ABB Robotics IRB 6790

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Product manual - IRB 6790 33

3HAC063331-001 Revision: B

1 Safety

1.5.1 Maintenance and repair

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Table of Contents5
Overview of this Manual9
Product Documentation12
How to Read the Product Manual14
Important Information about Robots with Protection Type Foundry Prime15
Safety17
Safety Information17
Limitation of Liability17
Requirements on Personnel18
Safety Signals and Symbols19
Safety Signals in the Manual19
Safety Symbols on Manipulator Labels21
Robot Stopping Functions27
Installation and Commissioning28
Maintenance and Repair31
Emergency Release of the Robot Axes34
Brake Testing35
Troubleshooting36
Decommissioning37
Installation and Commissioning39
Introduction to Installation and Commissioning39
Unpacking40
Pre-Installation Procedure40
Working Range44
Risk of Tipping/Stability47
Main Dimensions48
The Unit Is Sensitive to ESD49
On-Site Transportation50
Robot Transportation Precautions50
Securing the Robot with a Transport Support54
On-Site Installation55
Brief Installation Procedure55
Lifting the Base Plate56
Securing the Base Plate57
Lifting the Robot60
Lifting the Robot with Fork Lift60
Lifting the Robot with Roundslings61
Orienting and Securing the Robot65
Installation Requirements for Foundry Prime Robots68
Shut-Down Periods77
Manually Releasing the Brakes78
Loads Fitted to the Robot, Stopping Time and Braking Distances80
Fitting Equipment to the Robot81
On-Site Storage88
Increase the Lifetime of the Robot88
Restricting the Working Range89
Axes with Restricted Working Range89
Mechanically Restricting the Working Range of Axis 190
Electrical Connections92
Robot Cabling and Connection Points92
Start of Robot in Cold Environments94
Maintenance95
Introduction95
Maintenance Schedule and Expected Component Life96
Specification of Maintenance Intervals96
Maintenance Schedule97
Expected Component Life99
Inspection Activities100
Inspecting the Oil Level in Axis-1 Gearbox100
Inspecting the Oil Level in Axis-2 Gearbox103
Inspecting the Oil Level in Axis-3 Gearbox105
Inspecting the Oil Level in Axis-4 Gearbox107
Inspecting the Oil Level in Axis-5 Gearbox109
Inspecting the Oil Level in Axis-6 Gearbox111
Inspecting the Balancing Device114
Inspecting the Cable Harness118
Inspecting the Axis-1 Mechanical Stop Pin120
Inspecting the Additional Mechanical Stops122
Inspecting the Fork Lift Accessory124
Inspecting the Dampers126
Inspecting the Leak Flow (Overpressure Unit) in the System128
Analyzing Activities130
Analyzing the Water Content in Gearbox Oil130
Replacement/Changing Activities131
Type of Lubrication in Gearboxes131
Changing Oil, Axis-1 Gearbox132
Changing Oil, Axis-2 Gearbox137
Changing Oil, Axis-3 Gearbox142
Changing Oil, Axis-4 Gearbox146
Changing Oil, Axis-5 Gearbox150
Changing Oil, Axis-6 Gearbox154
Replacing the SMB Battery158
Cleaning Activities161
Cleaning the IRB 6790161
Repair165
Introduction165
General Procedures166
Performing a Leak-Down Test166
Mounting Instructions for Bearings167
Mounting Instructions for Sealings169
Dismantle and Mounting Tool, 3HAC028920-001172
Painting Damaged Nickel Coated Surfaces with Touch up Paint173
The Brake Release Buttons May be Jammed after Service Work174
Lifting Associated Procedures175
Attaching Lifting Accessories to Complete Arm System175
Attaching Lifting Accessories to an Un-Separated Lower and Upper Arm179
Attaching Lifting Accessories to the Upper Arm184
Complete Robot187
Removing the Cable Harness187
Refitting the Cable Harness209
Replacing the SMB240
Replacing the Brake Release Unit247
Upper and Lower Arms253
Replacing the Upper Arm253
Replacing the Wrist289
Replacing the Turning Disc311
Replacing the Lower Arm316
Frame and Base367
Replacing Spherical Roller Bearing, Link Ear367
Replacing the Balancing Device382
Replacing the Rear Bearings on the Balancing Device399
Unloading the Balancing Device411
Restoring the Balancing Device415
Replacing the Stop Pin418
Motors422
Replacing the Axis-1 Motor422
Replacing the Axis-2 Motor434
Replacing the Axis-3 Motor447
Replacing the Axis-4 Motor460
Replacing the Axis-5 Motor472
Replacing the Axis-6 Motor487
Gearboxes501
Replacing the Axis-1 Gearbox501
Replacing the Axis-2 Gearbox542
Replacing the Axis-3 Gearbox576
Replacing the Axis-6 Gearbox602
Calibration613
Introduction to Calibration613
Introduction and Calibration Terminology613
Calibration Methods614
When to Calibrate616
Synchronization Marks and Axis Movement Directions617
Synchronization Marks and Synchronization Position for Axes617
Calibration Movement Directions for All Axes618
Updating Revolution Counters619
Calibrating with Axis Calibration Method623
Description of Axis Calibration623
Calibration Tools for Axis Calibration626
Installation Locations for the Calibration Tools628
Axis Calibration - Running the Calibration Procedure629
Reference Calibration634
Verifying the Calibration636
Checking the Synchronization Position637
Decommissioning639
Environmental Information639
Scrapping of Robot641
Decommissioning of Balancing Device642
Reference Information645
Introduction645
Applicable Standards646
Unit Conversion647
Screw Joints648
Weight Specifications651
Standard Toolkit652
Special Tools653
Lifting Accessories and Lifting Instructions657
Spare Parts659
Spare Part Lists and Illustrations659
Circuit Diagrams661
Index663

ABB Robotics IRB 6790 - Page 33

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