Introduction
The ABB IRB 6700 is a robust industrial robot designed for high performance and reliability. To maintain this level of operation and ensure a long service life, using the correct consumables during maintenance and repair is paramount. This guide centralizes critical consumable information—oils, greases, batteries, specific O-rings, and sealants—drawn from the product manual, to assist technical personnel in planning and executing service tasks efficiently.
Target Audience: This reference is intended for installation, maintenance, and repair personnel working with the ABB IRB 6700 robot.
Crucial Note on Lubricants:
The information on lubricating oils for gearboxes is dynamic. Always refer to the latest revision of the "Technical reference manual - Lubrication in gearboxes (Document ID: 3HAC042927-001)" available on the ABB Library. This ensures you are using the most current and correct specifications for your robot's specific needs. The product manual itself defers to this document for detailed oil types and quantities.
IRB 6700 Consumables Overview
This diagram illustrates the primary categories of consumables required for maintenance of the ABB IRB 6700 robot, their applications, and key specifications.
1. Gearbox Oils (Axes 1-6)
Proper gearbox lubrication is essential for the longevity and performance of the IRB 6700. Using the wrong oil or incorrect oil levels can lead to premature wear, overheating, and potential failure.
Primary Reference
"Technical reference manual - Lubrication in gearboxes (3HAC042927-001)"
This document contains specific oil types, article numbers, and total volumes for each axis gearbox.
Inspection & Changing
Axis 1
- Inspect oil level (Section 3.3.1,
xx1200000950) - Change oil (Section 3.4.2)
- Oil hole nipple
xx1200000948 - Vent/level plug
xx1200000950
Axis 2
- Inspect oil level (Section 3.3.2,
xx1200000952) - Change oil (Section 3.4.3)
- Oil hole nipple
xx1200000951 - Vent/level plug
xx1200000952
Axis 3
- Inspect oil level (Section 3.3.3,
xx1200000955) - Change oil (Section 3.4.4)
- Oil hole nipple
xx1200000954 - Vent/level plug
xx1200000955
Axis 4
- Inspect oil level (Section 3.3.4,
xx1200000957) - Change oil (Section 3.4.5)
- Drain plug
xx1200000956 - Fill/level plug
xx1200000957
Axis 5
- Inspect oil level (Section 3.3.5,
xx1200000959) - Change oil (Section 3.4.6)
- Drain plug
xx1200000958 - Fill/level plug
xx1200000959
Axis 6
- Inspect oil level (Section 3.3.6,
xx1200000963) - Change oil (Section 3.4.7)
- Drain plug
xx1200000962 - Fill plug
xx1200000963
Key Considerations
Danger of Mixing
Never mix different types of oil unless explicitly specified.
Hot Oil
Handle with care; hot oil (up to 90°C) presents a burn risk. Wear protective gear. Warm oil drains quicker.
Pressure Build-up
Open plugs carefully to release any internal pressure.
Do Not Overfill
Overfilling can damage seals and gaskets. Always check levels after refilling.
Amount Varies
The refilled amount may differ from the total specified volume depending on how much was drained.
Disposal
Used oil is hazardous. Dispose of it according to local regulations (Section 6.1).
Pro Tip
For tightening torques of oil plugs, refer to Section 10 of this guide. Unless otherwise stated, the general torque for these M-profile plugs is 24 Nm.
2. Greases
Grease is used for various bearings and for lubricating seals during assembly to ensure proper function and prevent leaks.
Optimol PD0
ABB Art. No. 3HAC042534-001, 50 ml tube
Applications:
- Spherical roller bearing in the balancing device link ear (Section 3.5.1,
xx1300000773, 4.6.1, 4.6.2) - Bearings at the balancing device cradle (rear attachments) (Section 4.6.2,
xx1300000832, 4.6.3)
When lubricating the balancing device link ear, fill from the upper hole until grease appears in the lower hole (xx1300000783).
General Purpose Grease
ABB Art. No. 3HAB3537-1
Applications:
- Lubricating O-rings and seals during assembly
- Motor O-rings, gearbox seals, general bearing assembly
- Referenced in Sections 4.2.2 (Bearings), 4.2.3 (Seals), and various motor/gearbox replacement procedures
For rotating seals, fill 2/3 of the space between the dust tongue and sealing lip. For bearings, do not completely fill; 70% of available volume during operation is typical.
3. Batteries
The IRB 6700 uses a battery pack for the Serial Measurement Board (SMB) to retain revolution counter data.
SMB Battery Pack
Specifications
- Part Number: Refer to "Product manual, spare parts - IRB 6700 (3HAC044268-001)" (as per Section 3.4.8 of the main manual)
- Location: On the left-hand side of the frame, inside the SMB/BU recess (Section 3.4.8,
xx1200001069) - Replacement Interval: At given maintenance interval or when "Battery low alert (38213 Battery charge low)" is displayed (Section 3.2.2, 3.4.8)
Critical Precautions
ESD Sensitivity: The SMB unit is sensitive to Electrostatic Discharge. Always use an ESD wrist strap connected to the controller's ESD button (Section 1.3.7, xx1300000856 for IRC5 controller) when handling.
Battery Safety: Do not short circuit, recharge, puncture, incinerate, etc. Risk of fire or explosion. Wear safety glasses (Section 1.3.8).
Data Loss Prevention: To avoid losing synchronization and needing to update revolution counters, it's recommended to keep controller power ON until the battery is replaced (Section 3.4.8). If power is lost or battery is replaced without power, revolution counters must be updated (Section 5.5).
Disposal: Dispose of batteries according to local regulations (Section 6.1).
4. O-Rings & Gaskets
Correct O-rings and gaskets are vital for sealing against contaminants and preventing lubricant leakage. Always replace if damaged or during relevant component replacement. Lubricate O-rings with grease (3HAB3537-1) before installation.
| Component | O-Ring/Gasket Specification | ABB Part Number | Manual Reference(s) | Diagram (Example) |
|---|---|---|---|---|
| Motor Covers | ||||
| Axis 1 Motor Cover | O-Ring, D=169.5x3 | 3HAB3772-111 | 4.4.2, 4.7.1, 4.8.1 | xx1200001070 |
| Axis 2 Motor Cover | O-Ring, D=169.5x3 | 3HAB3772-111 | 4.4.2, 4.7.2, 4.8.2 | xx1200001070 |
| Axis 3 Motor Cover | O-Ring, D=169.5x3 | 3HAB3772-111 | 4.4.2, 4.5.1, 4.7.3, 4.8.3 | xx1200001070 |
| Axis 4 Motor Cover | O-Ring, D=119x3 | 3HAB3772-110 | 4.4.2, 4.5.1, 4.7.4 | xx1200001070 |
| Axis 5 Motor Cover | O-Ring, D=119x3 | 3HAB3772-110 | 4.4.2, 4.5.1, 4.5.2, 4.7.5 | xx1200001070 |
| Axis 6 Motor Cover | Gasket | 3HAC033489-001 | 4.4.2, 4.5.1, 4.5.2, 4.7.6 | xx1200001080 |
| Motor Flanges (Motor to Gearbox) | ||||
| Axis 1 Motor Flange | O-Ring, D=102x3 | 3HAB3772-107 | 4.7.1, 4.8.1 | xx1200001019 |
| Axis 2 Motor Flange | O-Ring, D=102x3 | 3HAB3772-107 | 4.7.2, 4.8.2 | xx1200001019 |
| Axis 3 Motor Flange | O-Ring, D=102x3 | 3HAB3772-107 | 4.7.3, 4.8.3 | xx1200001019 |
| Axis 4 Motor Flange | O-Ring, D=102x3 | 3HAB3772-107 | 4.7.4 | xx1200001019 |
| Axis 5 Motor Flange | O-Ring, D=102x3 | 3HAB3772-107 | 4.7.5 | xx1200001019 |
| Axis 6 Motor Flange | O-Ring, D=102x3 | 3HAB3772-107 | 4.7.6 | xx1200001019 |
| Gearbox Seals (Gearbox Housing) | ||||
| Axis 1 Gearbox | O-Ring, D=380.59x3.53 | 3HAB3772-93 | 4.8.1 | xx1200001244 |
| Axis 2 Gearbox | O-Ring, D=309.3x3.1 | 3HAB3772-144 | 4.8.2 | (Similar to Axis 1) |
| Axis 3 Gearbox | O-Ring, D=266.29x3.53 | 3HAB3772-145 | 4.8.3 | (Similar to Axis 1) |
| Axis 6 Gearbox | O-Ring, D=151.99x3.53 | 3HAB3772-58 | 4.8.4 | xx1300000828 |
| Other Seals | ||||
| SMB / BU Cover | O-Ring, D=84.5x3 | 21522012-429 | 4.4.2 | xx1300000737 |
| Balancing Device Link Ear | O-Ring, 85x3 | (Part of kit) | 4.6.1 | xx1300000773 (D) |
| Balancing Device Link Ear | Radial Sealing with dustlip, 50x68x8 (2 pcs) | (Part of kit) | 4.6.1 | xx1300000773 (C) |
| Balancing Device Cradle | Radial Sealing (2 pcs) | 3HAB3702-29 | 4.6.3 | (Part of maint. kit) |
Note: Always verify part numbers with the latest spare parts list for IRB 6700.
5. Sealants & Adhesives
Sealants and thread lockers are used to ensure secure fastening and leak-proof assemblies.
Loctite 243
Medium Strength Threadlocker
Application:
- Screws for balancing device cradle bearings (Section 4.6.3)
- Stop pin set screw (Section 4.6.4,
xx1300000476) - End cover of balancing device link ear (Section 4.6.1)
Loctite 2701
High Strength Threadlocker
Application:
- Screw securing front shaft of balancing device (Section 4.5.4, 4.6.2,
xx1300000782)
Loctite 574
Flange Sealant
Application:
- Contact surface of Axis 1 gearbox to frame (Section 4.8.1)
Sikaflex 521FC
Elastic Glue and Sealant, ABB Art. No. 3HAC042559-001
Application:
- SMB/BU cover O-ring during refitting (Section 4.4.2,
xx1300000737) - Balancing device rear cover (Section 4.6.6)
6. Miscellaneous Consumables
Cable Ties
Used in various cable harness refitting procedures (e.g., Section 4.4.2). Always use new cable ties for secure fastening.
VK Covers
These plastic covers are often damaged during removal and typically need replacement.
- Application: Balancing device link ear (
xx1200001278) and cradle (xx1300000662) - Part Numbers: Refer to "Product manual, spare parts - IRB 6700". Example: 3HAA2166-28
Cleaning Agents
Section 3.6.1 provides guidance on appropriate cleaning agents:
- Standard Protection: Light cleaning detergent. If rinsing with water, a rust-prevention solution is highly recommended
- Foundry Plus Protection: Light cleaning detergent or spirit
Never use solvents not approved by ABB. Avoid spraying directly at connectors, joints, or seals.
7. Practical Application
Consumables Checklist for Axis 2 Motor Replacement
When preparing to replace the Axis 2 motor (Section 4.7.2), ensure you have the following consumables on hand:
-
O-Ring for Motor Cover (D=169.5x3)
ABB Part No. 3HAB3772-111
-
O-Ring for Motor Flange (D=102x3)
ABB Part No. 3HAB3772-107
-
Grease for O-Rings
ABB Part No. 3HAB3537-1
-
Gearbox Oil for Axis 2 (If needed)
Refer to "Technical reference manual - Lubrication in gearboxes (3HAC042927-001)" for type and quantity
-
Cleaning supplies
To clean mating surfaces
8. Pro-Tips for Consumable Management
Latest Lubricant Specs
As emphasized, the "Technical reference manual - Lubrication in gearboxes (3HAC042927-001)" is your definitive source for oil. Download the latest version from ABB Library before any lubrication task.
Cleanliness is Key
When working with lubricants, O-rings, and seals, ensure all components and your work area are impeccably clean to prevent contamination that could lead to premature failures.
Consequences of Incorrect Use
Using non-specified consumables can void warranties, lead to robot malfunction, component damage, and pose safety risks.
Gleitmo-Treated Screws
Some screws may have a Gleitmo surface treatment for reduced friction. These can typically be reused 3-4 times. Wear nitrile rubber gloves when handling (Section 7.4).
ESD Precautions
Always use an ESD wrist strap when replacing the SMB battery or handling other static-sensitive electronic components.
Proper Disposal
Used oils, greases, and batteries are hazardous materials. Adhere strictly to local environmental regulations for their disposal (Sections 6.1, 6.2).
9. Critical Safety Precautions
While the primary focus is on identifying the correct consumables, how they are handled is equally important to prevent personal injury and equipment damage. The IRB 6700 manual highlights several key safety risks:
Gearbox Lubricants (Oil & Grease) - Section 1.3.9
Hot Lubricants Warning
Risk: Changing and draining gearbox oil/grease can involve handling lubricants heated up to 90°C.
Prevention: Always wear protective gear, including heat-resistant gloves and safety goggles, during these activities.
Allergic Reactions
Risk: Direct contact with lubricants can cause allergic reactions in some individuals.
Prevention: Wear protective gloves and goggles. Ensure appropriate skin protection if handling aggressive media.
Pressure Build-up
Risk: When opening an oil or grease plug, pressure may have built up inside the gearbox, potentially causing lubricant to spray out.
Prevention: Open plugs carefully and slowly, keeping your face and body away from the opening.
Mixing Oils
Risk: Mixing different types of oil can cause severe damage to the gearbox.
Prevention: Never mix different oil types unless explicitly specified by ABB.
SMB Battery Handling - Section 1.3.8
Critical "Don'ts"
- Do NOT short circuit
- Do NOT attempt to recharge
- Do NOT puncture
- Do NOT incinerate
- Do NOT crush
- Do NOT immerse in liquids
- Do NOT force discharge
- Do NOT expose to high temperatures
Violation of these can lead to fire or explosion.
Protective Measures
- Always wear safety glasses when handling batteries.
- In the event of leakage, wear chemical-resistant gloves and an apron.
- Remember the SMB unit itself is ESD sensitive. Use an ESD wrist strap connected to the controller when accessing or replacing the battery.
Conclusion
Proper management and use of consumables are fundamental to the successful maintenance and repair of the ABB IRB 6700 robot. This quick reference aims to simplify the process of identifying and planning for these essential materials.
By adhering to the specifications outlined in the ABB documentation, particularly for lubricants, and following best practices for handling and application, you can significantly contribute to the robot's operational efficiency, reliability, and overall lifespan.