ABB IRB 6700 Series

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Table of Contents5
Overview of this Manual9
Product Documentation14
How to Read the Product Manual16
Safety17
General Safety Information17
Limitation of Liability17
Protective Stop and Emergency Stop19
Safety Actions20
Fire Extinguishing20
Emergency Release of the Robot Axes21
Make Sure that the Main Power Has Been Switched off22
Safety Risks23
Safety Risks During Installation and Service Work on Robots23
Moving Robots Are Potentially Lethal25
First Test Run May Cause Injury or Damage26
Work Inside the Working Range of the Robot27
Enabling Device and Hold-To-Run Functionality28
Risks Associated with Live Electric Parts29
The Unit Is Sensitive to ESD31
Hot Parts May Cause Burns32
Safety Risks Related to Pneumatic/Hydraulic Systems33
Brake Testing34
Safety Risks During Handling of Batteries35
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)36
Safety Signals and Symbols38
Safety Signals in the Manual38
Safety Symbols on Product Labels40
Installation and Commissioning47
Introduction47
Unpacking48
Pre-Installation Procedure48
Working Range52
Risk of Tipping/Stability58
Main Dimensions59
On-Site Transportation61
Robot Transportation Precautions61
Securing the Robot with a Transport Support65
On-Site Installation67
Brief Installation Procedure67
Lifting the Base Plate68
Securing the Base Plate69
Lifting the Robot75
Lifting the Robot with Fork Lift75
Lifting the Robot with Roundslings76
Orienting and Securing the Robot80
Manually Releasing the Brakes85
Loads Fitted to the Robot, Stopping Time and Braking Distances87
Fitting Equipment to the Robot88
Restricting the Working Range96
Axes with Restricted Working Range96
Mechanically Restricting the Working Range of Axis97
Electrical Connections99
Robot Cabling and Connection Points99
Installation of Options102
Signal Lamp (Option)102
Installing the Motor Cooling Fan (Option)103
Start of Robot in Cold Environments109
Maintenance111
Introduction111
Maintenance Schedule and Expected Component Life112
Specification of Maintenance Intervals112
Maintenance Schedule113
Expected Component Life115
Inspection Activities116
Inspecting the Motor Seal116
Inspecting the Oil Level in Axis-1 Gearbox118
Inspecting the Oil Level in Axis-2 Gearbox123
Inspecting the Oil Level in Axis-3 Gearbox126
Inspecting the Oil Level in Axis-4 Gearbox129
Inspecting the Oil Level in Axis-5 Gearbox131
Inspecting the Oil Level in Axis-6 Gearbox133
Inspecting the Balancing Device136
Inspecting the Cable Harness140
Inspecting the Information Labels142
Inspecting the Axis-1 Mechanical Stop Pin146
Inspecting the Additional Mechanical Stops148
Inspecting the Fork Lift Accessory150
Inspecting the Dampers152
Inspecting the Signal Lamp (Option)154
Replacement/Changing Activities156
Type of Lubrication in Gearboxes156
Changing Oil, Axis-1 Gearbox158
Changing Oil, Axis-2 Gearbox165
Changing Oil, Axis-3 Gearbox170
Changing Oil, Axis-4 Gearbox176
Changing Oil, Axis-5 Gearbox180
Changing Oil, Axis-6 Gearbox184
Replacing the SMB Battery189
Lubrication Activities192
Lubricating the Spherical Roller Bearing, Balancing Device192
Cleaning Activities194
Cleaning the IRB 6700194
Repair197
Introduction197
General Procedures198
Performing a Leak-Down Test198
Mounting Instructions for Bearings199
Mounting Instructions for Seals201
Dismantle and Mounting Tool, 3HAC028920-001203
Cut the Paint or Surface on the Robot before Replacing Parts204
The Brake Release Buttons May be Jammed after Service Work205
Lifting Associated Procedures206
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
Attaching Lifting Accessories to Complete Arm System (IRB 6700 -300/2.70, -245/3.00)211
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
Attaching Lifting Accessories to an Un-Separated Lower and Upper Arm (IRB 6700 -300/2.70, -245/3.00)223
Attaching Lifting Accessories to the Upper Arm228
Complete Robot231
Removing the Cable Harness231
Refitting the Cable Harness255
Replacing the SMB285
Replacing the Brake Release Unit291
Upper and Lower Arms296
Replacing the Upper Arm296
Replacing the Wrist340
Replacing the Turning Disc365
Replacing the Process Turning Disc371
Replacing the Lower Arm377
Frame and Base443
Replacing Spherical Roller Bearing, Link Ear443
Replacing the Balancing Device461
Replacing the Rear Bearings on the Balancing Device479
Unloading the Balancing Device492
Restoring the Balancing Device496
Replacing the Stop Pin499
Motors503
Replacing the Axis-1 Motor503
Replacing the Axis-2 Motor517
Replacing the Axis-3 Motor530
Replacing the Axis-4 Motor543
Replacing the Axis-5 Motor554
Replacing the Axis-6 Motor571
Gearboxes586
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
Replacing the Axis-1 Gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)626
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
Replacing the Axis-2 Gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00)701
Replacing the Axis-3 Gearbox738
Replacing the Axis-6 Gearbox776
Calibration787
Introduction to Calibration787
Introduction and Calibration Terminology787
Calibration Methods788
When to Calibrate790
Synchronization Marks and Axis Movement Directions791
Synchronization Marks and Synchronization Position for Axes791
Calibration Movement Directions for All Axes793
Updating Revolution Counters794
Calibrating with Axis Calibration Method798
Description of Axis Calibration798
Calibration Tools for Axis Calibration800
Installation Locations for the Calibration Tools802
Axis Calibration - Running the Calibration Procedure803
Calibrating with Calibration Pendulum Method809
Verifying the Calibration810
Checking the Synchronization Position811
Decommissioning813
Environmental Information813
Scrapping of Robot815
Decommissioning of Balancing Device816
Robot Description819
Type a Vs Type B Motors819
Reference Information821
Introduction821
Applicable Standards822
Unit Conversion824
Screw Joints825
Weight Specifications828
Standard Toolkit829
Special Tools830
Lifting Accessories and Lifting Instructions835
Spare Parts837
Spare Part Lists and Illustrations837
Circuit Diagrams839
Index841

ABB IRB 6700 Series - Page 812

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