ABB Robotics IRB 6790 Product Manual

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IRB 6790

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Summary of Contents for ABB Robotics IRB 6790

Page 1 ROBOTICS Product manual IRB 6790...
Page 2 Trace back information: Workspace 20A version a8 Checked in 2020-03-09 Skribenta version 5.3.033...
Page 3 Product manual IRB 6790 - 235/2.65 IRB 6790 - 205/2.80 IRC5 Document ID: 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved. Specifications subject to change without notice.
Page 4 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.
Page 5: Table Of Contents
Mechanically restricting the working range of axis 1 ........Electrical connections ..................2.7.1 Robot cabling and connection points ............Start of robot in cold environments ..............Maintenance Introduction ...................... Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 6 Changing oil, axis-5 gearbox ..............3.5.7 Changing oil, axis-6 gearbox ..............3.5.8 Replacing the SMB battery ............... Cleaning activities ..................... 3.6.1 Cleaning the IRB 6790 ................Repair Introduction ...................... General procedures ................... 4.2.1 Performing a leak-down test ..............4.2.2 Mounting instructions for bearings .............
Page 7 Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagrams Circuit diagrams ....................Index Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
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Page 9: Overview Of This Manual
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 6790 . Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 3HAC064429-001 Product specification - IRB 6790 3HAC064168-001 Directions for use - Fork lift accessory for IRB 6700 3HAC048484-002 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Safety manual for robot - Manipulator and IRC5 or OmniCore con- 3HAC031045-001 troller...
Page 11 Mounting instructions for sealings on page 169. • Clarified text about position of robot and added table with depend- encies between axes during Axis Calibration. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 12: 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.
Page 13 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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 15: Important Information About Robots With Protection Type Foundry Prime
For more information, see Pressurized system on page Cleaning Special procedures are needed when cleaning the Foundry Prime robot. See section Cleaning the IRB 6790 on page 161. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
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Page 17: Safety
ABB is not liable for damages caused by the use of non-original spare parts and equipment. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 18: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the product manual. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 19: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 20 Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 21: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 22 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 23 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 24 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 25 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 26 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 27: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 28: Installation And Commissioning
The power supply wiring to the robot must be sufficiently fused and if necessary, it must be possible to disconnect it manually from the mains power. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 29 The risk assessment should also consider other hazards, such as, but not limited • Water • Compressed air • Hydraulics Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 30 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 32 Risk of fire or explosion. Operating temperatures are listed in Operating conditions, robot on page Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 33 1 Safety 1.5.1 Maintenance and repair Continued Related information See also the safety information related to installation and operation. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 34: Emergency Release Of The Robot Axes
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 35: Brake Testing
3 Inspect and verify that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 36: Troubleshooting
A risk assessment must be done to address both robot and robot system specific hazards. Related information See also the safety information related to installation, operation, maintenance, and repair. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 37: Decommissioning
1 Safety 1.7 Decommissioning 1.7 Decommissioning General See section Decommissioning on page 639. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
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Page 39: Installation And Commissioning
Note If the IRB 6790 is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...
Page 40: Unpacking
Install required equipment, if any. Weight, robot The table shows the weight of the robot. Robot model Weight IRB 6790 1300 kg Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 41 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 ±19.8 kN Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 42 +55°C (+131°F) Maximum ambient temperature (less than 24 hrs) +70°C (+158°F) Maximum ambient humidity 100% at constant temperature (gaseous only) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 43 Protection class Manipulator, protection type Foundry Prime IP69 Includes all manipulator electrical compartments, excludes the Harting connector on the connection panel which is IP67. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 44: Working Range
±93.7 revolutions Maximum value. The default working range for axis 6 can be extended by changing parameter values in the software. Illustration, working range IRB 6790 - 235/2.65 This illustration shows the unrestricted working range of the robot. 1187 1908 2650...
Page 45 2 Installation and commissioning 2.2.2 Working range Continued Illustration, working range IRB 6790 - 205/2.80 This illustration shows the unrestricted working range of the robot. 1281 2039 2794 Robot type Handling capacity Reach IRB 6790 205 kg 2.80 m Continues on next page...
Page 46 2.2.2 Working range Continued Turning radius axis 1 xx1300001082 Robot variant R1 (mm) IRB 6790 - 235/2.65 2650 IRB 6790 - 205/2.80 2794 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 47: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx1300000356 WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 48: Main Dimensions
Radius ax1, back = 633 mm Robot variant IRB 6790 - 235/2.65 2300 1135 1670 1,182.5 IRB 6790 - 205/2.80 2445 1280 1670 1,182.5 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 49: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 50: On-Site Transportation
Risk of tipping/stability on page • Always read and follow the instructions in section Pre-installation procedure on page 40 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 51 Recommended transport support on page IRB 6790 xx0800000037 Transport Support Hexagon socket head cap screw M16x140 Threaded bar M10x200 Nut M10 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 52 Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 6790 xx0800000040 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 53 ( 52 ) ( 62 ) xx1300001603 Variant IRB 6790 - 235/2.65 IRB 6790 - 205/2.80 Lower arm L 1135 1280 1000 1160 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 54: Securing The Robot With A Transport Support
Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see the section Shut-down periods on page 77 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 55: On-Site Installation
This procedure is a brief guide when installing the robot for the first time. Also see Pre-installation procedure on page First installation Use these procedures to install the IRB 6790 . Action Note Transport the manipulator to its intended location.
Page 56: Lifting The Base Plate
Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 57: Securing The Base Plate
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 58 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 59 All screws and pins are delivered in a plastic bag together with the base plate. xx1500000250 A Cylindrical guide pin B M5 x 40. Tightening torque 6 Nm. (x2) Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 60: Lifting The Robot
Directions for use - Fork lift accessory for IRB 6700 3HAC048484-002 Lifting the robot Action Note Lift the robot according to the user instructions enclosed with the fork lift accessory. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 61: Lifting The Robot With Roundslings
Roundsling, 2 m Length: 2 m. Lifting capacity: 2,000 kg. Roundsling, 2.5 m Length: 2.5 m. Lifting capacity: 2,000 kg. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 62 Lifting the robot with roundslings Action Note Fit lifting eyes to the outer holes on each corner of the base. xx1200001301 xx1200001302 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 63 Note The securing sling must not be strained at lifting. It only secures for tipping. xx1300001574 CAUTION The IRB 6790 robot weighs 1300 kg. All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum- stances, be present under the suspended...
Page 65: Orienting And Securing The Robot
45 H7 25 H8 0,12 0,12 D - D E - E xx1300000243 Description Holes for guide pins (x2) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 66 Tightening torque: 550 Nm (screws lubricated with Molykote 1000) 600-725 Nm, typical 650 Nm (screws none or lightly lubricated) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 67 Note Lightly lubricate screws before as- sembly. Tighten bolts in a crosswise pattern to ensure that the base is not distorted. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 68: Installation Requirements For Foundry Prime Robots
Run each axis on high speed at least once per hour. This activity will lubricate the gearbox cavities and gears, which reduces the risk for corrosion due to condensation in the gearboxes. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 69 Protect the interface plate from direct or indirect spray with the harness/interface cover. Put the interface plate where it is not subject to direct or indirect spray. xx1700001180 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 70 A gasket is required on the interface plate according to the figure. xx1700002199 Interface plate Gasket (attached with M6, 6 pcs) Gasket width dimension Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 71 Clean air inlet 0.2-0.3 bar 6 mm air hose (type Festo) Overpressure unit Flow sensor Sealed control cable signal Flow sensor cable Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 72 Remove the nuts from the studs on the interface plate. Pull the harness through the cover and fasten the cover with the nuts. xx1800000685 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 73 The I/O system is alerted when the leakage value is described as x + 1 l/min = alert value (where x - normal leakage for the system). Reset level is set to x + 0.5 l/min. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 74 The procedure is needed after replacement of, for example, cable harness. All values are set in factory at delivery. xx1900000621 Display Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 76 All warning labels are etched into the robot stainless steel plates. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 77: Shut-Down Periods
The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent of Motors On/Off mode, start-up and shut-down periods. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 78: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 80: Loads Fitted To The Robot, 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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 81: Fitting Equipment To The Robot
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) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 82 M1 ≤ 50 kg with a distance (a) ≤ 500 mm from the center of gravity in the axis-3 extension. xx1400002019 Mass center Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 83 2 Installation and commissioning 2.4.9 Fitting equipment to the robot Continued xx1300000866 Center of gravity 50 kg Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 84 B - B xx1300000263 Allowed position for attachment holes, M12 through. Be careful not to touch the cables when drilling. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 85 2.4.9 Fitting equipment to the robot Continued Variant IRB 6790 - 235/2.65 R=216 652.5 IRB 6790 - 205/2.80 R=216 652.5 Smallest circumscribed radius axis-4. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 86 IRB 6790 - 235/2.65 R=456 208.5 303.5 13.8 IRB 6790 - 205/2.80 R=456 208.5 303.5 13.8 Smallest circumscribed radius axis-3. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 87 Use suitable screws and tightening torque for your application. When the robot is used in a corrosive environment, the securing screws and washers must be of stainless steel. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 88: On-Site Storage
The cell must be ventilated during shut-down until the atmospheric humidity in the cell has reached the same level as the surrounding environment. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 89: Restricting 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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 90: Mechanically Restricting The Working Range Of Axis 1
When the robot is used in a corrosive environment, the securing screws and washers must be of stainless steel. Movable mechanical stop Mechanical stop pin axis-1 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 91 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 92: Electrical Connections
Robot cable, power Power cable length Article number 3HAC063487-001 15 m 3HAC063488-001 22 m 3HAC063489-001 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 93 The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. Flow sensor cable Connect the flow sensor cable to the controller and the flow sensor. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 94: Start Of Robot In Cold Environments
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 95: Maintenance
Note If the IRB 6790 is connected to power, always make sure that the IRB 6790 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...
Page 96: Maintenance Schedule And Expected Component Life
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 6790 : • Calendar time: specified in months regardless of whether the system is running or not.
Page 97: Maintenance Schedule
Activities and intervals, standard equipment The table below specifies the required maintenance activities and intervals: Maintenance activities Reference Cleaning activities Cleaning the IRB 6790 on Cleaning the robot page 161 Inspection activities Inspect the oil level in the actual gearbox if there is a...
Page 98 Replace when damage or cracks is detected or life limit is approaching that specified in section Expected component life on page iii The battery is to be replaced at given maintenance interval or at battery low alert. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 99: Expected Component Life
The most important factors are: • the washing detergent used • the ambient environment • installation, maintenance, and repair procedures • the operation cycle of the robot. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 100: Inspection Activities
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 101 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 102 132. Refit the oil plug. Tightening torque: 24 Nm. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 103: Inspecting The Oil Level In Axis-2 Gearbox
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 104 137. Refit the oil plug. Tightening torque: 24 Nm. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 105: Inspecting The Oil Level In Axis-3 Gearbox
Use this procedure to inspect the oil level in the gearbox. Action Note Run the robot to calibration position. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 106 142. Refit the oil plug. Tightening torque: 24 Nm. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 107: Inspecting The Oil Level In Axis-4 Gearbox
Use this procedure to inspect the oil level in the gearbox. Action Note Run the robot to calibration position. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 108 146. Refit the oil plug. Tightening torque: 24 Nm. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 109: Inspecting The Oil Level In Axis-5 Gearbox
Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 110 150. Refit the oil plug. Tightening torque: 24 Nm. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 111: Inspecting The Oil Level In Axis-6 Gearbox
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 112 Check the oil level. Required oil level is: • 50 mm ± 5 mm below the sealing surface of the oil plug. xx1300000693 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 113 154. Refit the oil plug. Tightening torque: 20 Nm. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 114: Inspecting The Balancing Device
Piston rod (inside balancing device) Link ear Rear attachments of the balancing device (cradle bearing) Required tools Visual inspection, no tools are required. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 116 Clean the area at the front ear from contamina- tion. Run the robot for some minutes, in order to move the balancing device piston. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 117 Keep the areas around the balancing device clean and free from objects, such as service tools. xx1300000423 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 118: Inspecting The Cable Harness
Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 119 Replace damaged cabling, if any. xx1300001094 Replace the cable harness if wear, cracks Removing the cable harness on or damage is detected. page 187. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 120: Inspecting The Axis-1 Mechanical Stop Pin
Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 121 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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 122: Inspecting The Additional Mechanical Stops
M12x70 and stainless steel wash- • Document for mechanical stop Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 123 Required equipment on page 122. Correct attachment screws: • Stainless steel M12x70 and stainless steel washers (2 pcs per additional mechanical stop) Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 124: Inspecting The Fork Lift Accessory
Article number Note Fork lift accessory set Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 125 Required equipment on page 122. Correct attachment screws: • M20x60 quality steel 8.8-A3F (2 pcs per addi- tional mechanical stop) Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 126: Inspecting The Dampers
• hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 127 Spare part number is found in Product replaced with a new one. manual, spare parts - IRB 6700/IRB 6700Inv. Attachment screws: M6x60. Locking liquid: Loctite 243. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 128: Inspecting The Leak Flow (Overpressure Unit) In The System
Motor cover axis 2 Motor cover axis 3 Motor cover axis 4 Motor cover axis 6 Connection to balancing device Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 129 Check the cable harness with leak detection Seal problem areas. spray. Bubbles indicates a leak. If the leakage still remains, contact ABB Service. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 130: Analyzing Activities
Normal replacement interval is required for the gearbox. 3000 6000 9000 12000 15000 xx0600003156 • A: Water content in gearbox oil • B: Months or hours in operation Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 131: Replacement/Changing Activities
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 132: Changing Oil, Axis-1 Gearbox
Used for both ventilation and level measure- penser). ment on manipulator types: B Level plug (300/2.70, 245/3.00) • IRB 6790 - 235/2.65, IRB 6790 - 205/2.80 Tightening torque: 24 Nm. Tightening torque: 24 Nm. Consumables Material...
Page 133 Remove the protective cap from the nipple of the oil hole and connect the oil dis- penser. xx1200000948 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 134 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 135 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 136 The robot color can otherwise be discolored. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 137: Changing Oil, Axis-2 Gearbox
- Lubrication in gearboxes. Type and amount of oil in gearboxes on page 131. Mercasol Rust preventive Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 138 Remove the protective cap from the nipple of the oil hole and connect the oil dis- penser. xx1200000951 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 139 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 140 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 141 Refit the protective cap on the nipple. Refit the level plug. Tightening torque: 24 Nm DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 142: Changing Oil, Axis-3 Gearbox
Mercasol Rust preventive Required documents Document name Document number Note Technical reference manu- 3HAC042927-001 al - Lubrication in gearboxes Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 143 WARNING Open the vent hole while using the dis- penser, to avoid damaging vital parts in the gear. xx1200000955 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 144 Remove the protective cap from the nipple of the oil hole and connect the oil dis- penser. xx1200000954 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 145 Refit the protective cap on the nipple. Refit the level plug. Tightening torque: 24 Nm DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 146: Changing Oil, Axis-4 Gearbox
Draining the axis-4 gearbox Use this procedure to drain the gearbox. Action Note Run the robot to calibration position. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 147 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 148 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 149 107. Refit the oil plug. Tightening torque: 24 Nm DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 150: Changing Oil, Axis-5 Gearbox
Draining the axis-5 gearbox Use this procedure to drain the gearbox. Action Note Run the robot to calibration position. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 151 Decommissioning on page 639 for more in- formation. Refill oil or refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 152 More information is found in Inspecting the oil level in axis-5 gearbox on page 109. Refit the oil plug. Tightening torque: 24 Nm Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 153 3 Maintenance 3.5.6 Changing oil, axis-5 gearbox Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 154: Changing Oil, Axis-6 Gearbox
Draining the axis-6 gearbox Use this procedure to drain the gearbox. Action Note Jog the robot to calibration position. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 155 Remove the oil plug from the fill hole. Note The fill hole is opened to speed up the drainage. xx1200000963 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 156 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 157 Refit the oil plug. Tightening torque: 20 Nm DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 158: Replacing The Smb Battery
The SMB battery (SMB = serial measurement board) is located on the frame as shown in the figure below. xx1700001632 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 159 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 160 Update the revolution counters. Updating revolution counters on page 619. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 161: Cleaning Activities
General To secure high uptime it is important that the IRB 6790 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Oil spills...
Page 162 3 Maintenance 3.6.1 Cleaning the IRB 6790 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...
Page 163 3 Maintenance 3.6.1 Cleaning the IRB 6790 Continued Washing detergent with pH 6-7 is allowed for short periods, provided the robot is rinsed properly with tap water afterwards. • The user must follow the recommendations regarding detergent concentration and pH value.
Page 164 This page is intentionally left blank...
Page 165: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 6790 , report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 166: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 167: Mounting Instructions For Bearings
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 168 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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 169: Mounting Instructions For Sealings
Do not try to grind or polish the shaft surface to get rid of the defect. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 170 Mount the sealing correctly with a mounting tool. Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 171 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 172: Dismantle And Mounting Tool, 3Hac028920-001
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 173: Painting Damaged Nickel Coated Surfaces With Touch Up Paint
Use Touch up paint Foundry Prime, grey to paint 3HAC035355-001 the damage. Note Always read the instruction in the product data sheet in the paint repair kit for Foundry Prime. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 174: The Brake Release Buttons May Be Jammed After Service Work
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 175: Lifting Associated Procedures
• frame Attachment points of lifting accessory Required tools Equipment, etc. Article number Note Lifting eye 3HAC16131-1 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 176 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 177 Run a roundsling through the hole in the frame. Roundsling, 1.5 m: Length: 1.5 m. Lifting capacity: 2,000 kg. Attach the roundsling choked. See figure! xx1200001209 xx1400000730 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 179: Attaching Lifting Accessories To An Un-Separated Lower And Upper Arm
Roundsling, 1 m Length: 1 m, lifting capacity: 1,000 kg. Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en- closed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 180 The lower and upper arms together weigh (accord- ing to variants) 510 kg. All lifting accessories used must be sized accord- ingly! Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 181 Run a roundsling around the lower arm, beneath Roundsling, 1.5 m: Length: 1.5 m. the securing screw. Lifting capacity: 2,000 kg. xx1200001252 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 182 13 mm, thickness: 3 mm. xx1400002196 Note xx1200001134 Save the stop screw installed, to refit after the lifting eye is removed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 183 To release the brake, connect the 24 VDC power supply. Connect to connector R2.MP2, axis-2 motor: • + = pin 2 • - = pin 5 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 184: Attaching Lifting Accessories To The Upper Arm
Lifting accessory (chain) 3HAC15556-1 Lifting instruction 3HAC15880-2 en- closed. Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 185 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1 Note Save the stop screw installed, to refit after the lifting eye is removed. xx1200001133 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 186 In case of necessary adjustments, use the shortening loops on the lifting accessory (chain) to find the level position. xx1400002197 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 187: Complete Robot
Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 188 Note the value to be able to compare it when repair is completed. xx1700001593 CAUTION Turn off the air pressure supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 189 Remove the wrist cover. xx1300002247 Remove the heat protection plates from the motor with the cabling still attached to the plate. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 190 Unscrew the attachment screws and re- move the motor cover. xx1200001080 Disconnect the motor cables. xx1300000488 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 191 Pull out the axis-6 motor cables by holding the cables with one hand at the motor and the other at the carrier. xx1300000666 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 192 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 193 Note Axis 3 and 4 motors only: Be careful not to damage the air hose or air nipple. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 194 The motor shall be refitted in the same position. xx1200001067 Use caution and pull out the motor cables. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 195 If the cabling is to be replaced by a new cable harness, remove the cover insert to use it on the new cabling. xx1700001803 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 197 Open the velcro strap at the cable fixing bracket. xx1700001810 Cable fixing bracket. Remove the metal clamp on top of the arm house. xx1300000541 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 198 • Together: Move the cable harness Person 2, working at the back: out of the arm tube. xx1700001568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 199 CAUTION Turn off the air pressure supply. Remove the base cover. xx1700001580 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 200 Remove the cover that protects the R1.MP and R1.SMB connectors. xx1700001581 Disconnect connectors: • R1.MP • R1.SMB • Air hose to balancing device xx1700001582 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 201 Be careful not to damage the air hose or air nipple. xx1200001135 Make sure the o-ring is present. xx1200001070 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 202 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section unit is sensitive to ESD on page 49 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 203 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section unit is sensitive to ESD on page 49 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 204 Remove the air coupling from the R1.MP connector. xx1700001583 Unscrew the attachment screws that hold the metal clamp frame. xx1300000542 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 205 Unscrew the attachment screws that secure the brake release unit bracket. Remove the bracket with the brake release unit fitted. xx1700002154 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 206 Use caution and pull out the cable harness from the SMB recess. xx1300000560 Disconnect the air hose from the balancing device. xx1700002246 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 207 Note The screws are reached from the outside of the lower arm. xx1300000540 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 208 4 Repair 4.4.1 Removing the cable harness Continued Action Note Use caution and pull the cable harness out. xx1300000733 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 209: Refitting The Cable Harness
Article number Note Shell Gadus S2 Grease 3HAC042536-001 Used to lubricate o-rings. O-ring D=84.5x3 21522012-429 Used on the SMB/BU cover. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 210 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 211 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 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 212 Also run the air hose to the balancing device beside the cable protection. xx1700001588 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 213 Connect connectors R1.MP and R1.SMB. Tightening torque for R1.SMB: 10 Nm. Also connect the air hose that belongs to the balancing device. xx1700001582 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 214 Refit the metal clamp inside the base. xx1700001584 Connect the balancing device air hose in- side the base. xx1700002245 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 216 Secure the SMB/BU cover with its attach- Screws: 4 pcs. ment screws from inside the SMB/BU re- cess. xx1700002155 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 217 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 49 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 218 SMB unit. xx1300000730 If removed, refit the bracket with the brake re- lease unit fitted. xx1700002154 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 219 If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm. xx1300000669 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 220 Replace the gasket if damaged. xx1200001067 Connect the motor cables. Connect in accordance with the markings on the connectors. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 221 Note Make sure the o-ring is undamaged and properly fitted. xx1200001135 Make sure that the covers are tightly sealed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 222 Note The screws are reached from the outside of the lower arm. xx1300000734 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 223 Note The screws are reached from the outside of the lower arm. xx1300000558 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 224 This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 225 Make sure all three washers are fitted. xx1400000382 A Gasket B Cable guide C Washer D Cover Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 226 Together: Move the cable harness Person 2, working at the wrist: past the axis-5 motor and into the wrist. xx1300000746 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 227 Refit the metal clamp axis-4, inside the arm tube. Note The screws are reached from outside the upper arm. xx1700000340 xx1700000339 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 228 • Use attachment screws made of stainless steel to fit the side cover. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 229 Make sure the gasket is fitted cor- rectly • Use attachment screws made of stainless steel to fit the cover. xx1200000045 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 230 Connecting the axis-3 and axis-4 motor cables Action Note Push the motor cables through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 231 O-ring, axis-2: 3HAC067762-001 Note O-ring, axis-3: 3HAC067762-001 O-ring, axis-4: 3HAC067744-001 Replace if damaged. xx1200001070 Wipe clean o-ring and o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 232 Connecting the axis-5 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 233 CAUTION When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 234 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Fit the heat protection plate with the Screws: M5x12. screws. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 235 Push the cable harness into the wrist re- cess and up into the axis-6 motor. xx1300000667 Push the carrier carefully into position. xx1300001113 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 236 Reconnect the connectors to the axis-6 motor. Note Place the resolver cable under the motor cable. xx1300000488 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 237 Make sure that the cable harness is placed in a way that it will not be damaged when the wrist cover is fitted. xx1600002061 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 238 Calibrating with Axis Calibration method on page 623. General calibration information is included in section Calibration on page 613. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 239 4 Repair 4.4.2 Refitting the cable harness Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 240: Replacing The Smb
Equipment to be Screws Washers Quantity fastened SMB cover M6x16 A2-70 (4 pcs) 4 pcs 9ADA619-56 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 241 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 242 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 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 243 Make sure the lock snaps into place during refit- ting. xx1300000729 Connect all connectors to the SMB board: • R1.SMB1-3, R1.SMB4-6 and R2.SMB xx1300000728 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 244 Check the sealing on the SMB cover. Replace SMB cover with sealing: 3HAC044077- complete cover if sealing is damaged. 002. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 245 If the value is higher than the initial value, fault trace according to Inspecting the leak flow (overpressure unit) in the system on page 128. xx1700001593 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 246 Update the revolution counters. Updating revolution counters on page 619. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 247: Replacing The Brake Release Unit
Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 248 Check the leak flow value on the flow sensor. Note the value to be able to compare it when repair is completed. xx1700001593 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 249 Remove the connectors X8, X9 and X10 from the brake release board. xx1300000670 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 250 Be careful not to damage the sockets or pins. Make sure the connector and its locking arms are snapped down properly. xx1700000978 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 251 Reconnect the battery, if it has been disconnected. Turn on the air pressure supply to the overpressure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 252 Update the revolution counters if the battery has been Updating revolution counters disconnected. on page 619. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 253: Upper And Lower Arms
Parts needed to be replaced after removal. Equipment, etc. Article number Note Grease 3HAC042536-001 Shell Gadus S2 Used to lubricate o-rings. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 254 Used to release the motor brakes. Calibration tool box, Axis 3HAC055412-001 Delivered as a set of calibration tools. Calibration Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 255 Jog the robot to a position where it is best to remove tools and other equipment fitted to wrist and upper arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 256 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 257 Remove the wrist cover. xx1300002247 Remove the heat protection plates from the motor with the cabling still attached to the plate. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 258 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 259 The motor shall be refitted in the same position. xx1300000656 Use caution and pull out the motor cables. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 260 Disconnect the motor cables. xx1300000488 Unscrew the attachment screws that hold the cable bracket. xx1300000484 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 261 Disconnecting the axis-3 and axis-4 motor cables Action Note DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 262 Be careful not to damage the air hose or air nipple. xx1200001135 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 264 Unscrew the screws and remove the seal- ing washers, holding the metal clamp inside the arm tube. xx1700001809 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 265 Remove the arm house metal clamp. xx1300000543 Open the velcro strap at the cable fixing bracket. xx1700001810 Cable fixing bracket. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 266 Together: Move the cable harness Person 2, working at the wrist: past the axis-5 motor and into the arm tube. xx1300000746 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 267 The weight of the complete upper arm (in- cluding the wrist) is 360 kg All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 268 Raise the lifting accessories to take the weight of the upper arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 269 Leave one of the remaining attachment screws fitted, remove the other screws. xx1300000747 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 271 Use the pinion to rotate the axis-3 gearbox to find the correct position for the guide pins in the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 272 Tightening torque depends on screw dimen- tachment screws. sion. Tightening torque, M16: 300 Nm Tightening torque, M12: 120 Nm Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 273 This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 274 Make sure all three washers are fitted. xx1400000382 A Gasket B Cable guide C Washer D Cover Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 275 Together: Move the cable harness Person 2, working at the wrist: past the axis-5 motor and into the wrist. xx1300000746 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 276 Refit the metal clamp axis-4, inside the arm tube. Note The screws are reached from outside the upper arm. xx1700000340 xx1700000339 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 277 • Use attachment screws made of stainless steel to fit the side cover. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 278 Make sure the gasket is fitted cor- rectly • Use attachment screws made of stainless steel to fit the cover. xx1200000045 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 279 Connecting the axis-3 and axis-4 motor cables Action Note Push the motor cables through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 280 O-ring, axis-2: 3HAC067762-001 Note O-ring, axis-3: 3HAC067762-001 O-ring, axis-4: 3HAC067744-001 Replace if damaged. xx1200001070 Wipe clean o-ring and o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 281 Connecting the axis-5 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 282 CAUTION When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 283 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Fit the heat protection plate with the Screws: M5x12. screws. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 284 Push the cable harness into the wrist re- cess and up into the axis-6 motor. xx1300000667 Push the carrier carefully into position. xx1300001113 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 285 Reconnect the connectors to the axis-6 motor. Note Place the resolver cable under the motor cable. xx1300000488 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 286 When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Refit the motor cover. xx1200001080 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 287 If the value is higher than the initial value, fault trace according to Inspecting the leak flow (overpressure unit) in the system on page 128. xx1700001593 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 288 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 289: Replacing The Wrist
Location of the wrist The wrist is located as shown in the figure. xx1300000597 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 290 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 291 Axis 2: -60° • Axis 3: +60° • Axis 4: +90° • Axis 5: +90° • Axis 6: no significance Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 292 Action Note DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 293 If removing the plate only for replacing the motor, the cabling does not need to be loosened from the plate. xx1500001029 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 294 Disconnect the motor cables. xx1300000488 Unscrew the attachment screws that hold the cable bracket. xx1300000484 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 295 Disconnecting the axis-5 motor cables Action Note DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 296 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 297 Note Make sure the roundsling is stretched, so it can carry the weight of the wrist. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 298 CAUTION Make sure that the cabling does not get damaged. xx1700001594 A Tubeshaft plate Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 299 Preparations before refitting the wrist Action Note DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 300 Always use guide pins in pairs. Lubricate the guide pins with some grease to make the wrist slide better. xx1700001595 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 301 Note Make sure the roundsling is stretched, so it can carry the weight of the wrist. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 302 Slide the wrist into fitting position. Make sure that the tubeshaft plate is placed properly in the groove in the wrist. xx1700001594 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 303 Tightening torque: 120 Nm. Connecting the axis-5 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 304 CAUTION When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 305 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Fit the heat protection plate with the Screws: M5x12. screws. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 306 Push the cable harness into the wrist re- cess and up into the axis-6 motor. xx1300000667 Push the carrier carefully into position. xx1300001113 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 307 Reconnect the connectors to the axis-6 motor. Note Place the resolver cable under the motor cable. xx1300000488 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 308 Make sure that the cable harness is placed in a way so it will not be damaged when the wrist cover is fitted. xx1500001672 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 309 Calibrating with Axis Calibration method on page 623. General calibration information is included in section Calibration on page 613. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 310 4 Repair 4.5.2 Replacing the wrist Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 311: Replacing The Turning Disc
Located on the axis-6 gear- box. Replace if damaged. Consumables Equipment, etc. Article number Note Grease 3HAC042536-001 Shell Gadus S2 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 312 Removing the turning disc Action Note Remove the screws and washers, that se- cure the turning disc. xx1300000492 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 313 Remove the turning disc. xx1300000493 Remove the seal from the turning disc. Note Replace the seal if damaged. xx1700001592 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 314 Grease: 3HAC042536-001 (Shell Gadus corner of the turning disc. S2). Note No grease is allowed on the screw flange. xx1700002094 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 315 Concluding procedure Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 316: Replacing The Lower Arm
5 Replace the lower arm. Spare part Spare part Spare part number Note Lower arm Product manual, spare parts - IRB 6790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 317 DANGER Never use this tool to unload or restore a balancing device! Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 318 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 319 Note the value to be able to compare it when repair is completed. xx1700001593 CAUTION Turn off the air pressure supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 320 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 321 The balancing device is now unloaded. move the front shaft of the balancing device. Let the Distance tool stay fitted during the continued procedure. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 322 Fit the lifting accessory (chain) to the Lifting accessory (chain): 3HAC15556-1 shackle and raise to unload the weight. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 323 Hydraulic pump 70 MPa: 3HAC13086-1 Hydraulic cylinder: 3HAC11731-1 xx1200001280 xx1700000378 The numbers in the figure refers to the marked tool pieces respectively. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 324 Make sure that all supplies for electrical power and hydraulic pressure are turned off. Remove the wrist cover. xx1300002247 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 325 Removing cable brackets Action Note Unscrew the screws that hold the bracket and let it hang free. xx1200001184 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 326 Be careful not to damage the air hose or air nipple. xx1200001135 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 327 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 328 The motor shall be refitted in the same position. xx1300000656 Use caution and pull out the motor cables. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 329 Disconnect the motor cables. xx1300000488 Unscrew the attachment screws that hold the cable bracket. xx1300000484 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 330 Pull out the axis-6 motor cables by holding the cables with one hand at the motor and the other at the carrier. xx1300000666 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 331 If the cabling is to be replaced by a new cable harness, remove the cover insert to use it on the new cabling. xx1700001803 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 333 Open the velcro strap at the cable fixing bracket. xx1700001810 Cable fixing bracket. Remove the metal clamp on top of the arm house. xx1300000541 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 334 • Together: Move the cable harness Person 2, working at the back: out of the arm tube. xx1700001568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 335 13 mm, thickness: 3 mm. xx1400002196 Note Save the stop screw installed, to refit after the lifting eye is removed. xx1200001134 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 336 Lubricate the guide pins with some grease to make the upper arm slide better. xx1300000659 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 338 Note The screws are reached from outside the lower arm! xx1300000540 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 339 Always use guide pins in pairs. Lubricate the guide pins with some grease to make the lower arm slide better. xx1300000788 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 340 Always use guide pins in pairs. Lubricate the guide pins with some grease to make the lower arm slide better. xx1700000055 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 341 Fit one attachment screw in one of the up- per holes using it for security and lower the lifting accessory a little. xx1300000790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 342 Remove the lifting accessory from the lower arm. Preparations before refitting the upper arm Action Note Wipe clean all contact surfaces. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 343 Use the pinion to rotate the axis-3 gearbox to find the correct position for the guide pins in the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 344 This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 346 Refit the arm house metal clamp. xx1300000543 Arrange the cables between the cable clamps in the upper arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 347 Make sure all three washers are fitted. xx1400000382 A Gasket B Cable guide C Washer D Cover Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 348 Together: Move the cable harness Person 2, working at the wrist: past the axis-5 motor and into the wrist. xx1300000746 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 349 Refit the metal clamp axis-4, inside the arm tube. Note The screws are reached from outside the upper arm. xx1700000340 xx1700000339 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 350 • Use attachment screws made of stainless steel to fit the side cover. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 351 Make sure the gasket is fitted cor- rectly • Use attachment screws made of stainless steel to fit the cover. xx1200000045 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 352 Connecting the axis-3 and axis-4 motor cables Action Note Push the motor cables through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 353 O-ring, axis-2: 3HAC067762-001 Note O-ring, axis-3: 3HAC067762-001 O-ring, axis-4: 3HAC067744-001 Replace if damaged. xx1200001070 Wipe clean o-ring and o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 354 Connecting the axis-5 motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 355 CAUTION When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 356 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Fit the heat protection plate with the Screws: M5x12. screws. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 357 Push the cable harness into the wrist re- cess and up into the axis-6 motor. xx1300000667 Push the carrier carefully into position. xx1300001113 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 358 Reconnect the connectors to the axis-6 motor. Note Place the resolver cable under the motor cable. xx1300000488 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 359 When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Refit the motor cover. xx1200001080 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 360 Make sure that the cable harness is placed so it will not be damaged when the wrist cover is fitted. xx1600002061 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 361 The activator must be used to harden the flange sealant. xx1700001875 Apply new flange sealant to the wrist cover. Flange sealant: 12340011-116 (Loctite 574). xx1700001811 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 362 Remove all residue of Loctite in the screw hole of the shaft. Wipe all contact surfaces inside the recess clean from contamination. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 363 Apply locking liquid (Loctite 2701) on the threads of the screw, first entering the threads in the frame. xx1300000782 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 364 Remove the lifting accessory from the bal- ancing device. Refit the cable bracket (if not already refit- ted). xx1200001283 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 365 Remove the distance tool. xx0800000480 A Distance tool: 3HAC030662-001 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 366 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 367: Frame And Base
1 Unload the balancing device. 2 Replace the spherical roller bearing. 3 Restore the balancing device. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 368 Used for removing and fitting shaft and bearings. Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 369 The Distance tool is only used to keep the balancing device springs in a locked position, after they have been Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 370 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 371 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 372 Preparations before removing the spherical roller bearing Action Note Jog axis-2 to the calibration position (if not already in this position). Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 373 All lifting accessories used must be sized accordingly. Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1 xx1300000661 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 374 Removing the shaft in the front (link ear) Action Note Remove the two screws. xx1900002146 Unscrew the attachment screw and washer. xx1200001279 • M16x70, stainless steel Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 375 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. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 376 Refit the smaller end cover by hand. xx1700001764 Apply some grease on the surface for the bearing. Grease: 3HAC042536-001. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 377 The weight of the balancing device (exclud- ing cradle) is 140 kg All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 378 Turn the power to the robot on temporarily. Use caution and jog the robot to the calibration position (if not already done). Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 379 Verify that the link ear is correctly turned. xx1300000784 Lubricate the shaft and place it to the front ear. xx1200001280 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 380 Refit the two screws and wipe clean from residual Locking liquid: Loctite 577 grease. Use locking liquid. xx1900002146 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 381 Screws: M10x30 Stainless Steel plate on the back of the balancing device. (3HAC060786-020). Tightening torque: 50 Nm. Flange sealant for conical fittings: Loctite 577. xx1300000554 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 382: Replacing The Balancing Device
2 Replace the balancing device. Spare part Spare parts Spare part number Note Balancing device Product manual, spare parts - IRB 6790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 383 Never use this tool to unload or restore a balancing device! Lock screw, M16x120 Used to secure lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 384 The Distance tool is only used to keep the balancing device springs in a locked position, after they have been Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 385 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 386 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 387 Preparations before removing the balancing device Action Note Jog axis-2 to the calibration position (if not already in this position). Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 388 All lifting accessories used must be sized accordingly. Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1 xx1300000661 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 389 The cover can be reused if not damaged. xx1300000662 Vent hole for air pressure: xx1700001800 Wipe off any residual grease inside the re- cess. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 390 Removing the shaft in the front (link ear) Action Note Remove the two screws. xx1900002146 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 391 The numbers in the figure refers to the marked tool pieces respectively. Put down the balancing device and let it rest on the frame. xx1200001281 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 392 Lifting shackle: SA-10-8-NA1 xx1300000661 Fit the lifting accessory to the shackle and Lifting accessory (chain): 3HAC15556-1 raise to unload the weight. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 393 Apply the refitting tool and press the shafts Dismantle and mounting tool: into position one at a time. 3HAC028920-001 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 394 Apply Loctite 243 on the screws and secure M16x50 stainless steel the shafts on both sides. Tightening torque: 300 Nm xx1300000663 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 395 Remove all residue of Loctite in the screw hole of the shaft. Wipe all contact surfaces inside the recess clean from contamination. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 396 Apply locking liquid (Loctite 2701) on the threads of the screw, first entering the threads in the frame. xx1300000782 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 397 Remove the lifting accessory from the bal- ancing device. Remove the locking screw (M16x120). xx1200001116 Jog axis-2 to: • -30° or +30°. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 398 Screws: M10x30 Stainless Steel plate on the back of the balancing device. (3HAC060786-020). Tightening torque: 50 Nm. Flange sealant for conical fittings: Loctite 577. xx1300000554 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 399: Replacing The Rear Bearings On The Balancing Device
Loctite 243 Flange sealant 12340011-116 Loctite 574 Activator 3HAC064686-001 Loctite 7649 Flange sealant for conical fit- Loctite 577 tings Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 400 Used for removing and fitting shaft and bearings. Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 401 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 402 Preparations before removing the rear bearings Action Note Jog axis-2 to the calibration position (if not already in this position). Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 403 All lifting accessories used must be sized accordingly. Fit a lifting shackle to the balancing device. Lifting shackle: SA-10-8-NA1 xx1300000661 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 404 The cover can be reused if not damaged. xx1300000662 Vent hole for air pressure: xx1700001800 Wipe off all residual grease inside the re- cess. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 405 Refitting the shaft end and rear bearings Action Note Wipe clean all contact surfaces from resid- ual grease and other contamination inside the recess. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 406 Part of tool Dismantle and mounting tool: balancing device. 3HAC028920-001. xx1700002296 The item number refers to marking on the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 407 Do not press yet! Hydraulic cylinder, 3HAC11731-1. xx1700000406 The item numbers refer to markings on the tools. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 408 Fit a VK cover to protect the bearing. Remove the lifting accessories Action Note Remove the lifting accessories. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 409 (3HAC060786-020). Tightening torque: 50 Nm. Flange sealant for conical fittings: Loctite 577. xx1300000554 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 410 4.6.3 Replacing the rear bearings on the balancing device Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 411: Unloading 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 412 To be used with the press tool. Hydraulic pump 70 MPa 3HAC13086-1 To be used with the hydraulic cylinder. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 413 DANGER DO NOT! remove any other screws then the rear cover attachment screws. xx1300000554 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 414 Unload the hydraulic cylinder. The hydraulic cylinder may now be removed from the tool, when necessary. CAUTION Do not remove the press tool! Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 415: Restoring The Balancing Device
The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Press device Bolt, press device Moving pin with marking Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 416 Press device bolts. Bolt, press device Moving pin with marking Bolt (4 pcs) Pin, attached to the fix plate Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 417 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! Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 418: Replacing The Stop Pin
Equipment to be Screws Washers Quantity fastened Mechanical stop M10x20 Stainless Steel 1 pcs 9ADJ400914P1259 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 419 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 420 3110 Waxcoat. Recommended drying shown in the figure. time is 24h.). xx1400000378 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 421 Fit the stop pin. xx1300000477 Apply locking liquid on the set screw, and Loctite 243 secure the stop pin. Set screw: M10x20 Stainless Steel 9ADJ400914P1259 xx1300000476 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 422: Motors
3 Remove the lifting tools. Spare parts Spare part Spare part number Note Axis-1 motor Product manual, spare parts - IRB 6790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 423 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 424 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 425 Note Axis 3 and 4 motors only: Be careful not to damage the air hose or air nipple. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 426 Removing the axis-1 motor Action Note DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 427 If needed, use removal tools to help re- Removal tool M12: 3HAC057339-002 move the motor. Always use removal tools in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 428 Wipe clean the contact surfaces and the o-ring groove. Check the o-ring. O-ring, 3HAB3772-107 Replace if damaged. xx1200001019 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 430 Perform a leak-down test (if not already Performing a leak-down test on done). page 166. Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 431 Replace the gasket if damaged. xx1200001067 Connect the motor cables. Connect in accordance with the markings on the connectors. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 432 Note Make sure the o-ring is undamaged and properly fitted. xx1200001135 Make sure that the covers are tightly sealed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 433 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 434: Replacing The Axis-2 Motor
5 Refill the axis-2 gearbox with oil. Spare parts Spare part Spare part number Note Axis-2 motor Product manual, spare parts - IRB 6790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 435 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 437 Note the value to be able to compare it when repair is completed. xx1700001593 CAUTION Turn off the air pressure supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 438 Be careful not to damage the air hose or air nipple. xx1200001135 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 439 - = pin 5 Remove the attachment screws. Bits extender: 3HAC12342-1 Use a bits extender in order to reach the screws. xx1200001117 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 440 Preparations prior to refitting motor Action Note DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 441 Securing the axis-2 motor Action Note Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 442 • Make sure that the direction of the cable exit is facing the correct way. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 443 Performing a leak-down test on page 166. Connecting the motor cables Action Note Push the motor cables through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 444 O-ring, axis-2: 3HAC067762-001 Note O-ring, axis-3: 3HAC067762-001 O-ring, axis-4: 3HAC067744-001 Replace if damaged. xx1200001070 Wipe clean o-ring and o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 445 Remove the lock screw securing the lower Lock screw, M16x120 arm. xx1200001115 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 446 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 447: Replacing The Axis-3 Motor
Shell Gadus S2 Used to lubricate o-rings. O-ring 3HAC067762-001 D=169.5x3 Used on motor cover. O-ring 3HAB3772-107 D=102x3 Used on motor flange. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 448 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 450 Note Axis 3 and 4 motors only: Be careful not to damage the air hose or air nipple. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 451 Removing the axis-3 motor Action Note Before removing the motor, make sure that the axis-3 gearbox is completely drained. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 452 CAUTION The motor weighs 26 kg. All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 454 Use this procedure to secure the motor. Action Note Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 455 To release the brakes, connect the 24 VDC power supply. Connect to connector R2.MP3: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 456 Disconnect the 24 VDC power supply. Connecting the motor cables Action Note Push the motor cables through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 457 O-ring, axis-2: 3HAC067762-001 Note O-ring, axis-3: 3HAC067762-001 O-ring, axis-4: 3HAC067744-001 Replace if damaged. xx1200001070 Wipe clean o-ring and o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 458 Connect the air hose to the nipple on the connection box. Turn on the air pressure supply to the overpressure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 459 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 460: Replacing The Axis-4 Motor
Shell Gadus S2 Used to lubricate o-rings. O-ring 3HAC067744-001 D=119x3 Used on motor cover. O-ring 3HAB3772-107 D=102x3 Used on motor flange. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 461 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 462 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 463 Note Axis 3 and 4 motors only: Be careful not to damage the air hose or air nipple. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 464 Use caution and pull out the motor cables. Removing the axis-4 motor Action Note CAUTION Use caution when releasing the brakes! Axis-4 can move unexpectedly! Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 465 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 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 466 Make sure the o-ring is seated in the groove. Lubricate the o-ring with some grease for a better fitting in the groove. xx1200001020 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 467 Apply two guide pins in opposite holes. Guide pin, M8x150: 3HAC15520-2 Always use guide pins in pairs. Put the motor onto the guide pins. xx1700000291 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 468 • Make sure that the direction of the cable gland is facing the correct way. Remove the guide pins. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 469 Push the motor cables through the cable gland opening. xx1300000738 Refit the cable gland cover. Note Replace the gasket if damaged. xx1200001067 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 470 CAUTION When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 471 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 472: Replacing The Axis-5 Motor
Guide pin, M8x100 3HAC15520-1 Always use guide pins in pairs. Rotation tool 3HAB7887-1 Used to rotate the motor pinion. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 473 Action Note Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 474 Check the leak flow value on the flow sensor. Note the value to be able to compare it when repair is completed. xx1700001593 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 475 Remove the wrist cover. xx1300002247 Remove the heat protection plates from the motor with the cabling still attached to the plate. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 476 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 477 The motor shall be refitted in the same position. xx1300000656 Use caution and pull out the motor cables. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 478 Always use removal tools in pairs. CAUTION The motor weighs 12 kg. All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 479 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 480 Note CAUTION Whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 482 Disconnect the 24 VDC power supply. Connecting the motor cables Action Note Push the motor cables in through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 483 CAUTION When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 484 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Fit the heat protection plate with the Screws: M5x12. screws. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 485 5 Secure the cover with its attachment screws. xx1300000772 Turn on the air pressure supply to the overpressure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 486 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 487: Replacing The Axis-6 Motor
Used on motor cover. O-ring 3HAB3772-107 D=102x3 Used on motor flange. Activator 3HAC064686-001 Loctite 7649 Flange sealant 12340011-116 Loctite 574 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 488 If no previous reference values exist, and routine on page 624. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 489 Check the leak flow value on the flow sensor. Note the value to be able to compare it when repair is completed. xx1700001593 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 490 Make sure that all supplies for electrical power and hydraulic pressure are turned off. Unscrew the attachment screws and re- move the motor cover. xx1200001080 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 491 The screw is located at the bottom of the carrier. Note The parts are sealed with flange sealant Loctite 577. Remove the part carefully. xx1300000485 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 492 Connect to R2.MP6-connector: • + = pin 2 • - = pin 5 Unscrew the motor attachment screws. xx1200001090 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 493 Make sure the motor pinion is not dam- aged! xx1200001091 xx1200001096 Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 494 Make sure the o-ring is seated in the groove. Lubricate the o-ring with some grease for a better fitting in the groove. xx1200001020 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 496 Make sure the motor pinion is not dam- aged! xx1200001091 xx1200001097 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 497 Tighten the M4 screw that holds the carrier. Seal the screw with Loctite 577. Note The screw is located at the bottom of the carrier. xx1300000485 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 498 Disconnect the 24 V DC power supply. Reconnect the connectors. xx1200001084 Check the gasket. Gasket: 3HAC033489-002 Replace if damaged. xx1200001095 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 499 Put washers in the holes of the gas- ket. • Use attachment screws made of stainless steel to fit the wrist cover. xx1900002085 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 500 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 501: Gearboxes
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. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 502 Motor, axis-1 M10x30 Stainless Steel 13x17x2 Stainless Steel 4 pcs 3HAC060786-020 3HAC060866-003 Mechanical stop M10x20 Stainless Steel 1 pcs 9ADJ400914P1259 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 503 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 504 Begin draining the axis-1 gearbox. Draining the axis-1 gearbox on page 133. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 505 Unscrew the attachment screws that secure the cable bracket. xx1200001184 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 506 Note Leave the outermost screw fitted as a safety precaution. xx1200001189 xx1200001185 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 507 Axis 3: +65° (approximately) • Axis 4: calibration position (0°) • Axis 5. +90° • Axis 6: calibration position (0°) xx1200001132 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 508 Save the stop screw installed, to refit after the lifting eye is removed. xx1200001133 Fit a lifting shackle in the wrist lifting eye. Lifting shackle: SA-10-8-NA1 xx1200001234 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 509 3 mm. xx1400002196 Fender washer Note xx1200001134 Save the stop screw installed, to refit after the lifting eye is removed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 510 Be careful not to damage the air hose or air nipple. xx1200001135 Make sure the o-ring is present. xx1200001070 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 511 - = pin 5 CAUTION The weight of the motor is 25 kg All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 512 Lifting accessory, motor: 3HAC14459-1. xx1200001072 Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 513 Remove the metal clamp inside the base. xx1700001584 Disconnect the balancing device air hose inside the base. xx1700002245 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 514 Action Note Open the hose clamp on the black cable protection and loosen the protection from the frame. xx1700002036 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 515 Raise the overhead crane to stretch the chains and roundslings. Make sure that the roundsling between the wrist and the frame is stretched. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 516 CAUTION The complete arm system weighs: 1,100 All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 517 Removing the gearbox Action Note Remove the attachment screws and washers that secure the gearbox to the base. xx1200001186 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 518 CAUTION The weight of the gearbox is 92 kg All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 519 Protect the sealing areas on top of the protec- tion tube, to avoid damaging them. xx1700001655 Lift away the gearbox. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 520 Wipe clean the contact surfaces on the base and the surfaces of the protection tube from any contamination. Put grease on the protection tube. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 521 All lifting accessories used must be sized accordingly. Wipe clean the contact surfaces from any contamination. Also wipe clean the o-ring groove. xx1200001245 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 522 Fit the o-ring in the groove of the gearbox. xx1200001244 Wipe clean the surfaces of the hole in axis-1 gearbox. xx1700002192 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 523 Remove the guide pins. Remove the lifting accessory and the lifting eyes. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 525 036. Grease: 3HAC042536-001. Lubricate the new o-ring with grease and fit it to the gearbox. xx1700001658 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 526 Fit the guide for the gear on top of the pro- Guide for reduction gear: 3HAC043870-009. tection tube. It protects the radial sealing from being damaged during refitting. xx1700002096 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 527 Remove old residues of flange sealant from the contact surfaces. Wipe clean the contact surfaces from any remaining contamination. Also wipe clean the o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 528 See figures for correct entering holes for the guide pins. xx1700002196 Position of Guide pin, M16x150: xx1700002197 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 529 Lower the arm system to align the other Position of Guide pin, M16x150: guide pin into the hole. xx1700002197 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 530 A Aligning tool B Attachment screws (2 pcs) C Correct fitting of the aligning tool. Tightening torque: 50 Nm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 531 Remove the guide for the reduction gear. xx1700002038 Remove the lifting accessories. Refit stop screws in the lifting accessory attachment holes. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 533 Securing the axis-1 motor Action Note Fit guide pins in opposite holes. Guide pin, M12x150: 3HAC13056-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 534 • Make sure that the direction of the cable gland exit is facing the correct way. xx1200001072 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 535 Make sure that the R1.SMB cable will run on the correct side of the R1.MP1, see the figure. xx1700001808 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 536 Refit the cover that protects the R1.MP and R1.SMB connectors. xx1700001581 Connect the earth cable. Screw dimension: M6x16. Washer dimension: 6.4x17x3. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 537 Refit the metal clamp inside the base. xx1700001584 Connect the balancing device air hose in- side the base. xx1700002245 Refit the base cover. xx1700001580 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 538 Replace the gasket if damaged. xx1200001067 Connect the motor cables. Connect in accordance with the markings on the connectors. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 539 Note Make sure the o-ring is undamaged and properly fitted. xx1200001135 Make sure that the covers are tightly sealed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 540 (9ADJ400914P1259) Apply locking liquid on the screw. Locking liquid: 3HAB7116-1 (Loctite 243). Tightening torque: 24 Nm xx1300000476 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 541 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 542: Replacing The Axis-2 Gearbox
Example 1: Position with space for pallets in front of the robot. Axis-1 in calibration position. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 544 D=169.5x3 Used on motor cover. O-ring, nitrile rubber 3HAB3772-48 319.3x5.7 VK cover 3HAA2166-28 VK 28x7 Locking liquid (Loctite 2701) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 545 Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs. Guide pin, M12x200 3HAC13056-3 Always use guide pins in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 546 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 547 Note the value to be able to compare it when repair is completed. xx1700001593 CAUTION Turn off the air pressure supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 548 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 549 The weight of the balancing device (exclud- ing cradle) is 140 kg All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 550 Removing the shaft in the front (link ear) Action Note Remove the two screws. xx1900002146 Unscrew the attachment screw and washer. xx1200001279 • M16x70, stainless steel Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 551 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 552 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1 Note Save the stop screw installed, to refit after the lifting eye is removed. xx1200001133 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 553 Note Make sure the roundsling is stretched, in order to carry the weight of the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 554 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 555 Be careful not to damage the air hose or air nipple. xx1200001135 Make sure the o-ring is present. xx1200001070 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 556 Connect to connector R2.MP2, axis-2 mo- tor: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 557 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 558 Unscrew the attachment screws of the cable bracket on the frame and let it hang loose. xx1200001283 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 559 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 560 DressPack. Use caution and lift the arm system and lay it down safely on the pallets. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 561 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! Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 562 Always use guide pins in pairs. Lubricate the guide pins with some grease to make the gearbox slide better. xx1700000445 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 564 Securing the axis-2 motor Action Note Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 565 • Make sure that the direction of the cable exit is facing the correct way. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 566 Always use guide pins in pairs. Lubricate the guide pins with some grease to make the lower arm slide better. xx1400000360 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 567 Slide the lower arm on to the guide pins. Use caution and move the arms into posi- tion at the axis-2 gearbox on the guide pins. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 568 Connecting the axis-2 motor cables Action Note Push the motor cables through the cable gland opening. xx1300000738 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 569 O-ring, axis-2: 3HAC067762-001 Note O-ring, axis-3: 3HAC067762-001 O-ring, axis-4: 3HAC067744-001 Replace if damaged. xx1200001070 Wipe clean o-ring and o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 570 Use this procedure to refit the cabling. Action Note Use caution and push the cable harness into the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 571 Remove all residue of Loctite in the screw hole of the shaft. Wipe all contact surfaces inside the recess clean from contamination. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 572 Apply locking liquid (Loctite 2701) on the threads of the screw, first entering the threads in the frame. xx1300000782 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 573 Remove the lifting accessory from the bal- ancing device. Refit the cable bracket (if not already refit- ted). xx1200001283 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 574 Remove the distance tool. xx0800000480 A Distance tool: 3HAC030662-001 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 575 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 576: Replacing The Axis-3 Gearbox
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 577 Equipment to be Screws Washers Quantity fastened Gearbox M12x70 Stainless Steel 13x19x2 Stainless Steel 31 pcs 3HAC060786-034 3HAC060866-004 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 578 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 652. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 579 Action Note Decide which calibration routine to use, and take actions accordingly prior to begin- ning the repair procedure. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 581 Note Axis 3 and 4 motors only: Be careful not to damage the air hose or air nipple. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 582 Removing the axis-3 motor Action Note Before removing the motor, make sure that the axis-3 gearbox is completely drained. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 583 CAUTION The motor weighs 26 kg. All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 584 Disconnect the 24 VDC power supply. Remove the motor by lifting it straight out. Make sure the pinion is not damaged. xx1200001131 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 585 Unscrew the attachment screws that hold the cable bracket under the arm house. xx1300000543 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 586 Fit a lifting eye to the wrist. Lifting eye: 3HAC16131-1 Note Save the stop screw installed, to refit after the lifting eye is removed. xx1200001133 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 587 In case of necessary adjustments, use the shortening loops on the lifting accessory (chain) to find the level position. xx1400002197 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 588 (chain), and make sure to place the chain the right way through the loops. xx1400002197 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 589 Always use guide pins in pairs. Lubricate the guide pins with some grease to make the gearbox slide better. xx1300001969 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 590 Remove the gearbox. Refitting the axis-3 gearbox Use these procedures to refit the axis-3 gearbox. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 591 Lift the gearbox to the upper arm and let it rest on the guide pins. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 592 Tightening torque: 120 Nm. Remove the lifting accessory. Preparations before refitting the upper arm Action Note Wipe clean all contact surfaces. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 593 Use the pinion to rotate the axis-3 gearbox to find the correct position for the guide pins in the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 595 Use this procedure to secure the motor. Action Note Fit guide pins in opposite holes. Guide pin, M10x150: 3HAC15521-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 596 To release the brakes, connect the 24 VDC power supply. Connect to connector R2.MP3: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 597 Note Remove the lifting accessories. Move the cable harness and DressPack back to the correct side of the robot. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 598 Fasten the cable bracket on top of the arm house. xx1300000541 Fasten the cable bracket under the arm house. xx1300000543 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 599 Push the motor cables through the cable gland opening. xx1300000738 Refit the cable gland cover. Note Replace the gasket if damaged. xx1200001067 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 600 CAUTION When fitting the motor cover, make sure that none of the cables inside will be dam- aged. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 601 General calibration information is included in section Calibration on page 613. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 602: Replacing The Axis-6 Gearbox
Turcon Roto VL seal 3HAC060656-002 The seal is damaged when the turning disc is removed and must be replaced. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 603 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 604 • hydraulic pressure supply to the robot, before entering the safe- guarded space. Remove the synchronization plate axis-6. xx1300000825 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 605 Remove the turning disc. xx1300000493 Remove the seal from the turning disc. Note Replace the seal if damaged. xx1700001592 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 606 Preparations before refitting the axis-6 gearbox Action Note DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 607 Fit the gearbox to the wrist. CAUTION Be careful not to damage motor pinion or gears! xx1700001601 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 608 Jog axis-5 to horizontal position. Refill oil in the gearbox. Filling oil into the axis-6 gearbox on page 156. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 609 Grease: 3HAC042536-001 (Shell Gadus corner of the turning disc. S2). Note No grease is allowed on the screw flange. xx1700002094 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 610 Calibrating with Axis Calibration method on page 623. General calibration information is included in section Calibration on page 613. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 611 4 Repair 4.8.4 Replacing the axis-6 gearbox Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
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Page 613: Calibration
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 615 Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6790 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 616: When To Calibrate
If the robot has absolute accuracy calibration, it needs to be calibrated for new absolute accuracy. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 617: Synchronization Marks And Axis Movement Directions
Synchronization marks, IRB 6790 Axis 1 Axis 2 xx1300000868 xx1300000869 Axis 3 Axis 4 xx1300000870 xx1300000871 Axis 5 Axis 6 xx1500000845 xx1300000872 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 618: Calibration Movement Directions For All 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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 620 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 621 Tap Manual Method (Advanced). xx1500000944 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 622 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 637. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 623: Calibrating With Axis Calibration Method
Keep a safe distance to the robot. 3 The axis position is stored in RobotWare with an active choice from the operator. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 624 The axis chosen for calibration is then automatically run by the calibration program to its exact calibration position during the calibration procedure. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 625 Axis to be calibrated Unrestricted. Axis is allowed to be jogged to other position than 0 degrees. Axis must be put in position 0 degrees. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 626: Calibration Tools For Axis Calibration
If any part is missing or damaged, the tool must be replaced immediately. xx1500001914 Tube insert Plastic protection Steel spring ring Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 627 RFID chip can be installed. Install the RFID chip according to supplier instruc- tions. Install the chip in flush with the tool end. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 628: Installation Locations For The Calibration Tools
Replace damaged parts with new. Spare part Article number Note Protection cover and plug set 3HAC064875-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 629: Axis Calibration - Running The Calibration Procedure
7 The robot performs a measurement sequence by rotating the axis back and forth. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 630 Use this procedure to start the Axis Calibration routine on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 631 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. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 632 Replace the cover with new spare part, if missing or damaged. xx1600002102 Protection cover and plug set: 3HAC064875-001. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 633 Then tighten 1/4 turn more. Replace the plug and the sealing with new spare part, if missing or damaged. xx1600002103 Protection cover and plug set: 3HAC064875-001. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 634: Reference Calibration
(step 5, see Brief introduction to Reference Calibration on page 634). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 635 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 636: Verifying The Calibration
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 637: Checking The Synchronization Position
If they do not, up- ization position for axes on page 617 date the revolution counters. Updating revolution counters on page 619. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
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Page 639: Decommissioning
Plastic/rubber Cables, connectors, drive belts, and so on. Oil, grease Gearboxes Aluminium Covers, synchronization brackets Nickel Coating, turning disc Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 640 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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 641: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 642: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 643 Double-check the number of coils cut and make sure all the tension in the springs is removed. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 644 This page is intentionally left blank...
Page 645: Reference Information
7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 646: Applicable Standards
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 647: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 648: Screw Joints
The standard torques are specified in the following tables. Any special torques are specified in the repair, maintenance or installation Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 649 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 1150 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 650 Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Lubricated with Molycote 1000, Gleitmo 603 or equivalent Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 651: Weight Specifications
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 652: Standard Toolkit
Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Plastic mallet Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 653: Special Tools
Standard toolkit on page 652, and of special tools, listed directly in the instructions and also gathered in this section. Special tools Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 654 Lifting accessory, gearbox 3HAC046128-001 Lifting accessory, gearbox Lifting eye 3HAC16131-1 xx1200001242 Lifting eye 3HAC14457-4 xx1200001242 Lifting shackle SA-10-8-NA1 xx1200001243 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 655 3HAC13086-1 Hydraulic pump 70 MPa Threaded bar, M16x340 Removal tools ScrewsM8x75, fully threaded 3HAC057339-002 Removal tool M12 Other tools Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 656 3HAB7887-1 Rotation tool IRB 6790 - 235/2.65, IRB 6790 - 205/2.80, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85 Included in Dismantle and mounting tool (3HAC028920-001). iii The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.
Page 657: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
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Page 659: Spare Parts
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. Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
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Page 661: Circuit Diagrams
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 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 662 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC...
Page 663: Index
120 unloading, 411 dampers base plate inspection, 126 guide pins, 57 detergents securing, 57 requirements, 162 batteries direction of axes, 618 disposal, 639 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 664 618 cable harness, 118 neodymium dampers, 126 disposal, 639 mechanical stop, 120 nodular iron inspecting balancing device, 114 disposal, 639 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 665 311 standards, 646 upper arm, 253 EN, 646 wrist, 289 EN IEC, 646 xx, 55, 68, 88, 128, 399 EN ISO, 646 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 666 36 turning disc replacing, 311 replacing, 55, 68, 88, 128 unloading zero position balancing device, 411 checking, 637 updating revolution counters, 619 Product manual - IRB 6790 3HAC063331-001 Revision: B © Copyright 2019 - 2020 ABB. All rights reserved.
Page 668 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.

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