**Preface**
This manual provides detailed mechanical and electrical maintenance and repair instructions for the robot. It is essential to read this guide thoroughly before performing any maintenance or repair tasks on the robot.
This manual is intended for:
- In-house maintenance staff
- External maintenance personnel
Readers are expected to have:
- Basic technical skills
- Knowledge of mechanical systems
- Understanding of electrical systems
**Chapter 1: Safety and Maintenance**
**1.2 Dangerous Situations**
**1.2.1 Pliers Safety**
Always ensure that pliers are in good condition and suitable for the task at hand. Use them properly to avoid accidents.
**1.2.2 Tool and Workpiece Safety**
Follow the user safety guide to ensure safe handling of tools and workpieces. Always wear appropriate protective equipment.
**1.2.3 Pneumatic and Hydraulic System Safety**
Refer to the user safety guide for specific instructions on working with pneumatic and hydraulic systems.
**1.2.4 Operational Hazards**
Be aware of potential hazards during robot operation. Follow all safety procedures outlined in the user safety guide.
**1.2.5 Installation and Maintenance Hazards**
Ensure proper safety measures are taken when installing or maintaining the robot. Always follow the manufacturer's guidelines.
**1.2.6 Electrical Component Safety**
Handle electrical components with care. Refer to the user safety guide for detailed instructions on working with electrical systems.
**1.3.4 Brake Check**
Before starting normal operations, check the motor brake. The procedure for checking the brake on each axis is as follows:
1. Move each robot joint to its position of maximum load.
2. Set the motor mode selection switch to the "MOTORS OFF" position on the robot controller.
3. Verify if the joint is in its original position.
If the joint remains in place even after turning off the motor, the brake is functioning correctly.
**1.3.5 Danger of Losing Deceleration Function (250mm/s)**
Operating the robot at speeds above 250 mm/s without proper deceleration can be dangerous. Always ensure the robot is under control and within safe operating limits.
**Chapter II: Related Information**
The table below outlines the torque values for different types of bolts used in the robot:
**Flat and Cross Bolts**
[Image: Torque values for flat and cross bolts]
**Hexagon Socket Type Bolts**
[Image: Torque values for hexagon socket bolts]
**Hexagonal Sleeve Type Bolts with Lubrication**
[Image: Torque values for lubricated hexagonal sleeve bolts]
**2.1.5 Standard Tools – IRB6600/6650/7600**
The following are standard tools used for maintenance of these models:
[Image: List of standard tools]
**2.1.6 Leak Test**
After replacing or repairing a motor or gear unit, it is necessary to perform a leak test on the gear oil. This involves using a special inspection device with serial number **3HAC 0207-1**.
**Method and Steps**
[Image: Step-by-step guide for conducting a leak test]
**2.1.7 Lifting Equipment**
Different maintenance tasks require specific lifting equipment. While the service guide includes information about the required tools, the actual usage instructions are not provided in this manual. Always refer to the tool’s user manual for proper use.
**Chapter III: Maintenance Information System (SIS)**
**3.0.1 Using the SIS System**
The SIS (Maintenance Information System) is a software tool integrated into the robot controller. It helps track maintenance schedules, working hours, and patterns. It also alerts the operator when maintenance is due.
For more detailed information, refer to:
- The official Maintenance Information System (SIS)
- How to define SIS input parameters
- How to set SIS parameters
- How to exchange SIS parameters
- How to read the SIS output log
**Basic Methods and Steps**
[Image: Overview of SIS system usage steps]
**3.0.2 Maintenance Information System (SIS)**
The SIS is a crucial function within the robot controller. It assists in managing the maintenance schedule, tracking working hours, and reminding operators when maintenance is required. This ensures the robot operates safely and efficiently over time.
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