Mastering the Maze
A Technician's Guide to Replacing the ABB IRB 6700 Cable Harness
A Technician's Guide to Replacing the ABB IRB 6700 Cable Harness
This guide is intended for trained and qualified maintenance and repair personnel who possess the necessary mechanical and electrical skills and have been trained by ABB on robot servicing. This is NOT a DIY guide for untrained individuals. Incorrect procedures can lead to severe injury or irreparable damage to the robot.
The ABB IRB 6700 is a workhorse industrial robot, designed for demanding applications and long service life. However, like any complex machinery, components can wear or sustain damage over time. The main robot cable harness, the intricate network carrying power and signals to every axis, is a critical component that may eventually require replacement due to wear, accidental damage, or as part of a major overhaul.
Replacing the cable harness on an IRB 6700 is a complex and meticulous procedure, demanding precision, careful organization, and adherence to safety protocols. This guide, based on the official ABB product manual (Document ID: 3HAC044266-001, Rev -), aims to provide qualified technicians with a structured overview and practical insights into this essential repair task. It goes beyond merely listing steps, offering context and highlighting crucial points for a successful replacement.
The robot's cable harness endures constant flexing and movement during operation. Replacement typically becomes necessary due to:
Before touching the robot, internalize these critical safety points:
Absolutely ensure all power sources (electrical, hydraulic, pneumatic) are completely shut off and locked out/tagged out (LOTO) according to your facility's procedures. Verify zero energy state. Reference section 1.3.6.
Carefully jog the robot to the recommended starting position (detailed below). Improper positioning can make access difficult or unsafe.
The robot's electronic components, particularly the Serial Measurement Board (SMB) and Brake Release Unit (BU), are highly sensitive to Electrostatic Discharge. Always use a grounded wrist strap (connected to the robot's ESD point, see section 1.3.7) and follow ESD-safe handling procedures throughout the process.
This task requires specific training and expertise. Attempting this without proper qualification can lead to severe injury or irreparable damage to the robot.
Even with power off, be mindful of potential stored energy (e.g., in the balancing device, though not directly involved here) and unexpected movements if brakes are manually released.
Referencing sections 4.4.1 and 4.4.2, ensure you have the following before starting:
The correct spare part for the specific IRB 6700 model (See Product manual, spare parts - IRB 6700).
As defined in section 7.6 (includes various spanners, sockets, Allen keys, torque wrenches, etc.).
Tools specific to handling DressPack components if installed.
This process involves carefully disconnecting and extracting the old harness section by section. Organization is key – label connectors and keep track of hardware.
Jog the robot to the recommended position:
Note: This position facilitates access. Adjustments might be needed based on tooling or specific robot configuration.
xx1300000821). Leave the DressPack cables within the housing for now.xx1200000052).Starting from the wrist, systematically disconnect each axis motor:
xx1300000486).xx1300000489).xx1300000490).xx1200001080).xx1300000488).xx1200001135).xx1200001066).xx1300000656). Preserve the gasket.xx1200001135), disconnect cables (xx1200001066), remove cable gland covers (xx1200001067), and extract cables.xx1200000045, xx1200000042).xx1300000668) to prevent snagging.xx1300000557).xx1300000592).xx1300000543).xx1300001973).xx1300000541).Note: This often requires two technicians working together.
xx1300000745, another from the wrist xx1300000746).xx1300000745, one at the back xx1300000594). Be mindful of the DressPack tube if installed (xx1300000739).xx1300000561).xx1300000591).xx1300001972).xx1200001135), disconnect cables (xx1200001066), remove cable glands (xx1200001067), and extract cables.ESD Caution: Put on your ESD wrist strap before this step!
xx1300000829).xx1300000669).xx1300000670).xx1300000732). Place them safely aside, perhaps over the balancing device.xx1300000732).xx1300000542).xx1200001237).xx1300000730), place the SMB unit safely in an ESD bag.xx1200001282).xx1300000733).The old harness should now be completely removed.
Installation is largely the reverse of removal, but requires careful routing, securing, and connection verification.
xx1300000668) with tape for easier routing.xx1300000733).xx1300000734). Do not fully tighten the Axis 3 clamp yet – allow for adjustment.xx1300000735).21522012-429) on the SMB/BU cover. Replace if damaged. Clean mating surfaces. Apply sealant (Sikaflex) to the O-ring.xx1300000655). Do not fully tighten screws yet.xx1300000593). Once satisfied, tighten the cover screws from inside the recess.xx1300000542).xx1300000732), ensuring correct orientation (SMB right, MP left, markings up xx1300000736).xx1300000591).xx1300001972).xx1200000052).xx1300000561).ESD Caution: Ensure wrist strap is connected.
xx1300000729). Fit the SMB bracket (xx1300000730).xx1300000728).xx1300000670).xx1300000834), reconnect the battery, place it in the recess, and refit the small battery cover (xx1300000829).xx1300000669).For both Axis 1 and Axis 2 motors:
xx1300000738).xx1200001067).xx1200001066).3HAB3772-111), clean groove, replace O-ring if needed, lubricate lightly (xx1200001070).xx1200001135). Use new standard screws, not the old self-threading ones.xx1300000595).xx1300000558).xx1300000541) and main (xx1300000543) arm house clamps.xx1300000739). Position it correctly relative to the DressPack tube, if present. Secure the cable guide/bracket.xx1300000745, xx1300000746).xx1300000592).xx1300000557).xx1200000042, xx1200000045, xx1300000658).xx1300001973).3HAB3772-111, Axes 4 & 5: 3HAB3772-110).xx1200001013, xx1300000489).xx1300000667, xx1300001113) and secure it (M4 screw at bottom, xx1300000485).xx1300000484).xx1300000488).3HAC033489-001). Replace if needed.xx1200001080).xx1300000772). Tighten to 10 Nm.This diagram illustrates the complete workflow for the ABB IRB 6700 cable harness replacement procedure:
flowchart TD
A[Preparation] --> B[Power Down & LOTO]
B --> C[Position Robot]
C --> D[Remove Covers & Access Panels]
subgraph Disconnection["Disconnection Phase"]
D --> E[Disconnect Axis 6]
E --> F[Disconnect Axis 5]
F --> G[Disconnect Axis 4]
G --> H[Disconnect Axis 3]
H --> I[Remove Upper Arm Harness]
I --> J[Disconnect Base/SMB]
J --> K[Disconnect Axis 2]
K --> L[Disconnect Axis 1]
L --> M[Remove SMB Unit]
M --> N[Extract Remaining Harness]
end
subgraph Installation["Installation Phase"]
N --> O[Route New Harness Through Lower Arm]
O --> P[Secure Frame Clamps]
P --> Q[Connect Base Connectors]
Q --> R[Refit SMB Unit]
R --> S[Connect Axes 1 & 2]
S --> T[Route Through Upper Arm]
T --> U[Connect Axes 3 & 4]
U --> V[Route To Wrist]
V --> W[Connect Axes 5 & 6]
W --> X[Refit All Covers]
end
X --> Y[Revolution Counter Update]
Y --> Z[Verification & Testing]
class Disconnection,Installation secondarybox
class Y,Z criticalbox
classDef secondarybox fill:#f0f7ff,stroke:#a0caff,stroke-width:2px,color:#133e8d
classDef criticalbox fill:#fff7ed,stroke:#fb923c,stroke-width:2px,color:#9a3412
This is MANDATORY. Since the robot was powered off and potentially moved during the repair, the system has lost track of the absolute position of each axis motor turn.
Update the revolution counters precisely according to section 5.5. Failure to do this will result in incorrect robot positioning and potential collisions.
Perform the first test run with extreme caution (see section 1.3.4). Start at very low speed in manual mode.
Verify the calibration position using the methods in section 5.6. Depending on the reason for harness replacement and robot history, a full standard calibration (or Absolute Accuracy calibration if applicable) might be advisable.
Added Complexity: Replacing the main harness on a robot with DressPack is significantly more complex due to the additional cables/hoses sharing the internal pathways.
Refer to DressPack Manual: While this guide covers basic handling, always consult the specific DressPack manual (e.g., 3HAC044270-001) for detailed procedures.
Routing Priority: Ensure the main harness and DressPack components are routed correctly relative to each other, especially through the upper arm (xx1300000739), to prevent interference and chafing.
Replacing the main cable harness on an ABB IRB 6700 is a significant undertaking that requires patience, meticulous attention to detail, and a strong understanding of the robot's mechanics and electronics. By following the procedures systematically, prioritizing safety (especially ESD precautions and power lockout), and performing thorough post-replacement checks including the crucial revolution counter update, qualified technicians can successfully restore the robot to full operational capability. Always refer to the official ABB documentation for the most current and detailed procedures specific to your robot model and configuration.
Learn how to address the common low battery alert and safely replace the Serial Measurement Board battery.
Step-by-step instructions for safely replacing any of the six axis motors on your ABB IRB 6700 robot.
Comprehensive guide to calibration procedures, including standard calibration, Absolute Accuracy, and revolution counter updates.