Maintenance Guide

Your Essential IRB 6700 Maintenance Schedule & Component Life Guide

The comprehensive resource for maintaining your ABB IRB 6700 robot in peak condition, maximizing uptime, and extending service life.

View Maintenance Schedule Component Life Data
ABB IRB 6700 Robot

Why Proactive Maintenance Matters

The ABB IRB 6700 is renowned for its durability and performance in demanding industrial environments. However, like any sophisticated machinery, it requires regular attention to maintain its peak condition. Ignoring maintenance isn't just risky; it's expensive.

Maximized Uptime

Prevents unexpected breakdowns during critical production runs.

Enhanced Safety

Ensures safety features function correctly and identifies potential hazards.

Optimal Performance

Keeps the robot operating within specified parameters for accuracy and speed.

Extended Lifespan

Proper care significantly extends the operational life of the robot and its components.

This guide breaks down the recommended maintenance schedule and expected component lifespans as outlined in the product manual (referencing document 3HAC044266-001, Revision -).

Calendar Time

Intervals measured in months (e.g., every 12 or 36 months). These apply regardless of how intensely the robot is used and often relate to components that degrade over time (like seals or battery chemistry).

Operating Hours

Intervals measured in the robot's actual operating time (e.g., every 12,000, 20,000, or 40,000 hours). These typically relate to wear-and-tear components affected by movement and load. The manual notes these hours are tracked by the Duty Time Counter (DTC).

Key Consideration

More frequent or intensive robot operation naturally leads to reaching operating hour intervals sooner. It's essential to track both calendar time and operating hours to ensure timely maintenance.

Recommended Schedule

The Maintenance Schedule:
A Practical Breakdown

The manual outlines a schedule combining regular checks, periodic inspections, and component replacement/lubrication activities. Always refer to the specific procedures detailed in the full IRB 6700 product manual for step-by-step instructions.

Maintenance Schedule Overview

flowchart TD
    classDef regular fill:#38bdf8,stroke:#0ea5e9,color:white
    classDef periodic fill:#6366f1,stroke:#4f46e5,color:white
    classDef replacement fill:#8b5cf6,stroke:#7c3aed,color:white
    
    A[Maintenance Schedule] --> B[Regular Activities]
    A --> C[Periodic Inspections]
    A --> D[Replacements & Lubrication]
    
    B --> B1[Cleaning the Robot]
    
    C --> C1[12 Month / 12,000 Hours]
    C --> C2[36 Month / 20,000 Hours]
    
    C1 --> C1A[Oil Levels Check]
    C1 --> C1B[Balancing Device Inspection]
    C1 --> C1C[Robot Harness Inspection]
    C1 --> C1D[Information Labels]
    C1 --> C1E[Mechanical Stops]
    
    C2 --> C2A[Dampers Inspection]
    C2 --> C2B[Fork Lift Device Check]
    C2 --> C2C[Signal Lamp Testing]
    
    D --> D1[20,000 Hours]
    D --> D2[40,000 Hours]
    
    D1 --> D1A[SMB Battery Replacement]
    D1 --> D1B[Balancing Device Lubrication]
    
    D2 --> D2A[Gearbox Oil Change]
    D2 --> D2B[Complete Robot Overhaul]
    
    class B,B1 regular
    class C,C1,C2,C1A,C1B,C1C,C1D,C1E,C2A,C2B,C2C periodic
    class D,D1,D2,D1A,D1B,D2A,D2B replacement
Hover over elements for details. Schedule based on ABB IRB 6700 product manual.

Regular Activities

Cleaning the Robot

Keep the robot free from excessive dirt, debris, and fluids. This prevents contamination, allows for easier visual inspection, and ensures proper heat dissipation.

Frequency depends heavily on the operating environment. Refer to page 170 in the manual.

Regular cleaning is especially important in dusty environments like foundries or machining workspaces.

Periodic Inspections

Based on time intervals (12/36 months) or operating hours (12k/20k/40k). Key inspections include:

  • Oil Levels (Axes 1-6) Pages 104-117
  • Balancing Device Page 118
  • Robot Harness Page 122
  • Mechanical Stops & Dampers Pages 128, 130, 134
  • Information Labels & Signal Lamp Pages 124, 136
Refer to the table on pages 101-102 for specific intervals.

Replacements & Lubrication

Typically at longer intervals (20k or 40k hours). Critical maintenance includes:

  • Changing Gearbox Oil (Axes 1-6) Pages 138-164
  • Replacing SMB Battery Page 165
  • Lubricating Balancing Device Page 168
  • Overhaul of Complete Robot Based on application/usage
Refer to the table on page 102 for specific intervals.

Maintenance Timeline

Ongoing

Regular Cleaning

Keep the robot free from excessive dirt, debris, and fluids. This prevents contamination, allows for easier visual inspection, and ensures proper heat dissipation.

Reference: Page 170
12 Months / 12,000 Hours

Oil Levels & Basic Inspections

  • Check oil levels in all axes (1-6)
  • Inspect balancing device for noise, damage, leaks
  • Check robot harness for wear, chafing, and damage
  • Verify information labels are present and legible
  • Inspect mechanical stops for damage or deformation
Reference: Pages 104-134
20,000 Hours

Battery & Lubrication

  • Replace SMB battery
  • Lubricate balancing device bearings
  • All previous 12,000 hour inspections

Always replace the SMB battery at the specified interval OR when a "Battery low" alert appears to avoid losing calibration.

Reference: Pages 165-168
36 Months / 40,000 Hours

Major Maintenance

  • Change gearbox oil for all axes (1-6)
  • Inspect dampers for damage, cracks, or leaks
  • Check fork lift device set (if applicable)
  • Verify signal lamp operation (if equipped)
  • Consider complete robot overhaul based on application

Use only the specified oil type for gearbox changes. Using incorrect oil can lead to inadequate lubrication, overheating, and premature failure.

Reference: Pages 138-164
Expected Lifespans

Decoding Expected Component Life

The manual provides estimated lifespans for key components under specific conditions. These are guidelines, and actual life can vary significantly based on usage, environment, and maintenance quality.

Component Lifespan Comparison

graph LR
    classDef normal fill:#0ea5e9,stroke:#0284c7,color:white
    classDef extreme fill:#f43f5e,stroke:#e11d48,color:white
    
    A[Component Lifespans]
    A --> B[Cable Harness]
    A --> C[Balancing Device]
    A --> D[Gearboxes]
    
    B --> B1[Normal Usage: 40,000 Hours]
    B --> B2[Extreme Usage: 20,000 Hours]
    
    C --> C1[Standard: 40,000 Hours]
    
    D --> D1[Expected Life: 40,000 Hours]
    
    class B1 normal
    class B2 extreme
    class C1,D1 normal

Normal Usage

Defined as typical material handling applications with standard movement patterns and load distributions.

Extreme Usage

Defined as applications involving frequent, severe movements like press tending, harsh palletizing, or significant axis 1 motion.

Data sourced from ABB IRB 6700 manual page 103.

Cable Harness

Normal Usage: 40,000 Hours
Extreme Usage: 20,000 Hours

Environmental Impact

Chemical and thermal extremes can shorten harness life regardless of usage type.

Inspection Points: Axis 2 & 3 bends, abrasion points, pinch points, connector strain.

Balancing Device

Expected Life: 40,000 Hours

Critical Safety Warning

Never attempt to disassemble the balancing device housing. It contains components under extremely high pressure. Accidental release of this stored energy can be lethal.

Inspection Points: Noise (dissonance), damage (scratches, wear), leaks, and contamination.

Gearboxes

Expected Life: 40,000 Hours

Accurate Prediction

ABB recommends using the Service Information System (SIS) within the IRC5 controller for a more accurate prediction based on actual load and usage patterns.

Oil Management: Use only specified lubricants designed for the load, temperature, and sealing materials.

Important Considerations

These are expected lifespans, not guarantees

Regular inspections are crucial for early detection of wear. The actual lifespan depends on many factors including usage patterns and environmental conditions.

"Extreme usage" significantly halves cable harness lifespan

Assess your application realistically. Press tending, harsh palletizing, or applications with significant axis 1 motion qualify as extreme usage.

Environmental factors play a major role

High temperatures, corrosive chemicals, or excessive particulate matter will accelerate wear. Adjust maintenance frequency accordingly in harsh environments.

Keep detailed maintenance records

Log all maintenance activities, inspection findings, and component replacements. This history is invaluable for troubleshooting and optimizing future maintenance.

Smart Planning

Integrating Schedule and Lifespan for Effective Maintenance

Track Both Calendar & Operating Hours

Monitor calendar time AND operating hours (DTC). Perform maintenance based on whichever interval comes first.

Factor in Usage Patterns

If your application qualifies as "Extreme Usage," plan for earlier cable harness inspection and replacement.

Factor in Usage Patterns

If your application qualifies as "Extreme Usage," plan for earlier cable harness inspection and replacement.

Budget for Replacements

Use the expected component life data to anticipate and budget for major component replacements like harnesses, balancing devices, or potential gearbox overhauls.

Leverage SIS

Utilize the controller's Service Information System for more accurate gearbox life predictions based on actual operational data.

Problem Resolution

Troubleshooting Common Issues

Understanding potential problems arising from deferred or improper maintenance can help in diagnosing issues faster.

Gearbox Issues (Oil Related)

Symptoms

  • Unusual noises (whining, grinding)
  • Overheating of specific axes
  • Jerky movements, increased motor current
  • Drive faults (overload) or visible leaks

Potential Maintenance Lapses

  • Low oil level or incorrect oil type used
  • Exceeding oil change intervals
  • Damaged seals or blocked breather vents

Recommended Action

Immediately inspect oil levels (in the correct robot position). Check maintenance logs for oil type and last change date. Inspect for leaks.

If noise/overheating persists, consult ABB service as internal damage may have occurred.

SMB Battery Failure

Symptoms

  • "Revolution Counter Not Updated" fault
  • "Synchronization Error" messages
  • Specific axis synchronization faults (e.g., 509 errors)
  • "Battery charge low" (38213) warning

Potential Maintenance Lapses

  • Exceeding the battery replacement interval
  • Ignoring the low battery warning
  • Extended controller power-off periods with weak battery

Recommended Action

Replace the SMB battery immediately. Crucially, you must then perform the "Update Revolution Counter" procedure (Page 542) by carefully jogging each axis to its calibration mark/position.

Failure to update revolution counters correctly after battery loss leads to incorrect positioning.

Cable Harness Problems

Symptoms

  • Safety circuit faults (e.g., emergency stop chain errors)
  • Communication errors (SMB communication faults)
  • Resolver signal errors leading to position inaccuracies
  • Erratic behavior of end-of-arm tooling

Potential Maintenance Lapses

  • Exceeding harness lifespan (especially under "Extreme Usage")
  • Inadequate inspection allowing chafing/cracking to develop
  • Loose or damaged securing brackets causing movement

Recommended Action

Thoroughly inspect the harness visually and tactilely (power off!), paying close attention to bend radii and potential abrasion points. Check connector security.

If damage is confirmed, the harness must be replaced (Pages 191, 211).

Balancing Device Malfunction

Symptoms

  • Difficulty moving axis 2 or 3 smoothly
  • Increased motor temperature/current on axes 2/3
  • Inability to hold position against gravity
  • Unusual noises (hissing, clunking)

Potential Maintenance Lapses

  • Ignoring scheduled inspections
  • Operating with known leaks or damage
  • Exceeding the expected lifespan
  • Lubrication failure on the front bearing

Recommended Action

Investigate noises and leaks immediately. Check for smooth movement (safely). If performance is degraded or failure is suspected, the unit likely needs replacement (Page 354).

Never attempt to disassemble the balancing device. It contains components under high pressure.

Environmental Impact: Tailoring Your Maintenance Approach

The standard schedule assumes a relatively clean, controlled environment. Adjustments are needed for harsher conditions.

Dusty/Dirty Environments

Foundries, grinding, and machining operations create particularly challenging conditions.

  • Increase cleaning frequency to prevent buildup on seals, bearings, and heat sinks.
  • Pay extra attention to seals around motors, gearboxes, and bearings. Dust and grit are abrasive and can accelerate wear.
  • Consider the IRB 6700 Foundry Plus option (IP67) for better sealing and corrosion resistance.

Extreme Temperatures

Temperature extremes can significantly impact component performance and lifespan.

  • High Heat: Can accelerate oil degradation. Consider shorter oil change intervals if operating near maximum temperature limits.
  • Cold: Increases oil viscosity. Implement warm-up routines (jogging axes slowly) before full production runs.
  • Ensure cooling fans (if applicable) are clean and operational in hot environments.

Chemical Exposure

Corrosive atmospheres can damage robot components, particularly seals and external surfaces.

  • Regularly check paint, labels, harness jackets, and seals for signs of degradation, swelling, or cracking.
  • Ensure any cleaning agents used are compatible with the robot's materials.
  • Consider protective covers or special paint options for severe environments.

Washdown Environments

For Foundry Plus models in washdown applications, special considerations apply.

  • Strictly follow ABB's cleaning guidelines (Page 170). Avoid spraying high-pressure water directly at seals, connectors, or joints.
  • Check for water ingress, especially around seals, after cleaning cycles.
  • Ensure protective covers are always in place during washing procedures.

Conclusion

Maintaining your ABB IRB 6700 is an investment in its longevity, reliability, and safety. By understanding the nuances of the maintenance schedule – differentiating between time-based and usage-based intervals – and considering the expected component lifespans based on your specific application and environment, you can create a proactive maintenance strategy. This approach minimizes costly downtime, ensures optimal performance, and maximizes the value of your robotic automation system.

Always consult the full ABB IRB 6700 Product Manual for detailed procedures and safety warnings before performing any maintenance.

Back to Schedule

Related Resources

Explore these additional guides to maximize your ABB IRB 6700 operation and maintenance.

User Guides

Step-by-Step Visual Guide: Checking IRB 6700 Gearbox Oil Levels (Axes 1-6)

Detailed instructions and visual guidance for properly checking oil levels in all axes of your IRB 6700.

Troubleshooting

Troubleshooting Low Battery Alert (38213): Replacing the IRB 6700 SMB Battery

A comprehensive guide to addressing the 38213 error code and properly replacing your SMB battery.

Troubleshooting

IRB 6700 Balancing Device Health Check & Repair Guide

Learn how to properly inspect, maintain, and troubleshoot this critical component of your IRB 6700.