ABB IRB 6790 Product Manual
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ABB IRB 6790 Product Manual

ABB IRB 6790 Product Manual

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IRB 6790

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Summary of Contents for ABB IRB 6790

  • Page 1 ROBOTICS Product manual IRB 6790...
  • Page 2 Trace back information: Workspace 25A version a17 Checked in 2025-03-11 Skribenta version 5.6.018...

  • Page 3: Product Manual

    Product manual IRB 6790 - 235/2.65 IRB 6790 - 205/2.80 IRC5, OmniCore Document ID: 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Increase the lifetime of the robot ..............Restricting the working range ................2.6.1 Axes with restricted working range ............. 2.6.2 Mechanically restricting the working range of axis 1 ........Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 6 4.4.4 Replacing the SMB ................. 4.4.5 Replacing the brake release unit ............... Upper and lower arms ..................4.5.1 Replacing the upper arm ................Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 7 Applicable standards ..................Unit conversion ....................Screw joints ....................Weight specifications ..................Standard toolkit ....................Special tools ....................Lifting accessories and lifting instructions .............. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 8 Table of contents Spare parts Spare part lists and illustrations ................Circuit diagrams Circuit diagrams ....................Index Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 9: Overview Of This Manual

    This manual describes the manipulator using either the IRC5 or the OmniCore controller. Product manual scope The manual covers all variants and designs of the IRB 6790. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 General Document name Document ID Product manual, spare parts - IRB 6790 3HAC064429-001 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Technical reference manual - Lubrication in gearboxes 3HAC042927-001 Directions for use - Fork lift accessory set 3HAC047054-001 3HAC048484-002...
  • Page 11 • Added a note about not running cabling submerged beneath de- tergent solution. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 12 Published in release 25A. The following updates are done in this revision: • Removed dimension specifications for all stainless steel fasteners. • Updated tightening torque for balancing device rear cover. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 13: 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 14 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 15: How To Read The Product Manual

    Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 16: Important Information About Robots With Protection Type Foundry Prime

    Cleaning Special procedures are needed when cleaning the Foundry Prime robot. See section Cleaning the IRB 6790 on page 179. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 17: Safety

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.

  • 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 instructions. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 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. xx2400000736 xx1500002616 Brake release buttons xx0900000820 xx1000001140 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 25 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 27: Robot Stopping Functions

    For more information see: • Product manual - OmniCore V250XT Type B • Product manual - OmniCore V400XT • Product manual - IRC5 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 28: Safety During Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 29 Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 31: Safety During Operation

    A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 32: Safety During Maintenance And Repair

    90 °C. Hot oil or grease Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 33 Specified amount de- on how much has previously pends on drained been drained from the gearbox. volume Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 34 Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 35: Emergency Release Of The Robot Axes

    Make sure that the brake release buttons on the manipulator are within reach and quickly accessible in case of emergency situations, even when the manipulator is installed on a height, on a wall, or suspended. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 36: Brake Testing

    For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 37: Safety During Troubleshooting

    The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. CAUTION Risk of hot surfaces that can cause burns. A risk assessment must be done to address both robot and robot system specific hazards.

  • Page 38: Safety During Decommissioning

    A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 39: Installation And Commissioning

    Safety on page 17 before performing any installation work. Note Always connect the IRB 6790 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...

  • Page 40: Unpacking

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.

  • Page 41: Technical Data

    The actual mounting angle must always be configured in the system parameters, otherwise the performance and lifetime is affected. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 42 Force z 14.6 ±4.5 kN 14.6 ±15.7 kN Torque xy ±21.0 kNm ±37.1 kNm Torque z ±5.0 kNm ±11.4 kNm Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 43 The table shows the allowed operating conditions for the robot: Parameter Value Minimum ambient temperature +5°C (41°F) Maximum ambient temperature +50°C (122°F) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 44 Manipulator, protection type Foundry Prime IP69 According to IEC 60529. Includes all manipulator electrical compartments, excludes the Harting connector on the connection panel which is IP67. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 45: Working Range

    2.65 m Illustration, working range IRB 6790 - 205/2.80 This illustration shows the unrestricted working range of the robot. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 46 2.2.3 Working range Continued 1281 2039 2794 xx1300000282 Robot type Handling capacity Reach IRB 6790 205 kg 2.80 m Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 47 2.2.3 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 48: Risk Of Tipping/Stability

    This figure shows the robot in its transportation position. (645 CL xx1300000356 Axis number Angle of axis Axis 1 0° Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 49 The robot might be positioned in a different position at delivery, due to actual configurations and options (for example DressPack). WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 50: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 51: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 52: On-Site Transportation

    Transportation in any other way can seriously damage the robot. If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim. Method 1 - recommended method Transportation according to method 1 is strongly recommended by ABB.
  • Page 53 Continued Method 2 - transportation with a tool mounted to the robot Transportation according to method 2 is approved by ABB, only if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
  • Page 54 Continued IRB 6790 xx0800000040 Recommended transport support Always use the recommended transport support when transporting a robot with tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 55 ( 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 56: 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 89 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 57: On-Site Installation

    Introduction 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 58: Lifting The Robot

    Lifting the robot Action Note Lift the robot with a fork lift according to the user instructions enclosed with the fork lift accessory. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 59: Lifting Robot With Lifting Accessory (Recommended Lifting Method)

    DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 60 Make sure all hooks and attachments maintain their correct positions while lifting the robot! Always move the robot at very low speeds, making sure it does not tip. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 62 WARNING The robot is likely to be mechanically un- stable if not secured to the foundation. (645 CL xx1300000356 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 63 If the lifting eyes have sharp edges that might damage the roundslings, lifting shackles must be used to attach the roundslings to the lifting eyes. xx1300001572 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 64 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 66 When the robot is used in a corrosive environment, the securing screws and washers must be of stainless steel. Suitable screws, lightly lubricated: M24 x 100 Quantity: 8 pcs Quality: Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 68: Installation Requirements For Foundry Prime Robots

    The overpressure system, designed to detect leakage, consists of an overpressure unit and a flow sensor. If the used detergent is assumed to damage the robot, contact ABB Support service. Precautionary measures Make sure that the Foundry Prime coating of the robot is not broken during testing, installation, or repair work.

  • Page 69: Description Of The Manipulator Cable Harness 3Hac090903-001

    Note This section describes the manipulator cable harness 3HAC090903-001, introduced in 2025. It replaces the previous cable harness, 3HAC061214-001, both as installed on new deliveries of IRB 6790 and as spare part for existing IRB 6790. Main features and functionality...
  • Page 70 See document Description and installation information - Manipulator harness - IRB 6790 in ABB Library for more information about how to exchange the cable harness. See References on page 10 for document number.

  • Page 71: Description Of The Overpressure System

    IN (2) via the flow sensor is routed to the robot system through OUT 2 and monitored by the controller. See figure and the Overpressure diagram - with detached pressure regulators on page Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 72 There is a constant, normal, leakage in the system. The leakage value is individual for each system and is a predefined value set by ABB. If the leakage exceeds the predefined value, the system alerts with a signal to the I/O system.
  • Page 73 (air exhaust at R1.MP). This will exclude the power cables to influence the flow data (leakage), as they are not pressurized. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 74 Pressure relief valve (OUT 2) Flow sensor display OUT (B) - Not visible in illustration OUT 2 connection OUT 1 connection Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 75 Components such as oil absorber, air dryer and pressure regulator are not included in the delivery of the overpressure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 76 MOTOR 6 Balancing * Oil cylinder * Dryer absorber Air hose Cable harness Not included in the delivery xx2400000647 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 77 MOTOR 6 Balancing * Oil cylinder * Dryer absorber Air hose Cable harness Not included in the delivery xx2400000646 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 78 There is a constant, normal, leakage in the system. The leakage value is individual for each system and is a predefined value set by ABB. If the leakage exceeds the predefined value, the system alerts with a signal to the I/O system.
  • Page 79 The flow sensor value is configured during installation/production using the procedure described in section Set the flow sensor on page Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 80 Components such as oil absorber, air dryer and pressure regulator are not included in the delivery of the overpressure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 81 * Air regulator MOTOR 5 MOTOR 6 * Dryer * Oil absorber Balancing cylinder Not included in the delivery Air hose Cable harness xx1900002084 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 82: Installation Requirements, Procedure And Guidelines

    Put the interface plate where it is not subject to direct or indirect spray. xx1700001180 Connector point / interface plate Harness/interface cover Cables between interface plate and manipulator base (5 m) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 83 For more information about the connections in the controller, see the product manual for the robot controller, listed in References on page Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 84 For an overpressure system designed after November 2024 with integrated pressure regulators, see Overpressure diagram - with integrated pressure regulators on page Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 85 Remove the nuts from the studs on the interface plate. Pull the harness through the cover and fasten the cover with the nuts and the washers. xx1800000685 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 86: Leakage Supervision System

    Screen is ON and indicates leak- (RUN mode). age values. Tap Edit. Tap A or B for adjustments of value. Edit appears. OutA flashes. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 87 The alarm is only shown in the event log by default. If other alarm handling is desired it has to be programmed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 88 For more information on how to detect and repair a leakage in the overpressure system, see section Inspecting the overpressure system on page 141 Repairing the overpressure leakage on page 205. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 89: Shut-Down Periods

    • The overpressure must be kept at 0.2 - 0.3 bar during 24 hours independent of Motors On/Off mode, start-up and shut-down periods. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 90: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 91 Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 92: 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 listed in References on page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 93: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 94 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 95 2 Installation and commissioning 2.4.7 Fitting equipment to the robot Continued xx1300000866 Center of gravity 50 kg Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 96: Holes For Fitting Extra Equipment

    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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 97 2 Installation and commissioning 2.4.7 Fitting equipment to the robot Continued Attachment holes on arm house cover for extra equipment IRB 6790 - 235/2.65, IRB 6790 - 205/2.80 Attachment holes on arm house cover for extra equipment Not valid for IRB 6790 Variant IRB 6790 - 235/2.65...
  • Page 98 When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 99: Extended Working Range, Axis 1 (Option)

    3.84 radians = the actual installation. 220 degrees. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 100 For more information about SafeMove, see Application manual - Functional safety and SafeMove2 (IRC5) or Application manual - Functional safety and SafeMove (OmniCore). References on page 10 for document numbers. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 101: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 102: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 103: Mechanically Restricting The Working Range Of Axis

    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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 104 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 105: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 106 Flow sensor cable Connect the flow sensor cable to the controller and the flow sensor. Connect the cables on page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 107: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 108: Test Run After Installation, Maintenance, Or Repair

    Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 109: 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.

  • Page 110: Maintenance Schedule And Expected Component Life

    3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 6790: • Calendar time: specified in months regardless of whether the system is running or not.

  • Page 111: Maintenance Schedule

    Inspecting the surface treatment Painting damaged nickel coated surfaces with touch up paint on page 191 Inspecting the overpressure system (unit) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 112 Interval for oil change if water content in oil is possible to measure. The battery is to be replaced at given maintenance interval or at battery low alert. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 113: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 114: Inspection Activities

    Used on oil plug. Always replace when refitting oil plug. 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 115 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 116 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 117: Inspecting The Oil Level In Axis-2 Gearbox

    Used on oil plug. Always replace when refitting oil plug. 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 118 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 119: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 120 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 121: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 122 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 123: Inspecting The Oil Level In Axis-5 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 124 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 125: Inspecting The Oil Level In Axis-6 Gearbox

    Used on oil plug. Always replace when refitting oil plug. 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 126 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 127 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 128: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 129 Leaks at o-rings, radial sealings etc. are not acceptable and must be attended to immediately to avoid damage to the bearing. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 130 Before entering the robot working area. Check the area around the o-ring and radial sealings at the front ear, for leakage. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 131 Keep the areas around the balancing device clean and free from objects, such as service tools. xx1300000423 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 132: Inspecting The Cable Harness

    3.3.8 Inspecting the cable harness Location of cable harness The cable harness is located as shown in the figure. xx1700001801 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 133 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 134 Replace damaged cabling, if any. xx1300001094 Replace the cable harness if wear, cracks Removing the cable harness on or damage is detected. page 207. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 135: Inspecting The Axis-1 Mechanical Stop Pin

    The axis-1 mechanical stop is located as shown in the figure. xx1700001603 Required equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 136 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 137: 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 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 138 Required equipment on page 137. Correct attachment screws: • Stainless steel M12x70 and stainless steel washers (2 pcs per additional mechanical stop) Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 139: Inspecting The Dampers

    Visual inspection, no tools are required. Inspecting, dampers The procedure below details how to inspect the dampers. Note A damaged damper must be replaced. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 140 - IRB 6700/IRB 6700Inv. Attachment screws: M6x60. Locking liquid: Loctite 2400 (or equivalent Loctite 243). Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 141: Inspecting The Overpressure 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 142 For information on how to repair a leakage, see Repairing the overpressure leakage. Perform a visual inspection of the connec- tion to the balancing device. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 143: Analyzing Activities

    Recommendations for oil in axes 4 and 5 No oil analysis is nesessary. Change oil periodically, at latest every 18 months. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 144: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 145: Changing Oil, Axis-1 Gearbox

    Type of lubrication in gearboxes on page 144. Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 146 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 147 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: P © Copyright 2019 - 2025 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 149 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 150: Changing Oil, Axis-2 Gearbox

    Technical reference manual - Lubrica- tion in gearboxes. O-ring, G 1/2" 3HAC061327-059 Used on oil plug. Always replace when refitting oil plug. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 151 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 152 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 153 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 154 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 155: Changing Oil, Axis-3 Gearbox

    Technical reference manual - Lubrica- tion in gearboxes. O-ring, G 1/2" 3HAC061327-059 Used on oil plug. Always replace when refitting oil plug. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 156 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 157 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 158 Refit the vent hole oil plug with a new o- O-ring, G 1/2": 3HAC061327-059 ring. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 159 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 160: Changing Oil, Axis-4 Gearbox

    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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 161 Remove the oil plug from the drain hole and let the oil run into the vessel. xx1200000956 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 162 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 163 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 164: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 165 Refill oil or refit the oil plug with a new o- O-ring, G 1/2": 3HAC061327-059 ring. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 166 123. Refit the oil plug with a new o-ring. O-ring, G 1/2": 3HAC061327-059 Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 167 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 168: Changing Oil, Axis-6 Gearbox

    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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 169 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 170 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 171 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 172: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 173 Pull out the battery and disconnect the battery cable. xx1200001069 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: P...
  • Page 174 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 175: Replacing The Desiccant Bag

    SMB cover 9ADA619-56 5 pcs Removing the SMB cover Use these procedures to remove cover and replace desiccant bag. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 176 Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. xx2100000965 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 177 6 Nm. xx2100000965 Concluding procedures Action Note Turn on the air pressure supply to the overpres- sure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 178 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 179: 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 180 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
  • Page 181 Remove waste material, such as sand, dust and chips, if it prevents cable movement. • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 182 This page is intentionally left blank...

  • Page 183: 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 184: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 185: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 186 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 187: Mounting Instructions For Sealings

    A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only one side of the sealing is static with a metal insert. xx2300000433 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 188 A Main lip B Grease C Dust lip Note Ensure that no grease is ap- plied to the red marked surface. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 189 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface. Tighten the screws evenly when fastening the flange joint.
  • Page 190 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 191: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 192: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 193: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 194 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 195 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 196 Roundsling, 1 m: Length: 1 m, lift- the wrist. ing capacity: 1,000 kg. xx1200001236 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 197: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 198 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 199 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 200 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 201 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 202: 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 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 203 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 204 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 205: Complete Robot

    Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 206: Concluding Procedure

    Inspecting the over- pressure system. Set the flow sensor after a repair, see the flow sensor. If the leakage still remains, contact ABB Service. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 207: Removing The Cable Harness

    Handle the cables carefully to avoid any scratches or damage that lead to leakage when the system is pressurized. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 208 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 209 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 210 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 211 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 212 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 213 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 214 Make sure that all supplies for electrical power and hydraulic pressure are turned off. Disconnect air hose from air fitting on mo- tor cover. xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 215 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 216 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 217 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 218 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 219 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 220 Make sure that all supplies for electrical power and hydraulic pressure are turned off. CAUTION Turn off the air pressure supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 221 Remove the cover that protects the R1.MP and R1.SMB connectors. xx1700001581 Disconnect connectors: • R1.MP • R1.SMB xx1700001582 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 222 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 223 Preparations before disconnecting the SMB unit 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 224 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 225 Removing the cable harness in the frame Action Note Remove the air coupling from the R1.MP connector. xx1700001583 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 226 Remove the cable protection plate by re- moving the two nuts. xx1700001585 Disconnect connectors on the SMB unit. xx1300001114 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 227 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 228 Note The screws are reached from the outside of the lower arm. xx1300000540 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 229 4 Repair 4.4.2 Removing the cable harness Continued Action Note Use caution and pull the cable harness out. xx1300000733 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 230: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 231 Also see additional installation information if the existing cable harness is 3HAC061214-001 and it is to be replaced by the new harness 3HAC090903-001. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 232 This will also make it easier to run the cable harness through the inside of the robot. xx1300000668 Run the cable harness through the lower arm. xx1300000733 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 233 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 234 Also connect the air hose that belongs to Adapter: 3HAC11774-3 the balancing device. Check the adapter for dirt or wear. Clean or replace if needed. xx1700001582 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 235 Tightening torque: 10 Nm xx1700001584 Refit the base cover. Tightening torque: 10 Nm xx1700001580 Install the cabling between the base and Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 236 SMB/BU cover in its hole a little. xx1700002155 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 237 Tightening torque: 10 Nm tachment screws from inside the SMB/BU recess. xx1700002155 Refit the cable protection plate with two nuts. xx1700001585 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 238 Connect the battery cable to the SMB unit. Make sure the lock snaps into place during refit- ting. xx1300000729 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 239 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 240 Reconnecting the axis-1 and 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 241 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 242 Make sure that the covers are tightly sealed. Connect air hose to air fitting on motor. Note Make sure that it 'clicks' when connecting xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 243 Note The screws are reached from the outside of the lower arm. xx1300000734 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 244 Refitting the cable harness - upper arm and wrist These procedures describes how to refit the cable harness in upper arm and wrist. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 245 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 246 Person 2, working at the back: • Together: Use caution and move the cable harness into the arm tube. xx1700001569 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 247 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 248 • Use attachment screws made of stainless steel to fit the side cover. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 249 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 250 A Cable protection B Cable ties Secure the cable harness to the cable fixing bracket with the velcro strap. xx1700001810 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 251 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 252 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 253 Make sure that the covers are tightly sealed. Connect air hose to air fitting on motor. Note Make sure that it 'clicks' when connecting xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 254 Replace the gasket if damaged. xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 255 Replace with standard attachment screws. Note Make sure the o-ring is undamaged and properly fitted. xx1200001013 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 256 Make sure that the cable harness is placed in a way that it will not be damaged when the cover is fitted. xx1600002061 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 257 The attachment screw securing the carrier may be difficult to fit. Make sure the carrier is level and completely pressed against the bottom. xx1300000485 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 258 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 259 Clean the gasket from dirt and old grease residues. • Lubricate with grease between gas- ket and cover. xx2100000526 Grease: 3HAC042536-001 (Shell Gadus Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 260 Note Make sure that it 'clicks' when connecting xx2100000587 Turn on the air pressure supply to the overpressure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 261 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 262: Replacing The Smb

    If damaged or lost, order new items according to this table. Equipment to be Screws Washers Quantity fastened SMB cover 9ADA619-56 5 pcs Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 263 Disconnect air hose from air fitting on SMB cover. xx2100000591 Open the small cover on the SMB cover, disconnect the battery cable and remove the battery. xx1700001806 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 264 ESD on page 51 Remove the screws and washers that secure the SMB unit bracket. xx1300000730 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 265: Refitting The Smb Unit

    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 51 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 266 SMB unit. xx1300000730 If removed, refit the bracket with the brake re- Tightening torque: 10 Nm lease unit fitted. xx1700002154 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 267 The unit is sensitive to ESD on page 51 Reconnect the battery cable. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 268 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 269: 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 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 270 Remove the push button guard from the SMB cover. The push button guard must be removed to ensure a correct refitting of the brake release unit. xx1700001813 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 271 Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 272 ESD on page 51 Fasten the brake release unit to the bracket. Maximum tightening torque: 5 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 273 Before continuing any service work, follow the safety procedure in section The brake release buttons may be jammed after service work on page 192! Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 274 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 275 Make sure all safety requirements are met when performing the first test run. See Test run after install- ation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 276: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 277: Required Tools And Equipment

    Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 278 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 279 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 280 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 281 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 282 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 283 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 284 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 285 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 286 Remove the cable protection by cutting the cable ties and opening the zipper. xx1700001802 A Cable protection B Cable ties Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 287 This will also make it easier to run the cable harness through the inside of the upper arm. xx1300000668 Remove the side cover on the arm tube. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 288 Remove the arm house metal clamp. xx1300000543 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 289 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 290 • 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 291 Raise the lifting accessories to take the weight of the upper arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 292 Leave one of the remaining attachment screws fitted, remove the other screws. xx1300000747 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 293: Refitting The Upper Arm

    Refitting the upper arm Use these procedures to refit the upper arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 294 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 295 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 296 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 297 Person 2, working at the back: • Together: Use caution and move the cable harness into the arm tube. xx1700001569 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 298 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 299 • Use attachment screws made of stainless steel to fit the side cover. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 300 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 301 A Cable protection B Cable ties Secure the cable harness to the cable fixing bracket with the velcro strap. xx1700001810 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 302 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 303 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 304 Make sure that the covers are tightly sealed. Connect air hose to air fitting on motor. Note Make sure that it 'clicks' when connecting xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 305 Replace the gasket if damaged. xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 306 Replace with standard attachment screws. Note Make sure the o-ring is undamaged and properly fitted. xx1200001013 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 307 Make sure that the cable harness is placed in a way that it will not be damaged when the cover is fitted. xx1600002061 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 308 The attachment screw securing the carrier may be difficult to fit. Make sure the carrier is level and completely pressed against the bottom. xx1300000485 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 309 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 310 Lubricate with grease between gas- ket and cover. xx2100000526 Grease: 3HAC042536-001 (Shell Gadus Put washers in the holes of the gasket. xx1900002085 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 311 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 312: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 313 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 314 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 315 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 316 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 317 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 318 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 319 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 320 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 321 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 322 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 323 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 324 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 325 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 326 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 327 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 328 Make sure the o-ring is undamaged and properly fitted. xx1200001013 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 329 If not, connect the 24 VDC power supply, release the brakes and move axis 5 manually to +90°. xx1200001081 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 330 The attachment screw securing the carrier may be difficult to fit. Make sure the carrier is level and completely pressed against the bottom. xx1300000485 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 331 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 332: Concluding Procedure

    Clean the gasket from dirt and old grease residues. • Lubricate the gasket with grease. xx2100000526 Grease: 3HAC042536-001 (Shell Gadus Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 333 Calibrating with Axis Calibration method on page 652. General calibration information is included in section Calibration on page 639. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 334 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 335: Replacing The Turning Disc

    Quantity fastened Turning disc 3HAC060786-010 3HAC060866-001 24 pcs Screws are not reusable after removal. Replace them with new screws. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 336 Action Note Remove the screws and washers, that se- cure the turning disc. xx1300000492 Remove the turning disc. xx1300000493 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 337 Grease: 3HAC042536-001 (Shell Gadus outwards from the turning disc when orient- S2). ing the seal, as shown in the figure. xx1700001878 xx1700002033 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 338 Then remove the screws and secure the turning disc with the specified attachment screws. xx1300000492 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 339 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 340: Replacing The Lower Arm

    Note Grease 3HAA1001-294 Tribol GR 100-0 PD, 50 ml For lubrication of the front bearing of the balancing device. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 341 Hydraulic pump 70 MPa 3HAC13086-1 To be used with the hydraulic cylinder. Hydraulic cylinder 3HAC11731-1 To be used with the press tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 342 Remove all external cable packages (DressPack) and tools from the robot. Removing the lower arm Use these procedures to remove the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 343 Axis 2: 0° • Axis 3: 0° • Axis 4: 0° • Axis 5: +90° • Axis 6: 0° Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 344 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 345 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 346 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 347 DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 348 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 349 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 350 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 351 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 352 Make sure the o-ring is present. xx1200001070 Disconnect the motor cables. xx1200001066 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 353 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 354 Note The parts are sealed with flange sealant Loctite 5400 (or equivalent Loctite 577). Remove the part carefully. xx1300000485 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 355 Remove the cable protection by cutting the cable ties and opening the zipper. xx1700001802 A Cable protection B Cable ties Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 356 This will also make it easier to run the cable harness through the inside of the upper arm. xx1300000668 Remove the side cover on the arm tube. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 357 Remove the arm house metal clamp. xx1300000543 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 358 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 359 • 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 360 Raise the lifting accessories to take the weight of the upper arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 361 Leave one of the remaining attachment screws fitted, remove the other screws. xx1300000747 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 362 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 363 The lower arm weighs 145 kg All lifting accessories used must be sized accordingly! Apply the lifting accessory to the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 364: Refitting The Lower Arm

    Refitting the lower arm Use these procedures to refit the lower arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 365 All lifting accessories used must be sized accordingly. Lift the lower arm onto the guide pins and slide it into position. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 366 Tightening torque M16: 300 Nm screws and washers. Attachment screws: 3HAC060786-041 (21 pcs) Washers: 3HAC060866-005 (HV200) (21 pcs) xx1300000789 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 367 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 368 3HAC060786-031 (25 of 27 pcs) Washers: 3HAC060866-005 (HV200) 3HAC060866-004 xx1400000359 Remove the guide pins and fit the two re- maining M12 screws. xx1300000659 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 369 Note The screws are reached from the outside of the lower arm. xx1300000734 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 370 Refitting the cable harness - upper arm Action Note Refit the metal clamp on top of the arm Tightening torque: 10 Nm house. xx1300000541 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 371 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 372 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 373 • Use attachment screws made of stainless steel to fit the side cover. xx1300000557 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 374 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 375 A Cable protection B Cable ties Secure the cable harness to the cable fixing bracket with the velcro strap. xx1700001810 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 376 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 377 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 378 Make sure that the covers are tightly sealed. Connect air hose to air fitting on motor. Note Make sure that it 'clicks' when connecting xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 379 Replace the gasket if damaged. xx1200001016 Connect the connectors. Connect in accordance with the markings on the connectors. xx1200001015 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 380 Replace with standard attachment screws. Note Make sure the o-ring is undamaged and properly fitted. xx1200001013 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 381 Make sure that the cable harness is placed in a way that it will not be damaged when the cover is fitted. xx1600002061 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 382 The attachment screw securing the carrier may be difficult to fit. Make sure the carrier is level and completely pressed against the bottom. xx1300000485 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 383 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 384 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Fit the heat protection plate with the screws. xx1500001030 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 385 Lubricate with grease between gas- ket and cover. xx2100000526 Grease: 3HAC042536-001 (Shell Gadus Put washers in the holes of the gasket. xx1900002085 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 386 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 387 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 388 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 389 Remove the distance tool. xx0800000480 A Distance tool: 3HAC030662-001 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 390 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 391: Frame And Base

    This is a brief summary of the replacement procedure, containing the major actions to be performed. 1 Unload the balancing device. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 392 3HAC15556-1 Lifting instruction 3HAC15880-2 en- closed. Dismantle and mounting tool 3HAC028920-001 Used for removing and fitting shaft and bearings. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 393 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 394 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 395 DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 396 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 397 Unloading the balancing device on loaded. page 393. Jog axis-2 to the calibration position (if not already in this position). Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 398 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 399 DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 400 DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 401 Lubricate the o-ring on the end cover and refit the Grease: 3HAC042536-001. cover by hand. Tighten screws. xx1700001662 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 402 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 403 Secure the shaft with screw and washer. Tightening torque: 200 Nm xx1200001279 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 404 • hydraulic pressure supply to the robot, before entering the robot working area. Remove the Distance tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 405 Tightening torque: 35 Nm. Flange sealant for conical fittings: Loctite 5400 (or equivalent Loctite 577). xx1300000554 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 406: Replacing The Balancing Device

    2 Replace the balancing device. Spare part Spare parts Spare part number Note Balancing device See Product manual, spare parts - IRB 6790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 407 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 408 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 409 Read and follow enclosed user instructions for the tool. Removing the balancing device Use these procedures to remove the balancing device. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 410 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 411 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 412 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 413 DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 414 DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 415: Concluding Procedure

    +30° position and with the balancing device fitted to the robot. Refitting the balancing device Use this procedure to refit the balancing device. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 416 Remove the cover plate on the back of the balan- cing device. DANGER DO NOT remove any other screws than the rear cover attachment screws. xx1300000554 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 417 Apply a big screwdriver between the cradle and the balancing device, as shown in the figure when the shafts are refitted. xx1300000838 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 418 A Loctite 574 (or equivalent) (red dot- ted lines) B Balancing device C Shaft Fit the retaining ring. xx1300000664 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 419 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 420 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 421 Secure the shaft with screw and washer. Tightening torque: 200 Nm xx1200001279 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 422 • hydraulic pressure supply to the robot, before entering the robot working area. Remove the Distance tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 423 Tightening torque: 35 Nm. Flange sealant for conical fittings: Loctite 5400 (or equivalent Loctite 577). xx1300000554 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 424: Replacing The Rear Bearings On The Balancing Device

    Loctite 574 (or equivalent) Activator 3HAC074342-001 Loctite 7091 Flange sealant for conical fit- Loctite 5400 (or equivalent Loctite 577) tings Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 425 Used for removing and fitting shaft and bearings. Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 426 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 427 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 428 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 429 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 430 Before pulling out the shaft end, put a big screw driver between the cradle and balan- cing device and use it as a distance tool. xx1300000838 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 431 The activator must be used to harden the flange sealant. xx1400000367 A Loctite 574 (or equivalent) (red dot- ted lines) B Balancing device C Shaft Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 432 Fit the retaining ring bore. xx1700000343 Apply locking liquid on the attachment Loctite 2400 (or equivalent Loctite 243) screw. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 433 Remove the lifting accessories Action Note Remove the lifting accessories. Concluding procedure Action Note Refit the retaining ring bore. xx1300000664 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 434 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 435: Replacing The Stop Pin

    Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 436: Required Consumables

    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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 437 3110 Waxcoat. Recommended drying shown in the figure. time is 24h.). xx1400000378 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 438 Apply locking liquid on the set screw, and Loctite 2400 (or equivalent Loctite 243) secure the stop pin. Set screw: 9ADJ400914P1259 xx1300000476 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 439: Motors

    3 Remove the lifting tools. Spare parts Spare part Spare part number Note Axis-1 motor See Product manual, spare parts - IRB 6790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 440 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 441 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 442 Make sure that all supplies for electrical power and hydraulic pressure are turned off. Disconnect air hose from air fitting on mo- tor cover. xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 443 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 444 Always use guide pins in pairs. 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 445 Disconnect the brake release tool / 24 VDC power supply. Refitting the axis-1 motor These procedures describes how to refit the motor. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 446 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 447 All lifting accessories used must be sized accordingly. Apply the lifting accessory. Lifting accessory, motor: 3HAC14459-1. Fit the rotation tool. Rotation tool: 3HAB7887-1 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 448 • 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 449 Disconnect the brake release tool / 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 450 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 451 Make sure that the covers are tightly sealed. Connect air hose to air fitting on motor. Note Make sure that it 'clicks' when connecting xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 452 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 453: Replacing The Axis-2 Motor

    5 Refill the axis-2 gearbox with oil. Spare parts Spare part Spare part number Note Axis-2 motor See Product manual, spare parts - IRB 6790 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 454 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 455 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 456 Disconnecting the 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 457 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 458 Connect to connector R2.MP2, axis-2 mo- tor: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 459 Fasten the lifting accessory. Attach the Lifting accessory, motor: 3HAC15534-1 lifting chain to the accessory and an over- Lifting accessory (chain): 3HAC15556-1 head crane. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 460 Wipe clean the contact surfaces and the o-ring groove. Fit a new o-ring. xx1200001019 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 461 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 462 Fit two of the attachment screws and Screws: 3HAC060786-020 washers. Washers: 3HAC060866-003 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 463 Performing a leak-down test on page 184. 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 464 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 465 Make sure that the covers are tightly sealed. Connect air hose to air fitting on motor. Note Make sure that it 'clicks' when connecting xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 466 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 467: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 468 • 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 469 Remove any equipment hindering access to the motor. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 470 Make sure that all supplies for electrical power and hydraulic pressure are turned off. Disconnect air hose from air fitting on mo- tor cover. xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 471 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 472 Unscrew the attachment screws that hold Bits extender: 3HAC12342-1 the motor. Use a bits extender to reach the screws. xx1200001126 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 473 If not there is a risk of damaging the pinion and xx1200001125 gear. Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 474 Wipe clean the contact surfaces and the o-ring groove. Fit a new o-ring. xx1200001019 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 475 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 476 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 477 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 478 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 479 Make sure that the covers are tightly sealed. Connect air hose to air fitting on motor. Note Make sure that it 'clicks' when connecting xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 480 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 481: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 482 If no previous reference values exist, and routine on page 653. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 483 Disconnect the air hose from the nipple on the connection box. CAUTION Turn off the air pressure supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 484 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 485 To release the brakes, connect the 24 VDC power supply. Connect to connector R2.MP4: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 486 Make sure the pinion is not damaged. xx1200001138 Refitting the motor These procedures describes how to refit the motor. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 487 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 488 Action Note Apply two guide pins in opposite holes. Guide pin, M8x150: 3HAC15520-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 489 To release the brakes, connect the 24 VDC power supply. Connect to connector R2.MP2: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 490 Washers: 3HAC060866-002, (4 pcs) xx1200001137 Perform a leak-down test. Performing a leak-down test on page 184. Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 491 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 492 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 493 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 494 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 495: Replacing The Axis-5 Motor

    Rotation tool 3HAB7887-1 Used to rotate the motor pinion. 24 VDC power supply Used to release the motor brakes. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 496 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 497 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 498 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 499 Unscrew the attachment screws and washers and remove the motor cover. xx1200001135 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 500 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 501 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 502 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 503 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 504 Remove the guide pins. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 505 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 506 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 507 Make sure the o-ring is undamaged and properly fitted. xx1200001013 Secure the cable harness with cable straps to the heat protection plate. xx1500001029 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 508 Clean the gasket from dirt and old grease residues. • Lubricate with grease between gas- ket and cover. xx2100000526 Grease: 3HAC042536-001 (Shell Gadus Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 509 Calibrating with Axis Calibration method on page 652. General calibration information is included in section Calibration on page 639. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 510 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 511: Replacing The Axis-6 Motor

    Used on motor cover. O-ring 3HAB3772-107 D=102x3 Used on motor flange. Activator 3HAC074342-001 Loctite 7091 Flange sealant Loctite 574 (or equivalent) Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 512 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 513 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 514 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 515 Loctite 5400 (or equivalent Loctite 577). Remove the part carefully. xx1300000485 Pull out the carrier from its position. xx1300001113 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 516 CAUTION The motor weighs 9 kg. All lifting accessories used must be sized accordingly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 517 Wipe clean the contact surfaces and the o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 518 Apply locking liquid with activator on the motor Activator (Loctite 7091). flange. Flange sealant (Loctite 574 (or equivalent)). xx1200001020 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 519 Check the gasket. Replace if damaged. xx1200001094 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 520 Make sure the motor pinion is not dam- aged! xx1200001091 xx1200001097 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 521 Seal the screw with Loctite 5400 (or equi- valent 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 522 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 523 Clean the gasket from dirt and old grease residues. • Lubricate with grease between gas- ket and cover. xx2100000526 Grease: 3HAC042536-001 (Shell Gadus Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 524 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 525: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 526 Note Oil collecting vessel The capacity of the vessel must be sufficient to take the complete amount of oil. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 527: Required Documents

    682. 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 528 Begin draining the axis-1 gearbox. Draining the axis-1 gearbox on page 146. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 529 Unscrew the attachment screws that secure the cable bracket. xx1200001184 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 530 Note Leave the outermost screw fitted as a safety precaution. xx1200001189 xx1200001185 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 531 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 532 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 533 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 534 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 535 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 536 DANGER Handling the tool incorrectly will cause xx2100000666 serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 537 CAUTION Turn off the air pressure supply. Remove the base cover. xx1700001580 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 538 Disconnect connectors: • R1.MP • R1.SMB xx1700001582 Disconnect the earth cable. Screw dimension : M6x16 Washer dimension : 6.4x17x3 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 539 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 540 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 541 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 542 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 543 Lift away the gearbox. Refitting the axis-1 gearbox These procedures describe how to refit the axis-1 gearbox. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 544 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 545 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 546 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 547 Remove the guide pins. Remove the lifting accessory and the lifting eyes. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 548 Wipe clean the contact surfaces from any remaining contamination. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 549 036. 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 550 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 551 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 552 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 553 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 554 Note xx1700002043 While lowering the complete arm system, check that the cylindrical pin is fitted cor- rectly. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 555 Refitting the frame cable protection Action Note Replace the o-ring on the protection ring. O-ring: 3HAB3772-58. xx1700001660 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 556 Wipe clean the contact surfaces and the o-ring groove. Fit a new o-ring. xx1200001019 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 557 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 558 5 = 0V 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 559 Perform a leak-down test (if not already Performing a leak-down test on done). page 184. Disconnect the brake release tool / 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 560 Also connect the air hose that belongs to Adapter: 3HAC11774-3 the balancing device. Check the adapter for dirt or wear. Clean or replace if needed. xx1700001582 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 561 Tightening torque: 10 Nm xx1700001584 Refit the base cover. Tightening torque: 10 Nm xx1700001580 Install the cabling between the base and Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 562 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 563 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 564 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 565 Locking liquid: Loctite 2400 (or equivalent Loctite 243) Tightening torque: 10 Nm xx1300000476 Refit the cable protection plate with two nuts. xx1700001585 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 566 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 567: Replacing The Axis-2 Gearbox

    Example 1: Position with space for pallets in front of the robot. Axis-1 in calibration position. If needed, run axis-1 into a position that gives the required space. The figure shows an example. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 568 DressPack in base and frame first. Location of the axis-2 gearbox The axis-2 gearbox is located as shown in the figure. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 569 If damaged or lost, order new items according to this table. Equipment to be Screws Washers Quantity fastened Gearbox 3HAC060786-036 3HAC060866-004 30 pcs Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 570 To be used with the hydraulic cylinder. Leak-down tester 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 571 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 572 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 573 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 574 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 575 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 576 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 577 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 578 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 579 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 580 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 581 Removing the axis-2 motor Action Note Before removing the motor, make sure that the axis-2 gearbox is completely drained. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 582 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 583 Note The screws are reached from outside the lower arm! xx1300000540 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 584 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 585 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 586 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 587 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 588 Wipe clean the contact surfaces and the o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 589 Apply locking liquid with activator on the motor Activator (Loctite 7091). flange. Flange sealant (Loctite 574 (or equivalent)). xx1200001020 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 590 Apply the rotation tool and use it to rotate Rotation tool: 3HAB7887-1 the pinion when mating it into the gear. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 591 Fit the rotation tool, if not already fitted. Rotation tool: 3HAB7887-1 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 592 Before putting the arms on the guide pins, make sure that the hole pattern is matched and in the correct position for all screws. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 593 Disconnect the 24 VDC power supply. Remove the lifting accessories. Refit stop screws in the lifting accessory attachment holes. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 594 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 595 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 596 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 597 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 598 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 599 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 600 Remove the distance tool. xx0800000480 A Distance tool: 3HAC030662-001 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 601 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 602: Replacing The Axis-3 Gearbox

    1 Remove the upper arm from the robot and position it as shown in the figure, for easy removal of the axis-3 gearbox. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 603 31 pcs Upper arm 3HAC060786-041 3HAC060866-005 (HV200) 9 pcs 3HAC060786-031 3HAC060866-004 27 pcs Motor, axis-3 3HAC060786-020 3HAC060866-003 4 pcs Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 604 Delivered as a set of calibration tools. Calibration Standard toolkit Content is defined in section Standard toolkit on page 682. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 605 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 606 DressPack in the upper arm and wrist first. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 607 Make sure that all supplies for electrical power and hydraulic pressure are turned off. Disconnect air hose from air fitting on mo- tor cover. xx2100000568 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 608 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 609 Unscrew the attachment screws that hold Bits extender: 3HAC12342-1 the motor. Use a bits extender to reach the screws. xx1200001126 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 610 If not there is a risk of damaging the pinion and xx1200001125 gear. Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 611 Note The screw is reached from the outside of the lower arm! xx1800000042 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 612 (as seen from behind) of the back lifting eye. See figure! xx1300000534 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 613 Raise the lifting accessories to take the weight of the upper arm. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 614 Leave one of the remaining attachment screws fitted, remove the other screws. xx1300000747 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 615 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 616 All lifting accessories used must be sized accordingly. Apply the lifting accessory to the gearbox. Lifting accessory, gearbox: 3HAC046128- Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 617 Also wipe clean the o-ring groove. Lubricate the o-ring with some grease. Fit the o-ring in the groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 618 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 619 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 620 Wipe clean the contact surfaces and the o-ring groove. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 621 Apply locking liquid with activator on the motor Activator (Loctite 7091). flange. Flange sealant (Loctite 574 (or equivalent)). xx1200001020 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 622 Apply the lifting accessories to the motor. Lifting accessory, motor: 3HAC15534-1 Note Make sure the cable gland exit is turned ac- cording to figure. xx1700000273 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 623 Remove the rotation tool. Perform a leak-down test. Performing a leak-down test on page 184. Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 624 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 625 Refit the cable gland cover. Tightening torque: 6 Nm Note Replace the gasket if damaged. xx1200001067 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 626 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 627 Filling oil into the axis-3 gearbox on page 157. Turn on the air pressure supply to the overpressure system. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 628 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 629: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 630 Remove all external cable packages (DressPack) and tools from the robot. Removing the axis-6 gearbox Use these procedures to remove the axis-6 gearbox. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 631 • 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 632 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 633 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 634 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 635 Jog axis-5 to horizontal position. Refill oil in the gearbox. Filling oil into the axis-6 gearbox on page 170. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 636 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 637 Calibrating with Axis Calibration method on page 652. General calibration information is included in section Calibration on page 639. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 638 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 108. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 639: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 640: Calibration Methods

    Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6790. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: •...
  • Page 641 References Article numbers for the calibration tools are listed in the section Special tools on page 683. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 642: When To Calibrate

    The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

  • Page 643: Synchronization Marks And Axis Movement Directions

    Synchronization marks, IRB 6790 Axis 1 Axis 2 xx1300000868 xx1300000869 Axis 3 Axis 4 xx1300000870 xx1300000871 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 644 5 Calibration 5.2.1 Synchronization marks and synchronization position for axes Continued Axis 5 Axis 6 Two variants of synchronization mark plates. xx1300000872 xx1300000873 xx1500000845 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 645: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 646: Updating Revolution Counters

    (try both directions, if needed). Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 647 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 648 Tap Manual Method (Advanced). xx1500000944 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 649 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 665. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 650: Updating Revolution Counters On Omnicore Robots

    On the start screen, tap Calibrate. The calibration summary page for the mechanical unit is displayed. In the Calibration Methods menu, select Revolution Counters. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 651 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 665. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 652: Calibrating With Axis Calibration Method

    FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
  • Page 653 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
  • Page 654 Make sure that the user rights admit to change the safety settings and to synchronize SafeMove. For robots with EPS, the same applies as for SafeMove. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 655: Calibration Tools For Axis Calibration

    There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
  • Page 656 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.

  • Page 657: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 658: Axis Calibration - Running The Calibration Procedure

    WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
  • Page 659 If not, tap Call Routine and then tap Axis calibration. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 660 Axis Calibration procedure. CAUTION SafeMove must be synchronized after the calibration is completed. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 661: After Calibration

    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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 662: Reference Calibration

    (step 5, see Brief introduction to Reference Calibration on page 662). Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 663 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 664: Verifying The Calibration

    The label is located on the lower arm. The label can also be placed elsewhere due to the harsh environment. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 665: Checking The Synchronization Position

    Using a MoveAbsJ instruction with argument zero on all axes. • Using the Jogging window on the FlexPendant.Using the Jog window on the FlexPendant. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 666: Checking The Synchronization Position On Irc5 Robots

    If they do not, up- ization position for axes on page 643 date the revolution counters. Updating revolution counters on page 646. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 667: Checking The Synchronization Position On Omnicore Robots

    If they do not, up- ization position for axes on page 643 date the revolution counters. Updating revolution counters on page 646. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 668 This page is intentionally left blank...

  • Page 669: Decommissioning

    See also Environmental information on page 670. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 670: Environmental Information

    6.2 Environmental information 6.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials shall be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
  • Page 671 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 672: Scrapping Of Robot

    A used robot does not have the same performance as on delivery. Springs, brakes, bearings, and other parts might be worn or broken. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 673: Decommissioning Of Balancing Device

    The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 674 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 675: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 676: Applicable Standards

    ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems - Part 1: General principles for design, normative reference from ISO 10218-1 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 677: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 678: Screw Joints

    7.4 Screw joints 7.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
  • Page 679 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 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 680 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 681: Weight Specifications

    All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

  • Page 682: 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: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 683: Special Tools

    Standard toolkit on page 682, 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 684 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: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 685 3HAC028920-001 Dismantle and mounting tool 3HAC030662-001 Distance tool xx1400000726 Hydraulic press tool, balancing 3HAC020902-001 device xx1300000672 3HAC11731-1 Hydraulic cylinder Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 686 Calibration tool box, Axis 3HAC055412-001 Calibration 3HAC043870-009 Guide for reduction gear xx1700002195 Leak-down tester Lock screw, M16x120 Oil collecting vessel Oil dispenser Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 687 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 688: Lifting Accessories And Lifting Instructions

    The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.

  • Page 689: 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.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 6790 3HAC063331-001 Revision: P...
  • Page 690 This page is intentionally left blank...

  • Page 691: Circuit Diagrams

    Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 692 9.1 Circuit diagrams Continued Product Article numbers for circuit diagrams 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 693: Index

    670 battery shutdown EPS, 99 service routine, 172 equipment, on robot, 93 brake release, 90 brake release unit damage elimination, 51 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 694 28 inspecting balancing device, 128 negative directions, axes, 645 inspecting oil levels neodymium axis 1, 114 disposal, 670 axis 2, 117 nodular iron Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 695 435 disposal, 670 rear bearings, 424 standards, 676 SMB unit, 175, 262 start of robot in cold environments, 107 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 696 1, 103 transport support, 56 wrist troubleshooting replacing, 312 oil spills, 179 safety, 37 turning disc zero position replacing, 335 checking, 665 upcycling, 670 Product manual - IRB 6790 3HAC063331-001 Revision: P © Copyright 2019 - 2025 ABB. All rights reserved.
  • Page 698 SHANGHAI 201315, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2019 - 2025 ABB. All rights reserved. Specifications subject to change without notice.

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