
power supply.
Connect to connector R2.MP3:
• + = 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.
15 Perform a leak-down test. See Performing a leak-down test on
page 198.
16 Disconnect the 24 VDC power supply.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

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 268.
Use this procedure to refit the cable brackets.
Action Note
1 Remove the lifting accessories.
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
on the inside of the lower arm.

Note

The screw is reached from the outside of

the lower arm!

xx1800000042

4 Fasten the cable bracket on top of the arm

house.

xx1300000541

5 Fasten the cable bracket under the arm

house.

xx1300000543

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
6 Secure the cable harness to the cable fixing
bracket with a cable tie.

Note

If DressPack is fitted, the cable fixing

bracket is replaced by the cable guide.

xx1300001973

xx1300000544

7 Refit the DressPack cable package into the

ball joint housings on the lower arm and
close them.

xx1400000195

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Connecting the axis-3 and axis-4 motor cables

Use this procedure to connect the motor cables.
Action Note
1 Push the motor cables through the cable
gland opening.

xx1300000738

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

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
4 Inspect the o-ring. O-ring, axis-1: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
Note file)
O-ring, axis-2: 3HAB3772-111 (circular
Replace if damaged. profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-3: 3HAB3772-111 (circular
profile) / 3HAC054692-002 (hexagon pro-
file)
O-ring, axis-4: 3HAB3772-110 (circular
profile) / 3HAC054692-001 (hexagon pro-
file)

xx1200001070

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.

Continues on next page

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4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
8 Refit the motor cover with its 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 DressPack cable packages

Action Note
1 Remove the lifting accessory.
2 Fit the bracket of the DressPack cable
package (if one is fitted) under the arm
house with its screws.

xx1200001332

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 4 Repair
4.8.5 Replacing the axis-3 gearbox
Continued

Action Note
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
1 Refill oil in the gearbox. See Filling oil into the axis-3 gearbox on
page 173.
2 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
3
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 26.

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4 Repair
4.8.6 Replacing the axis-6 gearbox

4.8.6 Replacing the axis-6 gearbox

Location of the axis-6 gearbox

The axis-6 gearbox is located as shown in the figure.

xx1300000824

Spare parts

Spare parts Spare part number Note

Axis-6 gearbox See Product manual, spare
parts - IRB 6700/IRB
6700Inv.
Product manual, spare
parts - IRB 6790
.

Consumables

Equipment, etc Article number Note

Grease 3HAB3537-1 Used to lubricate o-rings.
O-ring 3HAB3772-107 D=102x3
Used on motor flange.
Gasket 3HAC033489-001/ Used on motor cover.
3HAC044252-001
O-ring 3HAB3772-58 D=151.99x3.53
Used on gearbox.

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 4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Required tools and equipment

Equipment, etc. Article number Note

Rotation tool 3HAB7887-1 Used to rotate the motor pinion.
24 VDC power supply - Used to release the motor brakes.
Leak-down tester -
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.
Standard toolkit - Content is defined in section Standard
toolkit on page 829.

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 799.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.

Removing the axis-6 gearbox

Use these procedures to remove the axis-6 gearbox.

Preparations before removing the axis-6 gearbox

Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.

Continues on next page

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4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3 Drain the gearbox. See Draining the axis-6 gearbox on

page 184.
4 Remove all equipment fitted on the turning
disc.
5 If installed, remove the DressPack axis-6
support.

xx1400000208

xx1400000223

6 Jog the robot to:

• Axis 1 = No significance (as long as
the robot is secured to the founda-
tion).
• Axis 2 = +25°
• Axis 3 = +20°
• Axis 4 = 0°
• Axis 5 = -55°
• Axis 6 = -10°

Continues on next page

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 4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Action Note
7
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

8 Remove the synchronization plate axis-6.

xx1300000825

Removing the turning disc

Action Note
1 - IRB 6700 - 235/2.65, IRB 6700 - 205/2.80,
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
Remove the screws and washers, that se-
cure the turning disc.

xx1300000492

2 - IRB 6700 - 200/2.60, IRB 6700 - 155/2.85

Remove the screws and washers, that se-
cure the turning disc.

xx1300002302

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4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Action Note
3 - IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
Remove the screws and washers, that se-
cure the turning disc.

xx1400002195

4 Remove the turning disc.

xx1300000493

Removing the axis-6 gearbox

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, -205/2.80,
-175/3.05, -150/3.20)
• M6x30 quality 12.9 Gleitmo, 24 pcs
(IRB 6700 -200/2.60, -155/2.85)
• M8x50 quality 12.9 Gleitmo, 16 pcs
(IRB 6700 -300/2.70, -245/3.00)

xx1700001600

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 4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Action Note
2
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

3 Remove the gearbox.

If required fit two attachment screws and
press out the gearbox.

xx1700001601

Refitting the axis-6 gearbox

Use these procedures to refit the gearbox.

Preparations before refitting the axis-6 gearbox

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the o-ring and wipe it clean.

Note

The o-ring needs to be cleaned also on a

new spare part.

xx1300000828

3 Check the o-ring.

Replace if damaged.
4 Wipe clean the contact surfaces from any
contamination.
Also wipe clean the o-ring groove.

Continues on next page

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4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Action Note
5 Put some grease on the o-ring.
6 Fit the o-ring in the groove of the gearbox.
7 Foundry Plus:
Apply Loctite 574 on the surface shown in
the figure.

xx1400000717

Refitting the axis-6 gearbox

Action Note
1
CAUTION

Whenever parting/mating motor and gear-

box, the gears may be damaged if excess-
ive force is used.

2 Fit the gearbox to the wrist.

CAUTION

Be careful not to damage motor pinion or

gears!

xx1700001601

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 4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Action Note
3 Secure the gearbox with its attachment Screws:
screws. • M8x40 quality 12.9 Gleitmo, 16 pcs
(IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20)
• M6x30 quality 12.9 Gleitmo, 24 pcs
(IRB 6700 -200/2.60, -155/2.85)
• M8x50 quality 12.9 Gleitmo, 16 pcs
(IRB 6700 -300/2.70, -245/3.00)
Tightening torque:
35 Nm (IRB 6700 -235/2.65, -205/2.80,
-175/3.05, -150/3.20, -300/2.70, -245/3.00)
14 Nm (IRB 6700 -200/2.60, -155/2.85)

xx1700001600

4 Perform a leak-down test. See Performing a leak-down test on

page 198.
5 Jog axis-5 to horizontal position.
6 Refill oil in the gearbox. See Filling oil into the axis-6 gearbox on
page 186.

Refitting the turning disc

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 368.
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

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4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Action Note
4 IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, Tightening torque: 35 Nm.
IRB 6700 - 175/3.05, IRB 6700 - 150/3.20 Attachment screws: M8x25, Steel 12.9
Secure the turning disc with its attachment Gleitmo 603 (24 pcs)
screws and washers. Washers: Steel 8.4x13x1.5 (24 pcs)

xx1300000492

5 IRB 6700 - 200/2.60, IRB 6700 - 155/2.85 Tightening torque: 70 Nm

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

xx1300002302

6 IRB 6700 - 300/2.70, IRB 6700 - 245/3.00 Tightening torque: 70 Nm

Secure the turning disc with its attachment Attachment screws: M10x25, Steel 12.9
screws and washers. Gleitmo 603, (21 pcs)
Washers: Steel 11x17x25 (21 pcs)

xx1400002195

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 4 Repair
4.8.6 Replacing the axis-6 gearbox
Continued

Concluding procedure

Action Note
1 Refit the synchronization plate axis-6.

xx1300000825

2 Re-calibrate the robot. Pendulum Calibration is described in Oper-

ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 798.
General calibration information is included
in section Calibration on page 787.
3
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further described in First test run may
cause injury or damage on page 26.

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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 798.
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.

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5 Calibration
5.1.2 Calibration methods

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 SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy!

xx0400001197

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, Calibration Pendulum is used as default.

Continues on next page

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 5 Calibration
5.1.2 Calibration methods
Continued

Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of all ABB
robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).
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 and
is the most accurate method for the standard calibration. 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
with Axis Calibration method on page 798.
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.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute
Accuracy calibration is used as a TCP calibration. The CalibWare tool guides
through the calibration process and calculates new compensation parameters.
This is further detailed in the Application manual - CalibWare Field 5.0.
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 motor and transmission replacements that do not include
taking apart the robot structure, standard calibration is sufficient. Standard
calibration also supports wrist exchange.

References
Article numbers for the calibration tools are listed in the section Special tools on
page 830.
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.

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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 recalibrated 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 794. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.

The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be recalibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

790 Product manual - IRB 6700

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 5 Calibration
5.2.1 Synchronization marks and synchronization position for axes

5.2 Synchronization marks and axis movement directions

5.2.1 Synchronization marks and synchronization position for axes

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

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5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
Continued

Axis 5 Axis 6
Two variants of synchronization mark plates.

xx1300000872

xx1300000873

xx1500000845

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 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

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5 Calibration
5.3 Updating revolution counters

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 791.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 795.

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, -205/2.80, Yes No
-175/3.05, -150/3.20, -
200/2.60, -155/2.85
IRB 6700-300/2.70, -245/3.00 No No

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).

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 5 Calibration
5.3 Updating revolution counters
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

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5 Calibration
5.3 Updating revolution counters
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

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 5 Calibration
5.3 Updating revolution counters
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 811.

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5 Calibration
5.4.1 Description of Axis Calibration

5.4 Calibrating with Axis Calibration method

5.4.1 Description of Axis Calibration

Instructions for Axis Calibration procedure given on the FlexPendant

The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
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:
• 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.

• 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.

• The axis position is stored in RobotWare with an active choice from the
operator.

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 5 Calibration
5.4.1 Description of Axis 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.
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.

Note

When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.

Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.

Validation
In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to
its calibration position during the calibration procedure.
In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are
allowed to be jogged will be given on the FlexPendant. These axes are marked
with Unrestricted in the FlexPendant window.

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5 Calibration
5.4.2 Calibration tools for Axis 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.

Equipment, etc. Article number Note

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

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 5 Calibration
5.4.2 Calibration tools for Axis 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.

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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, if needed.
Spare part Article number Note
Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.

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 5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure

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.

Equipment, etc. Article number Note

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.

Required consumables
Consumable Article number Note
Clean cloth -

Spare parts

Spare part Article number Note

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

The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for 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 799.
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.

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5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
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 robots 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.

Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.
Action Note
1 On the ABB menu, tap Calibration.

xx1500000942

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 5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Action Note
2 All mechanical units connected to the system are
shown with their calibration status.
Tap the mechanical unit in question.

xx1500000943

3 Calibration method used at factory for each axis The FlexPendant will give all inform-
is shown, as well as calibration method used for ation needed to proceed with Axis
the robot during last field calibration. Calibration.
Tap Run Calibration Method. The software will
automatically call for the procedure for the valid
calibration method.

xx1500000944

4 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 803.

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.

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5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Situation Action
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 on page 804.
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 793

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.

Safety controller not synchronized - SafeMove message

Action Note
1 SafeMove generates the message "Safety control-
ler not synchronized".

xx1500002480

2 Confirm unsynchronized state by pressing Ac-

knowledge to continue Axis Calibration proced-
ure.
3 Restart Axis Calibration procedure by pressing
Play.

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 5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Continued

Unsynchronized speed exceeded - SafeMove message while saving robot data

Action Note
1 SafeMove generates the message "Unsynchron-
ized speed exceeded" while saving robot data.

xx1500002481

2 Press Acknowledge to continue Axis Calibration

procedure.
3 Restart Axis Calibration procedure by pressing
Play.

Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine

Action Note
1 SafeMove generates the message "Unsynchron-
ized time limit expired" (anytime).

xx1500002482

2 Press OK to continue Axis Calibration procedure.

3 Restart Axis Calibration procedure by pressing
Play.

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5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
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.

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 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.

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5 Calibration
5.6 Verifying the calibration

5.6 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 811.
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 791.
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.
4 Remove any calibration equipment from the robot.

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 5 Calibration
5.7 Checking the synchronization position

5.7 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 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 791 and Updating revolution
counters on page 794.

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 791 and
date the revolution counters. Updating revolution counters on page 794.

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This page is intentionally left blank
 6 Decommissioning
6.1 Environmental information

6 Decommissioning
6.1 Environmental information

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

Hazardous material
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
Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Base, lower arm, upper arm
Steel Gears, screws, base frame, and so on.
Neodymium Brakes, motors
Plastic/rubber Cables, connectors, drive belts, and so on.
Oil, grease Gearboxes
Aluminium Covers, synchronization brackets
Nickel Turning disc (foundry)

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.

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6 Decommissioning
6.1 Environmental information
Continued

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.

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 6 Decommissioning
6.2 Scrapping of robot

6.2 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries. 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.

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6 Decommissioning
6.3 Decommissioning of balancing device

6.3 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
Standard toolkit - Content is defined in section Standard
toolkit on page 829.
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 461.
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.

Continues on next page

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 6 Decommissioning
6.3 Decommissioning of balancing device
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!

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6 Decommissioning
6.3 Decommissioning of balancing device
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.

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 7 Robot description
7.1 Type A vs type B motors

7 Robot description
7.1 Type A vs type B motors

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)

Identifying the motor by article number

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.

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 235 205 175 150 200 155 300 245
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
3 3HAC045063-001 3HAC055435-001 X X X X X X
3HAC051323-001 3HAC055443-001 X X

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7 Robot description
7.1 Type A vs type B motors
Continued

Robot Article number Article number 235 205 175 150 200 155 300 245
axis Type A motor Type B motor /2.65 /2.80 /3.05 /3.20 /2.60 /2.85 /2.70 /3.00
4 3HAC045064-001 3HAC055436-001 X X X X X X
3HAC045762-001 3HAC055449-001 X X
5 3HAC045064-001 3HAC055436-001 X X X X X X X X
6 3HAC045066-001 3HAC055445-001 X X X X X X
3HAC045067-001 3HAC055438-001 X X

Interchangeable parts
Use the table to see if type A and type B motors are interchangeable on each robot
axis.

Robot axis Motor replacement from Requirements/notes for replacing type A motor
type A to type B with type B motor
1 Fully interchangeable.
2 Fully interchangeable.
3 Fully interchangeable.
4 Fully interchangeable.
5 Partly interchangeable. Replacement to type B requires replacement of
the heat protection plates that are fitted to the
motor.
6 Interchangeable in a wrist A type B motor does not fit a wrist that is manu-
that is manufactured in and factured before October 2015.
after October 2015.

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 8 Reference information
8.1 Introduction

8 Reference information
8.1 Introduction

General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

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8 Reference information
8.2 Applicable standards

8.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.

Standards, EN ISO
The product is designed in accordance with the requirements of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1:2011 Robots for industrial environments - Safety requirements -Part
1 Robot
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard Description
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design

Continues on next page

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 8 Reference information
8.2 Applicable standards
Continued

Other standards

Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments

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8 Reference information
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

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 8 Reference information
8.4 Screw joints

8.4 Screw joints

General
This section describes how to tighten the various types of screw joints on the IRB
6700 .
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.

UNBRAKO screws
UNBRAKO is a special type of 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. 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.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 3HAC042472-001

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.

Continues on next page

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8 Reference information
8.4 Screw joints
Continued

• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!

Oil-lubricated screws with slotted or cross-recess head 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.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with allen head screws.

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

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
M24 680 960 1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35

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 8 Reference information
8.4 Screw joints
Continued

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for
water and air connectors when one or both connectors are made of brass.

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

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

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8 Reference information
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 robot weighs 1300 kg.

All lifting accessories used must be sized accord-
ingly.

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 8 Reference information
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

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8 Reference information
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 829, and of special tools, listed directly in the instructions
and also gathered in this section.

Special tools

Continues on next page

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 8 Reference information
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
3HAC13056-4 Guide pin, M12x200 x x x x x
3HAC13056-4 Guide pin, M12x250
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 ii
Lifting accessory, gearbox x
3HAC046128-001 iii
3HAC046128-001 v
3HACxx vi Lifting accessory, gearbox x
3HAC046112-001 vii

Lifting eye
3HAC16131-1 2 2 2 2 2
M12
xx1200001242

Lifting eye
3HAC14457-4 2 x
M16
xx1200001242

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8 Reference information
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)

Lifting shackle
- x x x x x
SA-10-8-NA1
xx1200001243

Fender washer
- Outer diameter: minimum 26 mm, x x x x x
maximum 30 mm, hole diameter:
13 mm, thickness: 3 mm.
Roundsling, 1.5 m
- Length: 1.5 m. Lifting capacity: x x x
2,000 kg.
Roundsling, 1 m
- Length: 1 m, lifting capacity: 1,000 x x x x x x x x x x
kg.
3HAC047054-003 Fork lift accessory set x x x x x
Press, puller and unloading tools
3HAC12475-6 AdapterM20-M16 x x x
3HAC028920-001 Dismantle and mounting tool x x x x x

3HAC030662-001 Distance tool x x x x

xx1400000726

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
Removal tools
- ScrewsM8x75, fully threaded 3

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 8 Reference information
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)

3HAC057339-003 Removal tool M12 xi xi xi x x x

3HAC057339-004 Removal tool M14 xi xi xi 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 ix 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 ix

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
Pallet x x x x x

3HAC067546-001 x
3HAC067547-001 xi Pinion x
3HAC067545-001 xii
xx1800001147

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8 Reference information
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)

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 819.
ii IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
iii IRB 6700 - 200/2.60, IRB 6700 - 155/2.85, IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
v IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
vi IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
vii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00
Included in Dismantle and mounting tool (3HAC028920-001).
ix The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same 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.
x IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700 - 175/3.05, IRB 6700 - 150/3.20
xi IRB 6700 - 200/2.60, IRB 6700 - 155/2.85
xii IRB 6700 - 300/2.70, IRB 6700 - 245/3.00

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 8 Reference information
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.
This implies that the instructions delivered with the lifting accessories should be
stored for later reference.

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 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.mypo-
rtal.abb.com.

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This page is intentionally left blank
 10 Circuit diagrams
10.1 Circuit diagrams

10 Circuit diagrams
10.1 Circuit diagrams

Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.myportal.abb.com.
See the article numbers in the tables below.

Controllers

Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004
Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product Article numbers for circuit diagrams

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 260 3HAC025611-001
Circuit diagram - IRB 360 3HAC028647-009
Circuit diagram - IRB 460 3HAC036446-005
Circuit diagram - IRB 660 3HAC025691-001
Circuit diagram - IRB 760 3HAC025691-001
Circuit diagram - IRB 1200 3HAC046307-003
Circuit diagram - IRB 1410 3HAC2800-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 1520 3HAC039498-007
Circuit diagram - IRB 2400 3HAC6670-3
Circuit diagram - IRB 2600 3HAC029570-007
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 4600 3HAC029038-003
Circuit diagram - IRB 6400RF 3HAC8935-1
Circuit diagram - IRB 6600 type A 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6600 type B 3HAC13347-1
3HAC025744-001

Continues on next page

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10 Circuit diagrams
10.1 Circuit diagrams
Continued

Product Article numbers for circuit diagrams

Circuit diagram - IRB 6620 3HAC025090-001
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6640 3HAC025744-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6660 3HAC025744-001
3HAC029940-001
Circuit diagram - IRB 6700 3HAC043446-005
Circuit diagram - IRB 7600 3HAC13347-1
3HAC025744-001
Circuit diagram - Product.ProductName 3HAC050778-003
Circuit diagram - IRB 910SC 3HAC056159-002

840 Product manual - IRB 6700

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 Index

Index disposal, 813

handling, 35
battery
A replacing, 189
Absolute Accuracy, calibration, 789
battery shutdown
additional mechanical stop location, 148
service routine, 189
aluminum
bearing
disposal, 813
balancing device front eye, 192
ambient humidity
brake release, 85
operation, 51
brake release unit
storage, 51
replacing, 291
ambient temperature
brakes
operation, 51
testing function, 34
storage, 51
BRU
assembly instructions, 47
replacing, 291
assessment of hazards and risks, 18
buttons for brake release, 85
axis-6
gearbox C
replacing, 776 cabinet lock, 23, 29
axis-1 gearbox cable harness
replacing, 701 replacing, 231, 255
axis 1 cable harness attachments, 140
gearbox cabling, robot, 99
replacing, 586 cabling between robot and controller, 99
mechanical stop calibrating
replacing, 499 robot, 798
motor roughly, 794
replacing, 503 calibrating robot, 798
axis 2 calibration
gearbox Absolute Accuracy type, 788
replacing, 664 rough, 794
motor standard type, 788
replacing, 517 verification, 810
axis 3 when to calibrate, 790
gearbox calibration, Absolute Accuracy, 789
replacing, 738 calibration manuals, 789
motor calibration marks, 791
replacing, 530 calibration position
axis 4 jogging to, 811
motor scales, 791
replacing, 543 calibration scales, 791
axis 5 CalibWare, 788
motor carbon dioxide extinguisher, 20
replacing, 554 cast iron
axis 6 disposal, 813
motor changing oil
replacing, 571 axis 1, 158
Axis Calibration, 798 axis 2, 165
calibration tool axis 3, 170
article number, 800, 803 axis 4, 176
examining, 800 axis 5, 180
installation position, 802 axis 6, 184
overview of method, 798 cleaning, 194
procedure on FlexPendant, 803 climbing on robot, 23
protective cover and protection plug, 802–803 Cold environments, 109
connecting the robot and controller, cabling, 99
B connection
balancing device
external safety devices, 24
inspection, 136
cooling fan, 103
lubrication of front eye bearing, 192
copper
replacing, 461
disposal, 813
restoring, 496
unloading, 492 D
base plate damage to additional mechanical stop, 148
guide pins, 69 damage to mechanical stop, 146
securing, 69 dampers
batteries inspection, 152

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Index

danger levels, 38 I
direction of axes, 793 information labels location, 142
inspecting
E additional mechanical stop, 148
enabling device, 28 cable harness, 140
environmental information, 813 dampers, 152
equipment, on robot, 88 information labels, 142
ESD mechanical stop, 146
damage elimination, 31 motor seal, 116
sensitive equipment, 31 inspecting balancing device, 136
expected life, 115 inspecting oil levels
external safety devices, 24 axis 1, 118
axis 2, 123
F axis 3, 126
fan, 103 axis 4, 129
fire extinguishing, 20 axis 5, 131
fitting equipment to robot, 88 axis 6, 133
FlexPendant installation
jogging to calibration position, 811 mechanical stop axis 1, 97
MoveAbsJ instruction, 811 installation on track motion carriage, 83
updating revolution counters, 795 installing
foundation motor cooling fan, 103
requirements, 50 instructions for assembly, 47
securing robot, 82 integrator responsibility, 17
intervals for maintenance, 113
G
gearbox L
axis-6 labels
replacing, 776 robot, 40
axis 1 leak-down test, 198
replacing, 586 lifting
axis 2 complete arm system, 206
replacing, 664 lower and upper arm together, 217, 223
axis 3 robot, 75–76
replacing, 738 upper arm, 228
inspecting oil level axis 1, 118 lifting accessory, 828
inspecting oil level axis 2, 123 limitation of liability, 17
inspecting oil level axis 3, 126 Lithium
inspecting oil level axis 4, 129 disposal, 813
inspecting oil level axis 5, 131 loads on foundation, 49
inspecting oil level axis 6, 133 lower arm
oil change axis 1, 158 replacing, 377
oil change axis 2, 165 lubricating
oil change axis 3, 170 spherical roller bearing, 192
oil change axis 4, 176 lubrication
oil change axis 5, 180 amount in gearboxes, 156
oil change axis 6, 184 type of lubrication, 156
gearbox axis-1
replacing, 626 M
gearboxes magnesium
location of, 157 disposal, 813
grease maintenance intervals, 113
disposal, 813 maintenance schedule, 113
guide pins, base plate, 69 manually releasing brakes, 85
mechanical stop
H axis 1, 97
hanging replacing, 499
installed hanging, 23 mechanical stop location, 146
hazardous material, 813 motor
height axis 1
installed at a height, 23 replacing, 503
hold-to-run, 28 axis 2
holes for equipment, 88 replacing, 517
HRA, 18 axis 3
humidity replacing, 530
operation, 51 axis 4
storage, 51 replacing, 543

842 Product manual - IRB 6700

3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
 Index

axis 5 axis-1 gearbox, 586, 701

replacing, 554 axis-1 motor, 503
axis 6 balancing device, 461
replacing, 571 battery, 189
motor cooling fan, 103 brake release unit, 291
motor seal cable harness, 231, 255
inspecting, 116 gearbox axis-1, 626
MoveAbsJ instruction, 811 lower arm, 377
mechanical stop pin, 499
N SMB unit, 285
nation specific regulations, 17 turning disc, 365
negative directions, axes, 793 upper arm, 296
neodymium wrist, 340
disposal, 813 xx, 67, 479
NiCad requirements on foundation, 50
disposal, 813 responsibility and validity, 17
nodular iron restoring
disposal, 813 balancing device, 496
restricting
O working range axis 1, 97
oil revolution counters
amount in gearboxes, 156 storing on FlexPendant, 795
disposal, 813 updating, 794
type of oil, 156 risk of tipping, 58
oil change robot
axis 1, 158 labels, 40
axis 2, 165 lifting, 75–76
axis 3, 170 protection class, 51
axis 4, 176 protection types, 51
axis 5, 180 securing to foundation, 82
axis 6, 184 securing to track motion, 83
safety risks, 36 symbols, 40
oil level roundslings
gearbox axis 1, 118 lifting the robot, 76
gearbox axis 2, 123 rubber
gearbox axis 3, 126 disposal, 813
gearbox axis 4, 129
gearbox axis 5, 131 S
gearbox axis 6, 133 safety
operating conditions, 51 brake testing, 34
ESD, 31
P fire extinguishing, 20
pedestal moving robots, 25
installed on pedestal, 23 release robot axes, 21
plastic signal lamp, 102
disposal, 813 signals, 38
positive directions, axes, 793 signals in manual, 38
product standards, 822 symbols, 38
protection classes, 51 symbols on robot, 40
protection type, 51 test run, 26
protective equipment, 24 working range, 27
protective wear, 24 safety equipment
mechanical stop, 97
R signal lamp, 154
rear bearings safety fence, 18
replacing, 479 safety risk
region specific regulations, 17 electric parts, 29
release brakes, 21 hot parts, 32
replacing hydraulic system, 33
axis-6 gearbox, 776 installation, 23
axis-6 motor, 571 oil change, 36
axis-5 motor, 554 operational disturbance, 23
axis-4 motor, 543 pneumatic system, 33
axis-3 gearbox, 738 service work, 23
axis-3 motor, 530 voltage, 29
axis-2 gearbox, 664 safety signals
axis-2 motor, 517 in manual, 38

Product manual - IRB 6700 843

3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
Index

safety standards, 822 track motion

safety zones, 18 securing robot, 83
scales on robot, 791 transporting the robot, 65
schedule of maintenance, 113 transport support, 65
screw joints, 825 troubleshooting
securing oil spills, 194
base plate, 69 turning disc
securing the robot to foundation, attachment screws, 81 replacing, 365
serial measurement board type A motors, 819
replacing, 285 type B motors, 819
signal lamp, 102
signals U
safety, 38 unloading
SMB balancing device, 492
replacing, 285 updating revolution counters, 794
SMB battery upper arm
extension of lifetime, 189 replacing, 296
replacing, 189
speed V
adjusting, 109 validity and responsibility, 17
stability, 58 velocity
standards, 822 adjusting, 109
ANSI, 823 verifying calibration, 810
CAN, 823
EN, 822 W
EN IEC, 822 weight, 49
EN ISO, 822 axis-1 gearbox, 603, 606, 643, 645
start of robot in cold environments, 109 axis-1 gearbox and base, 641, 650
steel axis-1 motor, 508, 511, 597, 617, 635, 655
disposal, 813 balancing device, 383, 449, 455, 466, 471, 482, 671,
stop pin 707
replacing, 499 base plate, 68, 74
storage conditions, 51 robot, 79, 602, 611, 640, 652, 828
symbols upper arm, complete, 229, 313, 319, 321–322, 400,
safety, 38 414, 416–417, 750, 763–765
synchronization position, 794 working range
sync marks, 791 restricting axis 1, 97
system integrator requirements, 17 wrist
replacing, 340
T
temperatures X
operation, 51 xx
storage, 51 replacing, 67
testing Z
brakes, 34 zero position
three-position enabling device, 28 checking, 811
torques on foundation, 49

844 Product manual - IRB 6700

3HAC044266-001 Revision: N
© Copyright 2013 - 2018 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
3HAC044266-001, Rev N, en

© Copyright 2013 - 2018 ABB. All rights reserved.

Specifications subject to change without notice.