S4CPlus-Repair Manual Part 1 IRB6600

Repair Manual, part 1
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Repair Manual, part 1, IRB 6600/6650, M2000A

3HAC 16247-1
Revision A
The information in this manual is subject to change without notice and

should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABBs written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
Copyright 2003 ABB All rights reserved.

ABB Automation Technology Products AB
Robotics
SE-721 68 Vsters
Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Section 1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.3 Emergency release of the manipulators arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.5 Risk of disabling function "Reduced speed 250 mm/s". . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.3.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chapter 2: Reference information
13
2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Section 2.1: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.1.1 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.1.2 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.1.3 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.1.4 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.1.5 Special tools, IRB 6600/6650/7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.1.6 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.1.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Chapter 3: Repair activities, manipulator
23
3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Section 3.1: Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.1.1 Removal of cable harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.1.2 Refitting of cable harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.1.3 Removal of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.1.4 Refitting of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Section 3.2: Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.2.1 Removal of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.2.2 Refitting of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3.2.3 Removal of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.2.4 Refitting of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
3.2.5 Removal of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.2.6 Refitting of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Section 3.3: Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3.3.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

3.3.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
3HAC 16247-1
Table of Contents
Section 3.4: Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.4.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.4.2 Refitting of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.4.4 Refitting of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.5 Removal of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.4.6 Refitting of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.4.7 Unloading the balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.4.8 Restoring the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Section 3.5: Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5.1 Removal of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.5.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.5.3 Removal of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.5.4 Refitting of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.5.5 Removal of motor, axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.5.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.5.8 Refitting of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.5.10 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.5.11 Removal of motor, axis 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.5.12 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Section 3.6: Gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.6.1 Removal of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

3.6.2 Refitting of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.6.3 Removal of gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.6.4 Refitting of gearbox axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Chapter 4: Repair activities, controller cabinet
155
4.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Section 4.1: Complete controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.1.1 Replacement of battery unit, controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

4.1.2 Replacement of I/O and gateway units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.1.3 Replacement of bleeder resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1.4 Putting the computer unit in the service position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.1.5 Replacement of mass storage memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.1.6 Replacement of internal cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.1.7 Replacement of drive units and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.1.8 Replacement of system fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.1.9 Replacement of power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.1.10 Replacement of Peltier Cooler power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Chapter 5: Appendix 1: Part Lists
181
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Section 5.1: Part List, Manipulator IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.1.1 Mechanical stop ax 1, 3HAC 12812-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

5.1.2 Base incl frame ax 1, 3HAC 12685-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.1.3 Axis 3-4, (robot v. 175/2.55), 3HAC 10746-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.1.4 Axis 3-4, (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-1 . . . . . . . . . . . . . 184
5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4 . . . . . . 185
ii
3HAC 16247-1
Table of Contents
5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

5.1.8 Wrist (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-3 . . . . . . . . . . . . . . . . . .189
5.1.9 Wrist Foundry (robot v. 175/2.55) 3HAC 8114-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5 . . . . . . . . . .190
5.1.11 Material set manipulator, 3HAC 13263-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
5.1.13 Mtrl set balancing device, 3HAC 13265-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
5.1.14 Arm extension set, 250 mm, 3HAC 12311-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
5.1.15 Arm extension set, 450 mm, 3HAC 12311-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Chapter 6: Appendix 2: Foldouts
201
6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

6.0.2 Base incl. Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
6.0.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
6.0.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
6.0.5 Upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
6.0.6 Wrist complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
3HAC 16247-1
iii
Table of Contents
iv
3HAC 16247-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for repairing the complete robot
system, mechanically as well as electrically.
Usage
This manual should be used during repair work.
Who Should Read

This Manual?
This manual is intended for:
Prerequisites
Organization of
Chapters
repair personnel in the user's organization.
repair personnel in other organizations.
The reader should...
be a trained repair craftsman
have the required knowledge of mechanical repair work OR
have the required knowledge of electrical repair work.
The information product is organized in the following chapters:
Chapter
Contents
Safety
Reference information
Manipulator
Controller
Appendix
References
Reference
Document Id
Circuit Diagrams, Manipulator
3HAC 13347-1
Circuit Diagrams, Controller
3HAC 14189-2
Revisions
Revision
Description
First edition
3HAC 16247-1
Various corrections in text and in figures due to reconstructions, new spare part numbers, new tools, etc.
Manual completed with references to pagenumbers and numbering of sections (manipulator sections).
Manual completed with version IRB 6650.
0.0.1 Overview
3HAC 16247-1
0.0.2 Product Documentation
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
The Installation and Commissioning Manual contains the following information:
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Installation of controller software
System directory structure
Calibration
If there is any, model specific information
The Repair Manual contains the following information:
Safety, Service
Remove/Refitting instructions for all manipulator details considered spare parts
Remove/Refitting instructions for all controller cabinet details considered spare parts
The Maintenance Manual contains the following information:
Safety, Service
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during operation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16247-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
In addition, spare part information is supplied for the complete option.
3HAC 16247-1
1 Safety, service
1.0.1 Introduction
Chapter 1: Safety, service

1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
The chapter "Safety, service" is divided into the following sections:

1. General information contains lists of:
Safety, service -general
Limitation of liability
Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16247-1
1 Safety, service
1.1.1 Safety, service - General
Section 1.1: General information

1.1.1 Safety, service - General
Validity and
responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
1.1.2 Limitation of Liability
General
Any information given in this information product regarding safety, must not be construed as
a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if
all safety instructions have been complied with.
1.1.3 Related information
General
The list below specifies documents which contain useful information:
Documents
Type of information
Detailed in document
Installation of safety devices
Installation and Commissioning

Manual
Changing robot modes
Users Guide
Start-up
Restricting the working space
Installation and Commissioning

Manual
On-site installation Manipulator
Section
3HAC 16247-1
1 Safety, service
1.2.1 Safety risks related to gripper
Section 1.2: Safety risks

1.2.1 Safety risks related to gripper
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
1.2.2 Safety risks related to tools/workpieces
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
1.2.3 Safety risks related to pneumatic/hydraulic systems
General
Residual energy
Safe design
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
1.2.4 Safety risks during operational disturbances
General
Qualified personnel
Extraordinary
risks
3HAC 16247-1
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Care must be taken at all times.
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.
1 Safety, service
1.2.5 Safety risks during installation and service
1.2.5 Safety risks during installation and service
General risks during installation

and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available
for the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
tie rod.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
When dismantling/assembling mechanical units, watch out for falling objects.
Be aware of stored heat energy in the controller.
Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
1.2.6 Risks associated with live electric parts
Voltage related
risks, general
Voltage related
risks, controller
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
A danger of high voltage is associated with the following parts:
Be aware of stored electrical energy (DC link) in the controller.
3HAC 16247-1
1 Safety, service
1.2.6 Risks associated with live electric parts
Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.
The mains supply/mains switch
The power unit
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The drive unit (700 VDC)
The service outlets (115/230 VAC)
The power supply unit for tools, or special power supply units for the machining process
The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator
A danger of high voltage is associated with the manipulator in:
Voltage related
risks, tools, material handling
devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be damaged.
3HAC 16247-1
The power supply for the motors (up to 800 VDC)
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
1 Safety, service
1.3.1 Safety fence dimensions
Section 1.3: Safety actions

1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator
or controller)!
1.3.3 Emergency release of the manipulators arm
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, which may further increase any injury!
1.3.4 Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
10
3HAC 16247-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit
or a PC. This will affect the safety function Reduced speed 250 mm/s.
1.3.6 Safe use of the Teach Pendant Unit

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device
is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
During programming and testing, the enabling device must be released as soon as there is no
need for the robot to move.
The programmer must always bring the Teach Pendant Unit with him/her, when entering the
robots working space. This is to prevent anyone else taking control over the robot without the
programmer knowing.
1.3.7 Work inside the manipulators working range

If work must be carried out within the robots work envelope, the following points must be
observed:
- The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
- The robots speed is limited to max. 250 mm/s when the operating mode selector is in position
< 250 mm/s. This should be the normal position when entering the working space. The position
100% full speedmay only be used by trained personnel who are aware of the risks that this
entails.
- Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not
to get entangled with hair or clothing. Also be aware of any danger that may be caused by
rotating tools or other devices mounted on the manipulator or inside the cell.
- Test the motor brake on each axis, according to section Brake testing on page 10.
3HAC 16247-1
11
1 Safety, service
1.3.7 Work inside the manipulators working range
12
3HAC 16247-1
2 Reference information
2.0.1 Introduction
Chapter 2: Reference information

2.0.1 Introduction
General
3HAC 16247-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
13
2.1.1 Applicable Safety Standards
Section 2.1: Reference information

2.1.1 Applicable Safety Standards
Standards, general
Standards, robot
cell
14
The robot is designed in accordance with the requirements of:
EN 775 - Robot safety.
EN 292-1 - Basic terminology.
EN 292-2 - Technical principles.
EN 418 - Emergency stop.
EN 563 - Temperatures of surfaces.
EN 954-1 - Safety related parts of control systems.
EN 60204-1 - Electrical equipment of machines.
EN 1050 - Principles for risk assessment.
ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.
DIN 19258 - Interbus-S, International Standard
The following standards are applicable when the robot is part of a robot cell:
EN 953 - Fixed and moveable guards
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 349 - Minimum gaps to avoid crushing of parts of the human body.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
EN 1088 - Interlocking devices
EN 999 - The positioning of protective equipment in respect of approach speeds of the

human body.
ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing systems.
3HAC 16247-1
2.1.2 Screw joints
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on the manipulator as well
as the controller.
The instructions and torque values are valid for screw joints comprising metallic materials
and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type
screw joints.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated
screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated
in other ways
Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
3HAC 16247-1
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
15
2.1.2 Screw joints
Tightening torque
Screws with slotted or cross

recess head
Below are tables specifying the torque values for different screw joint types:
Dimension
Tightening torque (Nm)

Class 4.8 "dry"
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening torque
(Nm)
Class 8.8 "dry"
Tightening torque
(Nm)
Class 10.9 "dry"
Tightening torque
(Nm)
Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension

Class 10.9

Class 12.9
M8
28
34
M10
55
66
M12
96
115
M16
235
280
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
16
3HAC 16247-1
2.1.3 Weight specifications
2.1.3 Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
ABB recommends the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
Below is an example of how a weight specification is presented:

The motor weighs 65 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16247-1
17
2.1.4 Standard toolkit
2.1.4 Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1
18
Qty
Art. no.
Tool
Rem.
Ring-open-end spanner 8-19mm
Socket head cap 5-17mm
Torx socket no:20-60
Box spanner set
Torque wrench 10-100Nm
Torque wrench 75-400Nm
Ratchet head for torque wrench 1/2
Hexagon-headed screw M10x100
Socket head cap no:14, socket 40mm bit L 100mm
Socket head cap no:14, socket 40mm bit L 20mm To be shorted to

12mm
Socket head cap no:6, socket 40mm bit L 145mm
3HAC 16247-1
2.1.5 Special tools, IRB 6600/6650/7600
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 18, and of special tools, listed directly in the instructions and
also gathered in the table below.
Special tools, IRB

6600/6650/7600
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16247-1
Description
IRB 66X0/ IRB 7600/

Art. no.
Qty
Qty
Angel bracket
68080011-LP
Bolts (M16 x 60) for Mech stop axis 3
3HAB 3409-86
Bolts (M16 x 80) for Mech stop axis 3
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
Calibration tool ax1
3HAC 13908-4
CalPen (Calibration Pendulum)
3HAC 15716-1
Extension 300mm for bits 1/2"
3HAC 12342-1
Fixture lower arm
3HAC 13659-1
Fixture lower arm
3HAC 13660-1
Gearbox crank
3HAC 16488-1
Guide pins M12 x 150
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Guide pins sealing
3HAC 14445-1
Guide pins sealing
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
Guide pins sealing ax 2, 3, 100mm
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
19
Description
IRB 66X0/ IRB 7600/

Art. no.
Qty
Qty
Hydraulic pump 80Mpa
3HAC 13086-1
Hydraulic pump 80Mpa (Glycerin)
3HAC 13086-2
Levelmeter 2000 kit
6369901-348
Lifting device, base
3HAC 15560-1
Lifting device, manipulator
3HAC 15607-1
Lifting device, upper arm
3HAC 15994-1
Lifting device, upper arm
3HAC 15536-1
Lifting eye VLBG M12
3HAC 16131-1
Lifting eye M12
3HAC 14457-3
Lifting eye M16
3HAC 14457-4
Lifting tool (chain)
3HAC 15556-1
Lifting tool, gearbox ax 2
3HAC 13698-1
Lifting tool, gearbox ax 2
3HAC 12731-1
Lifting tool, lower arm
3HAC 14691-1
Lifting tool, motor ax 1, 4, 5
3HAC 14459-1
Lifting tool, motor ax 2, 3, 4
3HAC 15534-1
Lifting tool, wrist unit
3HAC 13605-1
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
Press tool, ax 2 bearing
3HAC 13527-1
Press tool, ax 2 bearing
3HAC 13453-1
Press tool, ax 2 shaft
3HAC 13452-1
Press tool, balancing device shaft
3HAC 17129-1
Press tool, balancing device
3HAC 15767-1
Puller tool, balancing device shaft
3HAC 12475-1
Removal tool, wheel unit
3HAC 15814-1
Removal tool, motor M10x
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
Tool set balancing device
3HAC 15943-2
Tool set balancing device
3HAC 15943-1
Turn disk fixture
3HAC 68080011-GU
Washers for Mech stop axis 3
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
20
3HAC 16247-1
2.1.6 Performing a leak-down test
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Spare part no. Art. no.
Leakdown tester
Note
3HAC 0207-1
Leak detection spray
Procedure
Step
3HAC 16247-1
Action
Note/Illustration
1.
Finish the refitting procedure of the motor or

gear in question.
2.
Remove the topmost oil plug on the gear in Art. no. specified above!
question, and replace it with the leakdown
tester .
Adapters may be required, which are
included in the leakdown tester kit.
3.
Apply compressed air, and raise the pres- Recommended value: 0.2 - 0.25 bar
sure with the knob until the correct value is (20 - 25 kPa)
shown on the manometer.
4.
Disconnect the compressed air supply.
5.
Wait for approx. 8-10 minutes. No pressure If the compressed air is significantly
loss must be detected.
colder or warmer than the gearbox to
be tested, a slight pressure increase or
decrease respectively may occur. This
is quite normal.
6.
Was any pressure drop evident?

Localize the leak as detailed below.
Remove the leakdown tester, and refit the
oil plug. The test is complete.
7.
Spray suspected leak areas with leak

detection spray .
Bubbles indicate a leak.
8.
When the leak has been localized: take the

necessary measures to correct the leak.
Art. no. specified above!
21
2.1.7 Lifting equipment and lifting instructions
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
but in the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
22
3HAC 16247-1
3 Repair activities, manipulator

3.0.1 Introduction
Chapter 3: Repair activities, manipulator

3.0.1 Introduction
Definitions
This chapter details all repair activities recommended for the manipulator, including for any
external units of the manipulator.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refitting of a certain component on the manipulator. Each unit contains all information required
to perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into:
3HAC 16247-1
Removal/refitting instructions for all the spare parts on the manipulator
Remaining instructions for all the spare parts in e.g. the manipulators external units, if
any.
23

3.1.1 Removal of cable harness
Section 3.1: Complete manipulator

Location complete cable harness
The cable harness is located throughout the manipulator as shown in the figure below.
E
H
J
O
C
K
A
xx0200000210
24
Connector at manipulator base, R1.MP and R1.SMB
Connectors at motor 1; R2.FB1 and R2.MP1
Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,

R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. Connectors at brake
release unit X8, X9 and X10.
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
Connectors at cable harness separation; R2.M5/6
Connectors at cable harness division, inside of upper arm tube; R3.FB5 and R3.MP5.
Connectors at motor 5; R4.FB5 and R4.MP5.
Rear cover plate
Connector R1.MP
Connector R1.SMB
Connection of earth cable
Velcro strap that secures the cable harness to the arm house
3HAC 16247-1

Required equipment
Equipment, etc.
Circuit Diagram
3HAC 13347-1 Included in Repair Manual, part

2.
Standard toolkit
3HAC 15571-1 The contents are defined in

section Standard toolkit on
page 18!
Other tools and procedures may be required.

See references to
these procedures in the
step-by-step instructions below.
Removal, cable
harness, axes 1-4
Note
These procedures include references to the tools required.
The procedure below details how to remove the cable harness, axes 1-4.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Step
1.
3HAC 16247-1
Action
Note/Illustration
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
run the manipulator to the specified position: improve access.
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
Axis 6: no significance
2.
Remove the rear cover plate on the manipulator by unscrewing its attachment screws.
3.
Disconnect the earth cable.
4.
Disconnect connectors R1.MP and R1.SMB.
5.
Pull the cable and connectors up through the

center of the frame.
6.
Disconnect all connectors at motor 1 and

motor 2.
Shown in the figure Location complete cable harness on page 24!
Specified in the figure Location complete cable harness on page 24!
25

Step
Action
Note/Illustration
7.
Open the SMB cover carefully.

The cable between the battery and the SMBunit may stay connected, in order to avoid
recalibration of the robot. Be careful not to let
the weight of the cover strain the cable!
In order to remove the cover completely, the
connector R1.G must be disconnected! This
causes a necessary recalibration of the
robot!
8.
Disconnect connectors R2.SMB, R1.SMB13, R1.SMB4-6. Disconnect X8, X9 and X10.
R 2.S MB
R 1.S MB1-3
R 1.S MB4-6
R 1.G
X8, X9, X10
R 2.G
xx0200000118.wmf
9.
Unscrew the four screws securing the cable

gland.
This releases the cable harness from

the frame.
10. Remove the adapter plate from the harness

by removing its two attachment screws and
the velcro strap.
Note! Different manipulator versions

are fitted with different plate versions.
Make sure the correct one is used to
avoid cable failure.
11. Remove the bracket securing the cables

inside the lower arm by unscrewing the nuts
from the stud bolts securing the clamp to the
lower arm.
FB3 FB4
FB5 FB6
MP3
MP4
MP5
MP6
xx0100000142.wmf
12. Remove the upper bracket securing the

cables to the arm house by unscrewing its
two attachment screws.
MP6
MP3
FB6
FB5
MP5
MP
FB3
FB4
xx0100000143.wmf
13. Disconnect connector R2.M5/6 at the rear

cable division point.
Shown in the figure Location complete cable harness on page 24!
14. Disconnect all connectors at motor 3 and

motor 4.
Specified in the figure Location complete cable harness on page 24!
15. Gently pull the cable harness out.
26
3HAC 16247-1

Location of cable
harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
B
A
F
xx0200000213
3HAC 16247-1
Cable bracket, wrist unit
Cable bracket, upper arm tube
Connectors at motor axis 5; R4.FB5 and R4.MP5
Connectors in upper arm tube; R3.FB5 and R3.MP5
Cable attachment, rear
Connectors at cable harness division point; R2.M5/6
Connectors at motor, axis 6; R3.FB6 and R3.MP6
27

Removal, cable
harness, axes 5-6
The procedure below details how to remove the upper cable harness. The separate cable that
goes from the connection point inside of the upper arm tube to the motor, axis 5, is not
included in this procedure. The removal of that cable is described further down in section
Removal, cable harness, axis 5 on page 29.
motors or gears!
Axis 5 must be oriented in the correct position (+90 ) to allow opening the motor 6 cover!
Step
1.
Action
Note/Illustration
Remove the cover, wrist unit and the cover,

upper arm tube.
A
B
xx0200000214
A: cover, wrist unit
B: cover, upper arm tube
2.
Remove the cover of motor, axis 6 and dis- Specified in the figure Location of cable
connect all connectors beneath.
harness ax 5-6 on page 27!
3.
Loosen the cable bracket on top of the

Shown in the figure Location of cable
wrist unit by unscrewing the three attach- harness ax 5-6 on page 27!
ment screws.
Two of the attachment screws are located C
visible at the rear attachment and the third
B
is located at the bottom of the cable
bracket, in the center.
xx0200000254
28
B: Attachment screws, rear of

cable bracket, 2 pcs
C: Attachment screw, bottom of

cable bracket, 1 pc
4.
Pick out the cabling from motor, axis 6.
5.
Loosen the cable bracket in the upper arm Shown in the figure Location of cable
tube by unscrewing the two screws on top harness ax 5-6 on page 27!
of the tube.
6.
Disconnect the two connectors (R3.FB5

and R3.MP5) in the tube.
7.
Remove eventual cable straps from the

harness.

3HAC 16247-1

Step
Action
Note/Illustration
8.
Remove the cable attachment, rear.

9.
Disconnect connectors R2.M5/6 at the

cable harness division point.

10. Gently pull the cable harness out.
Removal, cable
harness, axis 5
The procedure below details how to remove the cable, axis 5.
Step
3HAC 16247-1
Action
Note/Illustration
1.
Remove the complete wrist unit.
Detailed in Removal of complete

wrist unit on page 47.
2.
Remove the cover of motor, axis 5.
3.
Disconnect all connectors at motor, axis 5.
4.
Remove the cable gland cover at the cable exit

by unscrewing its two attachment screws.
5.
Remove the cable, axis 5.
29

3.1.2 Refitting of cable harness
Location of cable
harness
The cable harness is located throughout the manipulator as shown in the figure below.
E
H
J
O
C
K
A
xx0200000210
30
Connector at manipulator base, R1.MP and R1.SMB
Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,

R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. Brake release unit connectors X8, X9 and X10
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
Connectors at cable harness separation; R2.M5/6
Connectors at cable harness division, inside of upper arm tube; R3.FB5 and R3.MP5.
Connectors at motor 5; R4.FB5 and R4.MP5.
Rear cover plate
Connector R1.MP
Connector R1.SMB
Connection of earth cable
Velcro strap that secures the cable harness to the arm house
3HAC 16247-1

Required equipment
Equipment, etc.
Note
Cable harness, axes 1-4
3HAC 14940-1
IRB 6600
3HAC 16331-1
IRB 6650
3HAC 14140-1
Cable harness, axis 5
3HAC 14139-1
Circuit Diagram
3HAC 13347-1
Included in the Repair

Manual, part 2.
Standard toolkit
3HAC 15571-1
The contents are defined

in section Standard toolkit
on page 18!
Other tools and procedures

may be required. See references to these procedures
in the step-by-step instructions below.
Refitting, cable
harness, axes 1-4
These procedures include

references to the tools
required.
The procedure below details how to refit the cable harness, axes 1-4.
motors or gears!
Step
1.
3HAC 16247-1
Action
Note/Illustration
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
run the manipulator to the specified position: improve access.
Axis 1: 0 degrees
Axis 2: 0 degrees
Axis 3: 0 degrees
Axis 4: 0 degrees
Axis 5: +90 degrees
2.
Pull the cable and connectors down through Make sure the cables are not twisted
the center of the frame.
with each other or with eventual customer harnesses!
Make a note of the correct positions
of the connectors!
3.
Reconnect connectors R1.MP and R1.SMB

at the rear cover plate.
Make a note of the correct positions

of the connectors!
4.
Reconnect the earth cable.

harness on page 30!
31

Step
Action
Note/Illustration
5.
Refit the rear cover plate on the manipulator

with its attachment screws.
6.
Reconnect all connectors at motor 1 and

motor 2.
7.
Secure the gland plate with four attachment

screws from inside the SMB recess.
Specified in the figure Location of

cable harness on page 30!
MP2 MP1
MP4
SMB
MP3
MP5 MP6
xx0100000141
8.
Reconnect connectors R2.SMB, R1.SMB13, R1.SMB4-6. Reconnect X8, X9 and X10.

Reconnect R1.G if it has been disconnected.
X8, X9, X10
R2.S MB
R1.S MB1-3
R1.S MB4-6
R1.G
R 2.G
xx0200000118
9.
Secure the SMB cover with its attachment

screws.
10.
Secure the correct adapter plate to the harness with its two attachment screws.
11.
Pull the cable harness through the lower arm.
12.
Refit the bracket securing the cables inside

the lower arm.
Note! Different manipulator versions are fitted with different plate

versions. Make sure the correct one
is used to avoid cable failure.
FB3 FB4
FB5 FB6
MP3
MP4
MP5
MP6
xx0100000142
13.
Refit the bracket securing the cables to the

arm house.
Make sure not to twist the harness!
MP6
MP3
FB6
FB5
MP5
MP
FB3
FB4
xx0100000143
14.
32
Reconnect all connectors at motor 3 and

motor 4.
Specified in the figure Location of

cable harness on page 30!
3HAC 16247-1

Step
Location of cable
harness axes 5-6
Action
Note/Illustration
15. Reconnect connector R2.M5/6 gently at the

rear cable division point.
Be careful not to bend the attachment plate
when fastening the screws!

harness on page 30!
M6, 2 pcs.
16. Secure the cable harness to the arm house

with a velcro strap.

harness on page 30!
The cable harness of the axes 5-6 is located as shown in the figure below.
B
A
F
xx0100000145
Refitting, cable
harness, axes 5-6
3HAC 16247-1
Cable bracket, wrist unit
Cable bracket, upper arm tube
Connectors at motor axis 5; R4.FB5 and R4.MP5
Connectors in upper arm tube; R3.FB5 and R3.MP5
Cable attachment, rear
Connectors at cable harness division point; R2.M5/6
Connectors at motor, axis 6; R3.FB6 and R3.MP6
The procedure below details how to refit the upper arm cable harness. The separate cable that
goes from the connection point inside of the upper arm tube to the motor, axis 5, is not
included in this procedure. The refitting of that cable is described further down in section
Refitting, cable harness axis 5 on page 35.
A
33

motors or gears!
Step
1.
Action
Note/Illustration
The manipulator is required to be positioned

in the following position:
Axis 4: 0 degrees
Axis 5: +90 degrees
2.
Gently insert the cable harness from the rear

into the upper arm.
3.
Connect the two connectors inside the upper Shown in the figure Location of cable
arm tube, R3.FB5 and R3.MP5 and secure harness axes 5-6 on page 33!
the cable bracket with the two attachment
screws to the tube.
4.
Place the cabling to motor, axis 6, correctly

on the upper arm and gently pull the connectors through the hole on top of wrist unit to
motor, axis 6.
A
xx0200000185
5.
In case of excess cable

length: put a loop of cable in
this area with cable straps
(A). The cables are longer in
order to fit different upper
arm lengths.
Fasten the cable bracket, wrist unit with

Also shown in the figure Location of
three attachment screws, two of them visible cable harness axes 5-6 on page 33!
at the rear attachment point and the third
located on the bottom of the cable bracket, in C
the center.
B
xx0200000254
6.
34

cable bracket.
C: Attachment screw, bottom

of cable bracket.
Reconnect the connectors to motor, axis 6

and refit the motor cover.
3HAC 16247-1

Step
7.
Action
Note/Illustration
Refit the cover, upper arm and the cover,

wrist unit.
Make sure the cabling is placed correctly
when refitting the covers, and does not get
jammed.
A
B
xx0200000214
Refitting, cable
harness axis 5
A: cover, wrist unit
B: cover, upper arm tube
8.
Refit eventually removed cable straps to the

harness.
9.
Refit the cable attachment, rear.
10.
Reconnect connector R2.M5/6 gently at the Shown in the figure Location of cable
rear cable division point with two screws, M6. harness axes 5-6 on page 33!
Be careful not to bend the attachment plate
when fastening the screws!

harness axes 5-6 on page 33!
The procedure below details how to refit the cable, axis 5.
Step
Action
Note/Illustration
1.
Reconnect all connectors at motor, axis 5.
2.
Refit the cable gland cover at the cable exit with

its two attachment screws.
3.
Refit the cover of motor, axis 5.
4.
Refit the complete wrist unit.
Detailed in section Refitting of

complete wrist unit on page 50.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1
35

3.1.3 Removal of complete arm system
Location of arm
system
The complete arm system is defined as the complete manipulator except for the base and
gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
F
G
H
E
xx0200000224
Upper arm
Lower arm
Frame
Gearbox, axis 1
Base attachment screws
Balancing device
Block for calibration
Motor axis 1
Required equipment
Equipment, etc.
36
Note
3HAC 15607-1 Instruction 3HAC 15971-2

enclosed!
3HAC 16247-1

Equipment, etc.
Standard toolkit
Note
3HAC 15571-1 The contents are defined

in section Standard toolkit
on page 18!

Removal, arm
system

required.
The procedure below details how to lift and remove the complete arm system.
motors or gears!
The complete arm system weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Note/Illustration
Make sure the manipulator is posiManually releasing the brakes is detailed in

tioned as shown in figure to the right. If "Manually releasing the brakes" in the
it is not, position it that way.
Installation Manual.
50
m
xx0100000103
3HAC 16247-1
2.
Drain the oil from gearbox axis 1.
Detailed in "Oil change, gearbox axis 1" in

the Maintenance Manual.
3.
Remove the motor, axis 1.
Detailed in section Removal of motor, axis

1 on page 93.
4.
Run the overhead crane to a position

above the manipulator.
37

Step
38
Action
Note/Illustration
5.
Fit the lifting device and adjust it as

detailed in enclosed instruction.
Art. no. specified in Required equipment on

page 36!
Make sure the lift is done completely level!
How to adjust the lift is described in the
enclosed instruction to the lifting device!
Follow the instructions before continuing the lift!
6.
Remove the block for calibration from Shown in the figure Location of arm system
the bottom of the frame.
on page 36!
7.
Remove the arm system from the base Shown in the figure Location of arm system
by unscrewing its 24 attachment
on page 36!
screws.
8.
Lift the arm system and secure it in a

safe area.
Make sure all hooks and attachments

maintain in correct position while lifting the
manipulator!
Always move the manipulator at very low
speeds, making sure it does not tip.
3HAC 16247-1

3.1.4 Refitting of complete arm system
Location of arm
system
The complete arm system is defined as the complete manipulator except for the base and
gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
F
G
H
E
xx0200000224
Upper arm
Lower arm
Frame
Gearbox, axis 1
Base attachment screws and washers (24 pcs)
Balancing device
Motor axis 1
Required equipment
Equipment, etc.
3HAC 16247-1
Note
3HAC 15607-1 Instruction 3HAC 15971-2

enclosed!
39

Equipment, etc.
Note
Guide pins, M12 x 130
Used to guide the complete

arm system when refitting.
Always use the guide pins
in pairs!
Standard toolkit

page 18!

Refitting, arm
system

required.
The procedure below details how to lift and refit the complete arm system.
motors or gears!
The complete arm system weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
Action
Note/Illustration
1.
Fit the lifting device as detailed in enclosed Art. no. specified in Required equipinstruction.
ment on page 36!
2.
Lift the complete arm system and move it Make sure all the hooks and attachat very low speed, making sure it does not ments maintain in correct position
tip!
while lifting the manipulator!
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
3.
Fit two guide pins, M12 x 130, to the frame

attachment holes, as shown in the figure to
the right.
Fit one guide pin next to the guiding hole
(for the spring pin in the gearbox) and the
other guide pin straight across the frame.
A
A
B
xx0300000070
The figure above shows the frame, with

a view from below.
A: Attachment holes for the
guide pins, M12.
40
B: Guiding hole for the spring

pin located in the gearbox, axis
1.
3HAC 16247-1

Step
Action
Note/Illustration
4.
Look through the empty mounting hole of This is a complex task to be performed
motor 1 to assist in aligning the assembly with utmost care in order to avoid injury
during refitting of the arm system.
or damage!
The guiding pin in the gearbox must be fitted to the guiding hole of the frame.
Lower the arm system with guidance from
the guide pins previously fitted to the
frame.
5.
Refit 22 of the 24 attachment screws

before the arm system is completely lowered.
6.
Remove the guide pins and secure the arm Shown in the figure Location of arm
system to the base with its 24 attachment system on page 39!
screws and washers.
M12 x 70, 12.9 quality UNBRAKO,
tightening torque: 115 Nm.
Reused screws may be used, providing they are lubricated as detailed in
Screw joints on page 15 before fitting.
7.
Refit the block for calibration at the bottom Shown in the figure Location of arm
of the frame.
system on page 39!
8.
Refit the motor axis 1.
9.
Refill the gearbox axis 1 with lubricating oil. Detailed in "Oil change, gearbox axis
1" in the Maintenance Manual.
10. Recalibrate the robot.
Detailed in section Refitting of motor,

axis 1 on page 95.
Detailed in "Calibration" in the Installation Manual.
it is vital that:
3HAC 16247-1
41

3.2.1 Removal of turning disk
Section 3.2: Upper arm

Location of turning disk
The turning disk is located in the front of the wrist housing, as shown in the figure below. The
two different robot versions result in different designs of the turning disks.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 211.
B
E1
D
C
xx0200000217
Turning disk
Wrist unit
Oil plug, draining
Oil plug, filling
E1
Attachment screws, turning disk for robot version 175/2.55 (6 pcs)
E2
Attachment screws, turning disk for robot version 225/2.55, 175/2.8, 125/3.2 or 200/
2.75 (12 pcs)
Required equipment
Equipment, etc.
Standard toolkit

page 18!

See references to these
procedures in the stepby-step instructions
below.
42
Note
3HAC 16247-1

Removal, turning
disk
The procedure below details how to remove the turning disk.
motors or gears!
Step
3HAC 16247-1
Action
Note/Illustration
1.
Remove any equipment fitted to the turning

disk.
2.
Run the robot to a position where the oil

Shown in the figure Location of turnplug, draining of axis 6 gearbox faces down- ing disk on page 42!
wards.
3.
Drain the oil from gearbox 6.
Detailed in "Oil change, gearbox axis

4.
Remove the turning disk by unscrewing its

attachment screws .
Shown in the figure Location of turning disk on page 42!
43

3.2.2 Refitting of turning disk
Location of turning disk
The turning disk is located in the front of the wrist housing, as shown in the figure below. The
two different robot versions result in different designs of the turning disks.
E1
D
C
xx0200000217
44
Turning disk
Wrist housing
Oil plug, draining
Oil plug, filling
E1
Attachment screws, turning disk for robot version 175/2.55 (6 pcs)
E2
Attachment screws, turning disk for robot version 225/2.55, 175/2.8, 125/3.2 or 200/
2.75 (12 pcs)
3HAC 16247-1

Required equipment
Equipment, etc.
Note
Turning disk, dia 200
3HAC 9744-5
For robot version 175/2.55.

O-rings are not included!
Turning disk, dia 200
3HAC 13752-1
For robot version 225/2.55, 175/

2.8, 125/3.2 or 200/2.75.
O-rings are not included!
O-ring
3HAB 3772-65
(1 pc)
2152 0431-20
(6 pcs)
For robot v. 175/2.55.

Must be replaced when replacing the turning disk!
O-ring
3HAB 3772-64
(1 pc)
3HAB 3772-61
(12 pcs)
For robot v. 225/2.55, 175/2.8,

125/3.2 or 200/2.75.
Must be replaced when replacing the turning disk!
Grease
3HAB 3537-1
Used to lubricate the o-rings.
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Other tools and procedures may be

required. See references to these procedures in the step-bystep instructions
below.
Refitting, turning
disk
The procedure below details how to refit the turning disk.
motors or gears!
3HAC 16247-1
45

Step
1.
Action
Note/Illustration
Lubricate the turning disk o-ring

with grease.
page 45!
Fit the o-ring to the rear of the turning disk.
Fit also the 6 or 12 pcs of o-rings
(depending on robot version),
when refitting the attachment
screws.
xx0200000218
A: Sealing surface, o-ring
2.
Secure the turning disk with its

attachment screws.
Robot v. 175/2.55: 6 pcs, M14 x 25, tightening

torque: 175 Nm.
Robot v. 225/2.55, 175/2.8, 125/3.2 or 200/
2.75: 12 pcs, M12 x 30, 12.9 quality
UNBRAKO, tightening torque: 100 Nm.
Reused screws may be used, providing they
are lubricated as detailed in Screw joints on
page 15 before fitting.
3.
Refill the gearbox 6 with oil.
Detailed in "Oil change, gearbox axis 6" in the

Maintenance Manual.
4.
Refit any equipment removed during disassembly, to the turning

disk.
it is vital that:
46
3HAC 16247-1

3.2.3 Removal of complete wrist unit
Location of wrist
unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
B
C
xx0200000184
3HAC 16247-1
Wrist unit
Turning disk
Cover, wrist unit
Cover, upper arm tube
Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
Cable bracket, cables motor axis 6
Suffusion to lifting tool, wrist unit
Wrist unit attachment screws and washers
Upper arm tube
47

Required equipment
Equipment etc.
3HAC 13605-1
Circuit diagram
3HAC 13347-1
Included in Repair Manual,

part 2
Standard toolkit
3HAC 15571-1
The contents are defined in

page 18!

procedures in the step-bystep instructions below.
Removal, wrist
unit
Note

required.
The procedure below details how to remove the complete wrist unit.
motors or gears!
The complete wrist unit weighs 165 kg! All lifting equipment used must be dimensioned
accordingly!
Step
48
Action
Note/Illustration
1.
Remove all equipment fitted to the turning disk.
2.
Turn axis 4 to a position where the cover, upper Shown in the figure Location of
arm tube and wrist unit, faces upwards. Also wrist unit on page 47!
turn axis 5 so that the turning disc faces to the
side in order to allow access to the motor 6
cover.
3.
Remove the cover, wrist unit, on top of the

wrist unit.
Shown in the figure Location of

wrist unit on page 47!
4.
Remove the cover, upper arm tube.

5.
Remove the cover of motor, axis 6 and disconnect all connectors beneath.
3HAC 16247-1

Step
6.
Action
Note/Illustration
Loosen the cable bracket on top of the wrist by Shown in the figure Location of
unscrewing the three attachment screws.
Two of the attachment screws are located visiC
ble at the rear of the bracket (B) and the third
located at the bottom of the cable bracket, in
B
the center (C), shown in the figure to the right.
xx0200000254
B: Attachment screws, rear

of cable bracket, 2 pcs
C: Attachment screw, bottom of cable bracket, 1 pc
7.
Pick out the cabling from motor, axis 6 and

place it safely on the tube.
8.
Loosen the cable bracket in the upper arm tube

by unscrewing the two screws on top of the
tube.

9.
Disconnect the motor axis 5 by disconnecting

the two connectors in the upper arm tube
(R3.FB5, R3.MP5).

10. Fit the lifting device to the wrist unit.
Art. no. specified in Required

equipment on page 48!
11. Slightly raise the wrist unit to unload the screw

joint, facilitating removing the attachment
screws.
12. Remove the wrist unit attachment screws and
washers .

13. Pull the wrist unit out, lift it away and place it on
a secure surface.
3HAC 16247-1
49

3.2.4 Refitting of complete wrist unit
Location of wrist
unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
B
C
xx0200000184
50
Wrist unit
Turning disk
Cover, wrist unit
Cover, upper arm tube
Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
Cable bracket, cables motor axis 6
Suffusion to lifting tool, wrist unit
Attachment screws and washers, wrist unit
Upper arm tube
3HAC 16247-1

Required equipment
Refitting, wrist
unit
Equipment etc.
Note
Wrist, 175/2.55
3HAC 16627-1
Includes complete axis 6,

3HAC 9744-1/3HAC 16032-1
(Foundry).
Includes rotational motor incl.
gearbox, 3HAC 7941-29.
Wrist, 225/2.55, 175/2.8, 3HAC 16626-1

125/3.2 or 200/2.75
Includes complete axis 6,

3HAC 13890-1/2 (Foundry).
Includes rotational motor incl.
gearbox, 3HAC 7941-30.
Guide pin M12 x 200
3HAC 13056-3 Always use guide pins in

pairs!
3HAC 13605-1
Standard toolkit

page 18!

below.
The procedure below details how to refit the complete wrist unit.
motors or gears!
The complete wrist unit weighs 165 kg! All lifting equipment used must be dimensioned
accordingly!
Step
3HAC 16247-1
Action
Note/Illustration
1.
Fit two guide pins, M12 in the upper arm

tube, in two of the wrist unit attachment
screw holes.
Art. no. specified in Required equipment on page 51!

Shown in the figure Location of wrist
unit on page 50!
2.
Fit the lifting tool to the wrist unit.
Art. no. specified Location of wrist unit

on page 50!
51

Step
Action
Note/Illustration
3.
Lift the wrist unit and guide it to the upper

arm tube with help of the guide pins.
Make sure the cabling from motor, axis 5 is
safely run into the arm tube and doesnt get
into a scrape.
4.
Secure the wrist unit with 10 of the 12 attach- Shown in the figure Location of wrist
ment screws and washers.
unit on page 50!
12 pcs: M12 x 50, 12.9 quality
UNBRAKO, tightening torque: 115
Nm.
5.
Remove the guide pins and secure the two

remaining attachment screws as detailed
above.
6.
Remove the lifting tool from the wrist unit.
7.
Reconnect the motor axis 5 by connecting

the two connectors inside the upper arm
tube (R3.FB5, R3.MP5) and secure the
cable bracket with the two attachment
screws to the tube.
8.
In order to have access to motor 6 cover, the

axis 5 must be positioned +90 degrees.
Place the cabling to motor, axis 6, correctly
on the upper arm and gently pull the connectors through the hole on top of wrist unit to
motor, axis 6.

unit on page 50!
xx0200000185
Put a loop of cable in this area with

cable straps (A), if necessary. The
cables are longer to fit to different
upper arm lengths.
9.
Fasten the cable bracket at top of wrist unit Shown in the figure Location of wrist
with three attachment screws. Two of them unit on page 50!
are visible at the rear attachment point (B)
and the third is located on the bottom of the C
cable bracket, right in the center (C), shown
B
in the figure to the right.
xx0200000254

cable bracket
C: Attachment screw, bottom

of cable bracket
10. Reconnect the connectors to motor, axis 6

and refit the motor cover.
52
11. Refit the cover, upper arm tube.

unit on page 50!
12. Refit the cover, wrist unit.

unit on page 50!
3HAC 16247-1

Step
Action
Note/Illustration
13. Recalibrate the robot!
14. Refit any equipment previously removed

from the turning disk.
it is vital that:
3HAC 16247-1
53

3.2.5 Removal of upper arm
Location of upper
arm
The upper arm is located on top of the manipulator as shown in the figure below. The complete upper arm includes the wrist unit but this instruction also describes how to remove the
upper arm when there is no wrist unit mounted.
Note! The lifting device is attached differently depending on whether the wrist unit is
mounted on the upper arm or not. The attachment points are shown in the figure below.
Upper arm on page 209.
B
A
H
G
E
C
D
xx0200000163
54
3HAC 16247-1

Attachment hole for lifting eye, M12
Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
Oil plug, draining, gearbox axis 3
Connectors at cable harness division; R2.M5/6
Motor, axis 3
Motor, axis 4
Attachment screws and washers, upper arm
Sealing, axis 2/3 (between lower arm and gearbox axis 3)
Required equipment
Equipment
Lifting eye, VLBG M12
3HAC 16131-1
Lifting device, upper

arm
3HAC 15994-1
3HAC 15556-1
To be used together with lifting

eye, M12 and lifting device,
upper arm.
Standard toolkit
3HAC 15571-1

page 18!

below.
Removal, upper
arm
Note/Illustration
The procedure below details how to remove the upper arm.
motors or gears!
The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
Step
3HAC 16247-1
Action
Note/Illustration
1.
Remove all equipment fitted to turning disk.
2.
Move the manipulator arm to a horisontal position. Shown in the figure Location of
Run axis 4 so that the attachment hole for lifting eye upper arm on page 54!
is faced upwards!
55

Step
56
Action
Note/Illustration
3.
Fit the lifting eye, VLBG M12 to the attachment hole

on the upper arm, if the wrist unit is mounted.

upper arm on page 54!
4.
Upper arm including wrist unit: Fit one of the

pieces included in lifting device, upper arm to the
attachment for lifting device on the upper arm.

Fasten the lifting device on the
front attachment, as shown in
the figure above!
5.
Upper arm without wrist unit: Fit the lifting

device, upper arm to the attachments for lifting
device .

The attachments are shown in
the figure Location of upper
arm on page 54!
6.
Fasten the lifting tool (chain) onto the lifting eye,

the lifting device and an overhead crane.

7.
Detailed in "Oil change, gearbox axis 3" in the Maintenance

Manual.
8.
Disconnect connector R2.M5/6 at the cable harShown in the figure Location of

ness division as well as all remaining connections upper arm on page 54!
to the upper arm.
9.
Remove the cover on top of the motors, axis 3 and

4 and disconnect all connectors inside motors.
10.
Remove all brackets securing cabling to the upper

arm by unscrewing their attachment screws
respectively.
11.
Raise the lifting equipment to take the weight of the

upper arm.
12.
Carefully remove the attachment screws and wash- Shown in the figure Location of
ers, upper arm.
13.
Lift the upper arm and place it on a secure surface.

Make sure the lift is done completely level! In case
of necessary adjustments, use the shortening
loops on the lifting tool (chain), but make sure to
place the chain the right way through the loops!
14.
Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Location of
3HAC 16247-1

3.2.6 Refitting of upper arm
Location of upper
arm
The upper arm is located on top of the manipulator as shown in the figure below. The complete upper arm includes the wrist unit but this instruction also describes how to refit the
upper arm when there is no wrist unit mounted.
Note! The lifting device is attached differently depending on whether the wrist unit is
mounted on the upper arm or not. The attachment points are shown in the figure below.
B
A
H
G
E
C
D
xx0200000163
3HAC 16247-1
57

Attachment hole for lifting eye, M12
Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
Oil plug, draining, gearbox axis 3
Connectors at cable harness division; R2.M5/6
Motor, axis 3
Motor, axis 4
Attachment screws and washers, upper arm
Sealing, axis 2/3 (between lower arm and gearbox axis 3)
Required equipment
Equipment
Sealing, axis 2/3
3HAC 12443-2
Always use a new sealing

when reassembling!
Washer, axis 3 (3 pcs)
3HAC 12703-1
To be replaced if damaged.
Lifting eye, VLBG M12
3HAC 16131-1
Lifting device, upper

arm
3HAC 15994-1
3HAC 15556-1
To be used together with lifting

eye, M12 and lifting device,
upper arm.
Guide pins, sealing axis

2/3 80 mm
3HAC 14628-1
For guiding "Sealing, axis 2/3".
Guide pins, sealing axis

2/3 100 mm
3HAC 14628-2
For guiding "Sealing, axis 2/3".
Power supply
24 VDC, max 1,5A.

For releasing the brakes.
Rotation tool, motor
3HAC 17105-1
Used to rotate the motor shaft

beneath the motor cover,
when brakes are released with
24 VDC power supply.
Standard toolkit
3HAC 15571-1

page 18!

below.
Refitting, upper
arm
Note
The procedure below details how to refit the upper arm.
motors or gears!
58
3HAC 16247-1

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
Step
1.
Action
Note/Illustration
Fit the two guide pins, sealing axis 2/3 in

two of the attachment screw holes on
gearbox 3, see figure beside.
Guide the new sealing, axis 2/3 into position with the guide pins, on gearbox 3.
Always use a new sealing when reassembling!

xx0200000166
3HAC 16247-1
A: Holes for guide pins on the

gearbox.
B: Holes in the gearbox, axis 3,

for the attachment screws,
upper arm (33 pcs).
C: Gearbox attachment screws

(not affected in this instruction).
2.
Fit the lifting eye, VLBG M12 to the attach- Art. no. specified in Required equipment hole on the upper arm, if there is a ment on page 58!
wrist unit mounted.
Shown in the figure Location of upper
arm on page 57!
3.
Upper arm including wrist unit: Fit one

of the pieces included in the lifting device,
upper arm to the attachment for the lifting
device on the upper arm.
Fasten the lifting device on the front
attachment, as shown in figure above!
4.
Upper arm without wrist unit: Fit the lift- Art. no. specified in Required equiping device, upper arm to the attachments ment on page 58!
for the lifting device on the upper arm.
arm on page 57!
5.
In order to release the brake, connect the Connect to connector R2.MP3

24 VDC power supply to motor axis 3,
+: pin 2
after removing the motor cover.
-: pin 5

arm on page 57!
59

Step
Action
Note/Illustration
6.
Fasten the lifting tool (chain) onto the lift- Art. no. specified in Required equiping eye, the lifting device and an overhead ment on page 58!
crane.
7.
Lift the upper arm and run to its mounting

position.
Make sure the lift is done completely level!
8.
Fit in the gearbox attachment holes with

the attachment holes on the lower arm
with the guide pins.
It may be necessary to turn the gear by
rotating the motor pinion with a rotation
tool, motor beneath the motor cover.
xx0200000165
The rotation tool is used beneath the

motor cover, directly on the motor shaft
as shown in figure above.
A: Rotation tool
60
9.
Fit the three washers to be placed

beneath the attachment screws.

arm on page 57!
10.
Insert 31 of the 33 attachment screws,

upper arm into the attachment holes in
the lower arm.
Do not remove the guide pins until the
attachment screws are tightened as
detailed below.

arm on page 57!
Removing the plastic mechanical stops
may be required before fitting the upper
arm.
If guide pins are removed before the
screws are tightened, the sealing can
be involuntarily moved into wrong position.
11.
Secure the lower arm to gearbox axis 3,

with the attachment screws.
33 pcs: M12 x 50; 12.9 quality

UNBRAKO, tightening torque: 120 Nm.
Reused screws may be used, providing
they are lubricated as detailed in Screw
joints on page 15 before fitting.
12.
Remove the guide pins and fit the two

remaining attachment screws. Tighten
them as detailed above!
13.
Disconnect the brake release voltage and

remove the rotation tool from the motor.
14.
Remove the lifting devices.
15.
Refit any cabling removed during the

removal process.
16.
Reconnect all connectors inside motors,

axis 3 and 4. Refit the motor covers.
17.
Reconnect connector R2.M5/6 gently at

the cable harness division point, with 2
screws, M6.
Be careful not to bend the attachment
plate when fastening the screws!
3HAC 16247-1

Step
Action
Note/Illustration
18.
Perform a leakdown test.
Detailed in Performing a leak-down test

on page 21.
19.
Refill the gearbox with oil.
Detailed in "Oil change, gearbox axis 3"

in the Maintenance Manual.
20.
Recalibrate the robot.
it is vital that:
3HAC 16247-1
61

3.3.1 Removal of complete lower arm
Section 3.3: Lower arm

Location of lower
arm
The lower arm is located as shown in the figure below.

Frame-Lower arm 2 on page 207.
A
D
C
xx0200000255
62
Lower arm
Pivot point, axis 2
Front shaft, balancing device, including securing screw
Attachment for lifting eye, M12, balancing device
3HAC 16247-1

Attachment
points, lower arm
The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to
the gearbox is identical for axis 2.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
B
(1)
(2)
404
401
202
204
406
402
403
D
405
409
E
xx0200000031
3HAC 16247-1
Gear box
Lower arm
Balancing device piston rod ear
Frame
Shaft hole
201
Sealing, axis 2/3
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
63

Required equipment
Equipment, etc.
3HAC 14691-1 Tool that may be rent from

ATRP/S.
Press tool, axis 2 shaft
3HAC 13452-1
Lifting eye, M12
3HAC 14457-3 Used to lift the balancing

device.
Puller tool, balancing

device shaft
3HAC 12475-1 Used to pull out the shaft from

the balancing device front ear.
Hydraulic pump 80Mpa
3HAC 13086-1 To be used together with the

press tool, axis 2 shaft and the
puller tool.
Hydraulic pump 80 Mpa

(Glycerin)
3HAC 13086-2 To be used together with the

press tool, axis 2 shaft and the
puller tool.
Retaining ring plier
Standard toolkit

page 18!

below.
Removal, lower
arm
Note
The procedure below details how to remove the complete lower arm.
motors or gears!
The lower arm weighs 160 kg! All lifting equipment used must be dimensioned accordingly!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
64
Action
Note/Illustration
1.
Remove the upper arm.
Detailed in section Removal of upper arm

on page 54.
2.
Disconnect and remove the cables from Detailed in section Removal of cable harinside the lower arm.
ness on page 24.
Release any cable attachments.
3HAC 16247-1

Step
Action
Note/Illustration
3.
Apply the lifting eye to the balancing

device and raise to unload the device.
Art. no. specified in Required equipment

on page 64.
Attachment shown in the figure Location
of lower arm on page 62.
4.
Unload the balancing device in order to Detailed in section Unloading the balancmake the piston rod and front ear adjust- ing device on page 89.
able when pulling the front shaft out.
5.
Remove the securing screw from the

balancing device front shaft.
6.
Apply the shaft puller tool to the shaft

through the hole in the frame.
The shaft has a M20 thread diameter
and a 35 mm depth of thread, as shown
35
xx0300000056
Pull the shaft out using the puller tool
Note! The dimension of the shaft puller
and the hydraulic pump.
tool is M20. Do not mix up with the shaft
press tool used when mounting the shaft.
on page 64.
7.
Lower the balancing device until it rests

safely against the bottom of the frame.
8.
Move the lower arm backwards to the

lowest position possible.
9.
Apply the lifting tool to the lower arm.
Shown in the figure Location of lower arm

on page 62.
xx0300000015
10. Drain the oil from gearbox 2.

11.
3HAC 16247-1

on page 64!
Detailed in "Oil change, gearbox 2" in the
Maintenance Manual.
Raise the tool to unload the lower arm.
12. Remove the protection plug.
Shown in the figure Attachment points,

lower arm on page 63!
13. Remove the protection washer and the

retaining ring.

Use a plier for the retaining ring.
65

Step
Action
Note/Illustration
14.
Fit the press (/puller) tool to the shaft as Art. no. specified in Required equipment
shown in the figure to the right and
on page 64!
mount the hydraulic pump to it.
15.
Pull the shaft out.
16.
Remove the lower arm attachment

screws and washers that attaches the
lower arm to the gearbox 2.
17.
Lift the lower arm down and place it on a

secure surface.
18.
Remove the bearing and thrust washer

from the shaft hole in the lower arm.
19.
Remove the sealing from the lower arm. Shown in the figure Attachment points,
On reassembly a new sealing must be
used!
xx0300000010
66


On reassembly a new bearing must be
used!
3HAC 16247-1

3.3.2 Refitting of complete lower arm
Location of lower
arm
The lower arm is located as shown in the figure below.

Frame-Lower arm 2 on page 207
A
D
C
xx0200000255
3HAC 16247-1
Lower arm
Pivot point, axis 2
Front shaft, balancing device, including securing screw
Attachment for lifting eye, M12, balancing device
67

Attachment
points, lower arm
The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to
the gearbox is identical for axis 2.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
B
(1)
(2)
404
401
202
204
406
402
403
D
405
409
E
xx0200000031
68
Gear box
Lower arm
Balancing device piston rod ear
Frame
Shaft hole
201
Sealing, axis 2/3
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
3HAC 16247-1

Required equipment
Equipment, etc.
Bearing
3HAC 12441-2
Always use a new bearing when

reassembling!
Sealing, axis 2/3
3HAC 12443-2
Always use a new sealing when

reassembling!
VK-cover VK 120 x 12 3HAA 2166-23
Mount on new lower arm or

replace if damaged.
3HAC 14691-1
Tool to be rent from ATRP.

Two guidings, 3HAC 14446-1,
must be used for guiding the
sealing, axis 2/3.
Guidings
3HAC 14446-1
For guiding the sealing axis 2/3.
3HAC 17105-1
Used to rotate the motor pinion

and gear if necessary, when
brakes are released.
Power supply
24 VDC, 1.5 A.
Press tool, axis 2

shaft
3HAC 13452-1
Press tool, axis 2

bearing
3HAC 13453-1
Hydraulic pump 80
Mpa
3HAC 13086-1
To be used together with the

press tools.
Hydraulic pump 80
Mpa (Glycerin)
3HAC 13086-2
To be used together with the

press tools.
Tool that may be rent from
ATRP/S.
Retaining ring plier
Grease
3HAB 3537-1
Isopropanol
1177 1012-208 For cleaning the shaft.
Standard toolkit
3HAC 15571-1

below.
Refitting, lower
arm
Note
For lubricating shaft hole.

The contents are defined in section Standard toolkit on page 18!
The procedure below details how to refit the complete lower arm.
motors or gears!
3HAC 16247-1
69

The lower arm weighs 160 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Fit a new VK-cover on a new lower arm Part no. specified in Required equipment
or replace the existing if damaged.
on page 69!
2.
Fit two guidings in the attachment holes Art no. specified in Required equipment
of the lower arm.
on page 69!
xx0200000262
A: Attachment holes for the two guidings

3.
Fit the new sealing, axis 2/3 on the

guidings.
Always use a new sealing when reassembling!

Art no. specified in Required equipment
on page 69!
4.
Apply the lifting tool to the lower arm.

on page 69!
5.
Lift the lower arm and run it to its mounting position.
6.
In case the holes of the lower arm and Connect power supply to connector
the ones of the gearbox axis 2 doesnt R2.MP2
match, use power supply to release the
+: pin 2
motor axis 2 brakes and rotate the pin -: pin 5
ion and gear with the rotational tool.
xx0200000165
The rotation tool (A) is used beneath the

motor cover, directly on the motor shaft as
shown in figure above.
on page 69!
7.
70
Secure the lower arm with 31 of the 33

attachment screws and washers in
gearbox 2.
33 pcs: M12 x 50, 12.9 quality UNBRAKO,

3HAC 16247-1

Step
Action
Note/Illustration
8.
Remove the guidings and secure the

two remaining screws as detailed
above!
9.
Clean the shaft with isopropanol.
10. Apply grease to the shaft hole.

11.

on page 69!
on page 69!
Push the shaft in by hand.
E
F
A B
xx0300000014
A: Retaining ring
B: Protection washer
C: Bearing
D: Thrust washer
E: Shaft
F: Protection plug
12. Apply the press tool, axis 2 shaft

against the shaft.

on page 69!
13. Tighten the M16 nut.
Tightening torque: 20 Nm.
14. Set the indicator to zero and press the Approx. force: 30-50 kN.
shaft in with the hydraulic cylinder of the
press tool.
15. Increase the pressure of the glycerin
pump to 50 kN.
16. Check the measurement dial readout.
Correct value: 2.45 mm 0.15 mm.
17. Remove the press tool, axis 2 shaft.
Release the pressure from the glycerin

pump first, then from the hydraulic cylinder (approximately 1/2 minute after), in
order to avoid movement of the shaft.
18. Refit the thrust washer to the shaft.

19. Apply grease to the location of the shaft Art no. specified in Required equipment
where the bearing is to be mounted.
on page 69!
20. Press the bearing in with the press tool, Always use a new bearing when reassemaxis 2 bearing.
bling!
on page 69!
3HAC 16247-1
21. Refit the protection washer and the

retaining ring.

22. Refit the protection plug.

71

Step
Action
Note/Illustration
23.
Refit and restore the balancing device.
Detailed in section Refitting of balancing

device on page 85.
24.
Refit the upper arm.
Detailed in section Refitting of upper arm

on page 57.
25.
Perform a leak-down test.
Detailed in section Performing a leakdown test on page 21.
26.
Detailed in section "Oil change, gearbox

axis 2" in the Maintenance Manual.
27.
Refit and reconnect all cables inside the Detailed in section Refitting of cable harlower arm.
ness on page 30.
Resecure any cable attachments.
28.
Recalibrate the robot!
Detailed in "Calibration" in the Installation

Manual.
it is vital that:
72
3HAC 16247-1

3.4.1 Removal of SMB related equipment
Section 3.4: Frame and base

Location of SMB
related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below. (IRB 7600 shown.)
Note that the manipulator is shown with the SMB cover already removed!
A B C D
E F G
xx0200000203
Attachment screw, SMB battery cover
SMB battery cover
SMB battery
Cable, battery/SMB board
SMB cover
Attachment screw, SMB cover
SMB unit
Pins
Required equipment
Equipment, etc. Spare part. no. Art. no.
Removal, battery
Note
Standard toolkit
3HAC 15571-1 The contents are defined in section

Standard toolkit on page 18!
Circuit Diagram
3HAC 13347-1 Included in Repair Manual, part 2
The procedure below details how to remove the SMB battery.

motors or gears!
3HAC 16247-1
73

Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.
Step
Removal, SMB
unit
Action
Note/Illustration
1.
Remove the SMB battery cover by unscrew- Shown in the figure Location of
ing its attachment screws.
SMB related equipment on page 73!
2.
Disconnect the cable, battery/SMB board

from the battery.
3.
Remove the SMB battery.

Battery includes protection circuits. Replace it SMB related equipment on page 73!
only with the specified spare part or with an
ABB approved eqvivalent.

SMB related equipment on page 73!
The procedure below details how to remove the SMB unit.
motors or gears!
voltages.
or similar.
Step
74
Action
Note/Illustration
1.
Remove the SMB cover by unscrewing Shown in the figure Location of SMB
its attachment screws.
related equipment on page 73!
2.
Remove the connectors X8, X9 and X10

from the brake release board, if need of
more space.
3.
Remove the locknut and washer from

the pins securing the board.
4.
Gently disconnect the connectors from Connectors R1.SMB1-3, R1.SMB4-6 and

the SMB unit when pulling the board out. R2.SMB
5.
Disconnect the battery cable from the

SMB unit.
Shown in the figure Location of SMB

3HAC 16247-1

3.4.2 Refitting of SMB related equipment
Location of SMB
related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below. (IRB 7600 shown.)
Note that the manipulator is shown with the SMB cover already removed!
A B C D
E F G
xx0200000203
Attachment screw, SMB battery cover
SMB battery cover
SMB battery
Cable, battery/SMB board
SMB cover
Attachment screw, SMB cover
SMB unit
Pins
Required equipment
Equipment, etc. Spare part no. Art. no.
3HAC 16247-1
SMB Unit
3HAC 13149-1
SMB Battery
3HAC 16831-1
Note
Battery includes protection circuits.
Replace it only with given spare
part no. or an ABB approved eqvivalent.
Cable, battery/SMB
board
3HAC 13151-1
Circuit Diagram
3HAC 13347-1 Included in Repair Manual, part 2
Standard toolkit

75

Refitting, battery
The procedure below details how to refit the SMB battery.

motors or gears!
voltages.
or similar.
Step
Refitting, SMB
unit
Action
Note/Illustration
1.
Reconnect the cable, battery/SMB board to Art. no. is specified in Required equipthe battery and fit the SMB battery.
ment on page 75!
2.
Secure the SMB battery cover with its

attachment screws .

related equipment on page 75
3.
The procedure below details how to refit the SMB unit.
motors or gears!
voltages.
or similar.
Step
76
Action
Note/Illustration
1.
Connect the battery cable to the SMB

board.
2.
Fit the SMB unit onto the pins and con- Art. no. is specified in Required equipment
nect all connectors to the board.
on page 75!
R1.SMB1-3, R1.SMB4-6 and R2.SMB
3.
Secure the SMB unit to the pins with

the locknut and washer.
3HAC 16247-1

Step
Action
Note/Illustration
4.
If disconnected, reconnect the connectors X8, X9 and X10 to the brake

release board.
5.
Secure the SMB cover with its attach- Shown in the figure Location of SMB
ment screws.
6.

Manual.
it is vital that:
3HAC 16247-1
77

3.4.3 Removal of brake release unit
Location of brake
release unit
The brake release unit is located together with the SMB unit on the left hand side of the frame,
right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Some of the early designs are equipped with a separate box on the frame, with the brake
release unit inside, not shown in the figure.
D
xx0200000226
Brake release unit
Attachment screws, brake release unit (4 pcs)
Buttons
SMB battery pack
SMB cover
Attachment screws, SMB cover
Required equipment
Equipment, etc.
Standard toolkit

page 18!

below.
78
Note

required.
3HAC 16247-1

Removal, brake
release unit
The procedure below details how to remove the brake release unit.
motors or gears!
voltages.
or similar.
Step
Action
Note/Illustration
1.
Open the SMB cover by unscrewing the

attachment screws.
Let the battery stay connected, to avoid
the need of synchronization of the robot!
Shown in the figure Location of brake

release unit on page 78!
2.
Disconnect the connectors X8, X9 and

X10 from the brake release unit.
A
2
C
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
Location of brake release unit shown in

the figure Location of brake release unit
on page 78!
3HAC 16247-1
3.
Unscrew the four attachment screws,

brake release unit.
4.
Remove the brake release unit from the

plate.

79

3.4.4 Refitting of brake release unit
Location of brake
release unit
The brake release unit is located together with the SMB unit on the left hand side of the frame,
right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Some early designs are equipped with a separate box on the frame, with the brake release unit
inside, not shown in the figure.
D
xx0200000226
Brake release unit
Attachment screws, brake release unit (4 pcs)
Buttons
SMB battery pack
SMB cover
Attachment screws, SMB cover
Required equipment
Equipment, etc.
80
Note
Brake release unit with

buttons
3HAC 16035-1 Located together with the

SMB-unit at the left hand side
of the frame.
Brake release circuit
3HAC 14301-1 The early version, where

brake release unit is located in
a separate box on the frame.
Standard toolkit

page 18!
3HAC 16247-1

Equipment, etc.
Note

below.
Refitting, brake
release unit
The procedure below details how to refit the brake release unit.
motors or gears!
voltages.
or similar.
Step
Action
Note/Illustration
1.
Fasten the brake release unit on the plate Shown in the figure Location of brake
with the attachment screws.
2.
Connect the connectors X8, X9 and X10 to

the brake release unit.
A
2
C
xx0200000129
3.
Close the SMB cover with attachment

screws.
If the battery has been disconnected the
robot must be synchronized.
A: Connector X8
B: Connector X9
C: Connector X10

Eventual synchronization detailed in
"Calibration" in the Installation Manual.
it is vital that:
3HAC 16247-1
81

3.4.5 Removal of balancing device
Location of balancing device
The balancing device is located on rear top of the frame as shown in the figure below.
A C
I,J
D, E
H
G
B
K
F
xx0200000223
Balancing device
Hole for lower arm locking screw
Attachment hole for lifting eye
Rear cover
Support shaft inside (included in balancing device 3HAC 14678-1)
Attachment screws, rear cover
Balancing device front eye, including shaft and securing screw
Hole in the frame through which shaft puller tool is to be inserted
Bearing attachment
Parallel pin (inside bearing attachment)
Plug
Attachment screws, bearing attachments
Required equipment
Equipment, etc
82
Note
Locking screw
3HAA 1001-266 M16 x 60.

For securing the lower arm.
Lifting eye, M12
3HAC 14457-3
Press tool, balancing

device
3HAC 15767-1
Puller tool, balancing

device shaft
3HAC 12475-1
3HAC 16247-1

Equipment, etc
Removal, balancing device
Note
Hydraulic cylinder
3HAC 11731-1
To be used with press tool

3HAC 15767-1.
Hydraulic pump
3HAC 13086-1
To be used with hydraulic cylinder, 3HAC 11731-1.
Securing screw
9ADA 183-66
M12 x 35, 2 pcs required.

For securing the bearing
attachments to the balancing
device when lifting.
Guide pin, M16 x 300
3HAC 13120-5
Always use guide pins in pairs
Standard toolkit
3HAC 15571-1

page 18!
The procedure below details how to remove the balancing device.
motors or gears!
The balancing device weighs 210 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Run the lower arm to a position close to

the calibration position.
2.
Secure the lower arm to the frame by

inserting the locking screw (1) into the
hole.
xx0200000454

3.
3HAC 16247-1
Apply lifting eye to the balancing device,

and raise to unload the device.
83

Step
84
Action
Note/Illustration
4.
Unload the balancing device with the

press tool in order to make the piston rod
and front ear adjustable when pulling the
shaft out.

Detailed in Unloading the balancing
device on page 89.
5.
Remove the securing screw from the

shaft.
Shown in the figure Location of balancing device on page 82!
6.
Apply the shaft puller tool to the shaft

through the hole in the frame.
The shaft has a M20 thread diameter and
a 35 mm depth of thread, as shown in the
35
figure to the right.
xx0300000056
Pull the shaft out using the puller tool and
Note! The dimension of the shaft puller
the hydraulic pump.
tool is M20. Do not mix up with the shaft
press tool used when mounting the
shaft.
The hole in the frame is shown in the
figure Location of balancing device on
page 82!
7.
Restore the balancing device.
8.
Secure the two bearing attachments to the Shown in the figure Location of balancbalancing device by replacing the plug on ing device on page 82!
the outside of each attachment, with a
2pcs: M12 x 35.
screw.
9.
Remove the two bearing attachments from Shown in the figure Location of balancthe frame by unscrewing their four attach- ing device on page 82!
ment screws.
Make sure the parallel pins inside are
not lost!
10.
Fit two guide pins, through the upper

holes of the bearing attachments, to the
frame.
11.
Lift the balancing device gently backwards Note! Make sure not to burden the
to a secure area, allowing the bearing
guide pins with the weight of the balattachments to slide on the guide pins.
ancing device!
Detailed in Restoring the balancing

device on page 91.
3HAC 16247-1

3.4.6 Refitting of balancing device
Location of balancing device
The balancing device is located on rear top of the frame as shown in the figure below.
A C
I,J
D, E
H
G
B
K
F
xx0200000223
Balancing device
Hole for lower arm locking screw
Attachment hole for lifting eye
Rear cover
Support shaft inside (included in balancing device 3HAC 14678-1)
Attachment screws, rear cover
Balancing device front eye shaft, including securing screw
Hole through which shaft puller tool is to be inserted
Bearing attachment
Parallel pin (inside bearing attachment)
Plug
Attachment screws, bearing attachments
Required equipment
3HAC 16247-1
Equipment
Note
Balancing device
3HAC 16198-1
IRB 6600.
Includes balancing device 3HAC
14678-1!
Includes o-rings 3HAB 3772-44.
Balancing device
3HAC 16907-1
IRB 6650.
Includes balancing device 3HAC
16189-1!
Includes o-rings 3HAB 3772-44.
85

Equipment
O-ring
3HAB 3772-44
Locking screw
3HAA 1001-266 M16 x 60.

Securing screw
9ADA 183-66
M12 x 35, 2 pcs required.

For securing the bearing attachments to the balancing device
when lifting.
Bearing grease
3HAB 3537-1
For lubricating the o-rings and the

shaft.
Grease
3HAA 1001-294 80 ml, Optimol PDO.

For lubrication of spherical roller
bearing in ear, in case of new balancing device.
3 pcs, to be replaced if damaged!
Locking liquid
Loctite 243.
To apply to the securing screw in
the shaft.
Grease pump
To lubricate spherical roller bearing.
Guide pin, M16 x

300
3HAC 13120-5
Lifting eye, M12
3HAC 14457-3
Press tool, balancing device
3HAC 15767-1
Press tool, balancing device shaft
3HAC 17129-1
Hydraulic cylinder
3HAC 11731-1
To be used with press tool 3HAC

15767-1 and press tool, shaft
3HAC 17129-1.
Hydraulic pump
3HAC 13086-1
To be used with hydraulic cylinder

3HAC 11731-1.
Standard toolkit
3HAC 15571-1
The contents are defined in section

Other tools and

procedures may
be required. See
references to
these procedures
in the step-by-step
instructions below.
Refitting, balancing device
Note
Always use guide pins in pairs.
The procedure below details how to refit the balancing device.
motors or gears!
86
3HAC 16247-1

The balancing device weighs 210 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
Secure the lower arm to the frame by inserting the locking screw into the hole (1).
xx0200000454
3HAC 16247-1
2.
Secure the bearing attachments to the bal- Shown in the figure Location of balancing device with two screws, on the out- ancing device on page 85!
side of the attachments.
M12 x 35, 2 pcs.
3.
Refit the two parallel pins in the frame.
4.
Fit two guide pins to the upper holes in the

frame, where the bearing attachments are to
be attached.
5.
Fit the lifting eye to the balancing device.
6.
Lift the balancing device and bring it forward, Note! Make sure not to burden the
gliding the bearing attachments on to the
guide pins with the weight of the balguide pins (upper holes).
ancing device!
7.
Remove the guide pins.
8.
Secure the rear of the balancing device by Shown in the figure Location of balfastening the two bearing attachments to the ancing device on page 85!
frame with their four attachment screws.
4 pcs, M16x70, 12.9 quality
UNBRAKO, tightening torque: 300
Nm 45 Nm.
9.
Remove the screws from outside of the

bearing attachments and refit the plugs.
10.
Raise the balancing device to a position

where the front shaft may be inserted
through the piston shaft front eye.
Shown in the figure Location of balancing device on page 85!
87

Step
Action
Note/Illustration
11.
Unload the balancing device with the press

tool.
Detailed in Unloading the balancing

device on page 89.
For an easier reassembling of the
shaft, the piston rod may be pressed
out more than necessary and then
pressed in when fitting the shaft.
12.
Lubricate the shaft with grease.
13.
Apply the shaft press tool to the lubricatedshaft through the hole in the frame.
Fit the shaft using the shaft press tool and
the hydraulic pump.
The shaft and the hole in the frame

are shown in the figure Location of
balancing device on page 85!
Note! Make sure the shaft is pressed
all the way to the bottom.
14.
Refit the securing screw in to the shaft using M16x180, tightening torque: 50 Nm.
locking liquid.
Locking liquid specified in Required
15.
When assembling a new device:

Lubricate the bearing in the ear with grease
through the lubricating nipple, with a grease
pump.
Fill until excessive grease pierces between
the shaft and the sealing spacer.
Art. no. and amount specified in

Required equipment on page 85!
Lubrication further detailed in "Lubrication, balancing device bearing" in
the Maintenance Manual.
16.
Detailed in Restoring the balancing

device on page 91.
17.
Remove the locking screw (1) that secures

the lower arm to the frame.
xx0200000454
it is vital that:
88
3HAC 16247-1

3.4.7 Unloading the balancing device
Press tool and

hydraulic cylinder
This section implies that the lower arm is already secured according to the instruction for the
current repair activity, e.g removal of the balancing device.
The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
1
0
D
xx0200000174
Bolt (4 pcs)
Hydraulic cylinder
Fix plate
Moving pin with marking
Required equipment
Equipment, etc.
3HAC 16247-1
Note

device
3HAC 15767-1
Hydraulic cylinder
3HAC 11731-1 To be used with press tool

3HAC 15767-1.
Hydraulic pump
3HAC 13086-1 To be used with hydraulic cylinder, 3HAC 11731-1.
Standard toolkit

page 18.
89

Unloading the
balancing device
The procedure below details how to unload the balancing device, using the press tool 3HAC
15767-1. How to remove the press tool, is detailed in section Restoring the balancing device
on page 91.
Step
1.
Action
Note/Illustration
Remove the rear cover of the balancing

device, by unscrewing the attachment
screws (E).
xx0200000175
90
E: Rear cover attachment screws

(4 pcs)
2.
Remove the support shaft.
3.
Remove the o-ring.
4.
Mount the press tool, balancing device

to the rear of the balancing device with
enclosed bolts. Tighten them properly!

on page 89!
See the figure Press tool and hydraulic
cylinder on page 89!
5.
Fit the hydraulic cylinder to the press

tool.

on page 89!
6.
Connect the hydraulic pump to the cylinder.

on page 89!
7.
Increase the pressure and press until

the marking on the moving pin indicates
the correct position (flushed with the surface).

Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.
8.
Turn the fix plate to position 1 in order to See the figure Press tool and hydraulic
lock the tool in loaded condition.
9.
Unload the hydraulic cylinder.
10.
The hydraulic cylinder may now be

removed from the tool, when necessary.
3HAC 16247-1

3.4.8 Restoring the balancing device
Press tool and

hydraulic cylinder
Restoration is done after repair work that has included the unloading of the balancing device.
The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
1
0
D
xx0200000174
Bolt (4 pcs)
Hydraulic cylinder
Fix plate
Moving pin with marking
Required equipment
Equipment, etc. Spare part no. Art. no.
3HAC 16247-1
Note
Hydraulic cylinder
3HAC 11731-1 To be used with press tool 3HAC

15767-1.
Hydraulic pump
3HAC 13086-1 To be used with hydraulic cylinder,

3HAC 11731-1.
Standard toolkit

Standard toolkit on page 18.
91

Restoring the balancing device
The procedure below details how to restore the balancing device, i.e. removing the press tool
3HAC 15767-1.
Step
92
Action
Note/Illustration
1.
Refit the hydraulic cylinder to the press

tool, in case it has been removed.
Shown in the figure Press tool and

hydraulic cylinder on page 91!
2.
Press with the cylinder and the hydraulic Shown in the figure Press tool and
pump until the fix plate is movable again. hydraulic cylinder on page 91!
Turn the fix plate to position 0.
Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.
3.
Unload the cylinder and make sure the

moving pin indicates that the tool has
returned to its starting position.
4.
Remove the hydraulic cylinder.
5.
Remove the press tool by unscrewing the Shown in the figure Press tool and
bolts.
6.
Lubricate and refit the o-ring at the rear of

the balancing device.
7.
Refit the support shaft and the lubricated Make sure the o-rings are seated propo-ring.
erly!
8.
Refit the rear cover to the balancing

device with its attachment screws.
Shown in the figure Press tool and

4 pcs: M10x30, tightening torque: 50 Nm.

3HAC 16247-1

3.5.1 Removal of motor, axis 1
Section 3.5: Motors

Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below.
xx0200000200
Motor, axis 1
Motor attachment screws and washers
Required equipment
Equipment, etc.
Lifting tool, motor axis 1, 4, 5
3HAC 14459-1
Removal tool, motor M12
3HAC 14631-1 Always use the removal

tools in pairs!
Power supply
3HAC 16247-1
Note
24 VDC, 1.5 A.
Circuit Diagram
3HAC 13347-1 Included in Repair Manual, part 2.
Standard toolkit
3HAC 15571-1 The contents are defined

in section Standard toolkit on page 18!
93

Removal
The procedure below details how to remove motor, axis 1.

motors or gears!
is used!
Step Action
Note/Illustration
1. Remove the cover for connector access on

top of the motor by unscrewing its four attachment screws.
2. Remove the cable gland cover at the cable
exit by unscrewing its two attachment screws.
xx0200000199
A: Cable gland cover
Make sure the gasket is not damaged!

3. Disconnect all connectors beneath the motor
cover.
4. Apply lifting tool, motor axis 1, 4, 5 to the
motor.
5. In order to release the brakes, connect the 24 Connect to connector R2.MP1

VDC power supply.
+: pin 2
6. Remove the motor by unscrewing its four

attachment screws and plain washers.
-: pin 5
Shown in the figure Location of motor

on page 93!
7. If required, press the motor out of position by Art. no. specified in Required equipfitting removal tool, motor to the motor attachment on page 93!
ment screw holes.
Always use the removal tools in pairs!
8. Lift the motor to get the pinion away from the
gear and disconnect the brake release voltage.
9. Remove the motor by gently lifting it straight
up.
94
3HAC 16247-1

3.5.2 Refitting of motor, axis 1
Location of motor
below.
xx0200000200
Motor, axis 1
Required equipment
Equipment, etc.
Note
Motor, axis 1
3HAC 15879-1
Includes motor 3HAC 14673-6.

Includes pinion 3HAC 11350-1.
Includes o-ring 2152 2012-430.
O-ring
2152 2012-430 Must be replaced when reassembling motor!
Grease
3HAB 3537-1
Lifting tool, motor axis

1, 4, 5
3HAC 14459-1
Power supply
3HAC 16247-1
Used to lubricate the o-ring.
24 VDC, max. 1,5 A.

Circuit Diagram
3HAC 13347-1 Included in the Repair Manual,

part 2.
Standard toolkit
95

Equipment, etc.

See references to
these procedures in
the step-by-step
instructions below.
Refitting, motor
Note
The procedure below details how to refit motor, axis 1.

motors or gears!
is used!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of the Art no. specified in Required
motor is seated properly. Lightly lubricate the o- equipment on page 95!
ring with grease.
2.
Apply lifting tool, motor axis 1, 4, 5 to the motor. Art no. specified in Required
3.
In order to release the brake, connect the 24

VDC power supply.
Connect to connector R2.MP1

+: pin 2
-: pin 5
4.
Fit the motor, making sure the motor pinion is

properly mated to gearbox of axis 1.
Make sure the motor is turned

the right way, i.e. connections
forwards.
Make sure the motor pinion does
not get damaged!
5.
Secure the motor with four attachment screws

and plain washers.
M10 x 40, tightening torque: 50

Nm.
6.
Disconnect the brake release voltage.
7.
Reconnect all connectors beneath the motor

cover.
8.
Refit the cable gland cover at the cable exit with Make sure the cover is tightly
its two attachment screws.
sealed!
9.
Refit the motor cover with its four attachment

screws.
Make sure the cover is tightly

sealed!
10.
Detailed in "Calibration" in the

it is vital that:
96
3HAC 16247-1

3.5.3 Removal of motor axis 2
Location of motor
below.
B
D
A
xx0200000169
Motor axis 2
Hole for lock screw
Cable gland cover (located on the lower side of the motor)
Motor attachment holes (4 pcs)
Required equipment
Equipment etc.
Locking screw
3HAA 1001-266 M16 x 60.

Lifting tool, motor

axis 2, 3, 4
3HAC 15534-1
Power supply
3HAC 16247-1
Note
24 VDC, 1.5 A.
Removal tool, motor

M12
3HAC 14631-1
Always use the removal tools in

pairs!
3HAC 15521-2
For guiding the motor.

Guides are to be used in pairs!
97

Equipment etc.
Circuit diagram
3HAC 13347-1
Included in the Repair Manual,

part 2.
Standard toolkit
3HAC 15571-1

required. See references to these procedures in the stepby-step instructions
below.
Removal, motor
Note
The procedure below details how to remove the motor, axis 2.

motors or gears!
is used!
Step
Action
Note/Illustration
1.
Run the manipulator to a position close enough to Shown in the figure Location of
its calibration position, to allow the lock screw to motor on page 97!
be inserted into the hole for lock screw.
2.
Lock the lower arm by inserting the lock screw into Art. no. specified in Required
the hole.
3.
Drain the oil from gearbox, axis 2.
4.
Remove the cover on top of the motor by

unscrewing its four attachment screws.
5.
Remove the cable gland cover at the cable exit by Shown in the figure Location of
unscrewing its two attachment screws.
motor on page 97!
Make sure the gasket is not
damaged!
6.
Disconnect all connectors beneath the motor

cover.
7.
In order to release the brake, connect the 24 VDC Connect to connector R2.MP2
power supply.
+: pin 2
Detailed in "Oil change, gearbox axis 2" in the Maintenance

Manual.
8.
98
-: pin 5
Remove the motor by unscrewing its four attachment screws and plain washers.
3HAC 16247-1

Step
3HAC 16247-1
Action
Note/Illustration
9.
Fit the two guide pins in the two lower motor

attachment holes.

motor on page 97!
10.
If required, press the motor out of position by fitting removal tool, motor to the remaining motor
attachment holes.

motor on page 97!
pairs!
11.
Remove the removal tools and fit the lifting tool,

motor axis 2, 3, 4 to the motor.

12.
Lift the motor to get the pinion away from the gear. Make sure the motor pinion
does not get damaged!
13.
Remove the motor by gently lifting it straight out

and place it on a secure surface. Disconnect the
brake release voltage.
99

3.5.4 Refitting of motor axis 2
Location of motor
The motor, axis 2, is located on the left hand side of the manipulator as shown in the figure
below.
B
D
A
xx0200000169
Motor axis 2
Hole for lock screw
Cable gland cover (located on the lower side of the motor)
Required equipment
100
Equipment, etc.
Note
Motor axis 2, 175/

2.55
3HAC 15882-1

Includes o-ring 2152 2012-430
Motor axis 2, 225/

2.55, 175/2.8, 125/
3.2 and 200/2.75
3HAC 15885-1

O-ring
2152 2012-430
Must be replaced when reassembling motor!
Grease
3HAB 3537-1
For lubricating the o-ring!
Guide pin, M10 x

150
3HAC 15521-2

Guides are to be used in pairs!
Lifting tool, motor

axis 2, 3, 4
3HAC 15534-1
3HAC 16247-1

Equipment, etc.
Note
Power supply
24 VDC, 1.5 A.

pinion
3HAC 17105-1

when mating it to the gear, when
brakes are released with 24VDC
power supply.
Circuit diagram
3HAC 13347-1

part 2.
Standard toolkit
3HAC 15571-1

below.
Refitting, motor
The procedure below details how to refit the motor axis 2.

motors or gears!
is used!
Step
3HAC 16247-1
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art. no. specified in Required equipthe motor is seated properly. Lightly lubricate ment on page 100!
the o-ring with grease.
2.
In order to release the brake, remove the

cover on top of the motor and connect the 24
+: pin 2
VDC power supply.
-: pin5
3.
Fit the lifting tool, motor axis 2, 3, 4 to the

motor.
4.

attachment holes.

motor on page 100!
5.
Lift the motor and guide it on to the guide pins,

as close to the correct position as possible
without pushing the motor pinion into the gear.
See that the motor is turned the right direction,
i.e. the cables facing downwards.
101

Step
Action
Note/Illustration
6.
Remove the lifting tool and allow the motor to

rest on the guide pins.
7.
Use the rotation tool in order to rotate the

Art. no. specified in Required equipmotor pinion when mating it to the gear (see ment on page 100!
figure beside).
Fit the motor, making sure the motor pinion is
A
properly mated to the gear of gearbox axis 2
and that it doesnt get damaged.
xx0200000165
The rotation tool is used beneath

the motor cover, directly on the
motor shaft as shown in figure
above.
A: Rotation tool
8.
9.
Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
and plain washers.
Reused screws may be used, providing they are lubricated as
detailed in Screw joints on page 15
before fitting.
10.
Remove the lifting tool.
11.
12.

cover.
Connect in accordance with markings on connectors.
13.
Refit the cable gland cover at the cable exit

with its two attachment screws.

motor on page 100!
14.
Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
15.
Remove the lock screw from the hole for lock Shown in the figure Location of
screw.
motor on page 100!
16.
Perform a leak down test.
Detailed in Performing a leak-down

test on page 21.
17.
Detailed in "Oil change, gearbox

18.

it is vital that:
102
3HAC 16247-1

Location of motor
below.
A
B
C
xx0200000186
Motor, axis 3
Cable gland cover, motor axis 3
Attachment screws and washers (4 pcs)
Required equipment
Equipment, etc.
Power supply
3HAC 16247-1
Note
24 VDC, 1.5 A.
Removal tool, motor

M12
3HAC 14631-1

pairs!
3HAC 15521-2

Always use guide pins in pairs.
Mech stop axis 3
3HAC 12708-1
Used to fix axis 3 (one method of

three, see step one in the
removal procedure).
Use attachment screws 3HAB
3409-86 (M16 x 60).
Washers for Mech

stop axis 3
3HAA 1001-186
Circuit Diagram
3HAC 13347-1

part 2.
103

Equipment, etc.
Standard toolkit
Note
3HAC 15571-1

below.
Removal, motor

motors or gears!
is used!
Step
1.
Action
Note/Illustration
Unload the manipulator upper arm by either:

Use a fork lift to rest the upper arm
onto.
Use lifting slings and an overhead

crane to rest the upper arm.
Use a mechanical stop to rest the

upper arm. Fit the mechanical stop in
the attachment hole (A) with tightening
torque: 115 Nm.
B
A
xx0300000051
The upper arm must be positioned as horizon- Fit the mechanical stop to the third
tal as possible!
and final attachment hole (A),
below the fixed stop (B) in the upper
arm. See the figure above!
104
2.
3.
Remove any equipment hindering access to

motor axis 3.
4.

5.
Remove the cable gland cover at the cable

exit by unscrewing its two securing screws.
6.

cover.


motor on page 103!
3HAC 16247-1

Step
Action
Note/Illustration
7.
Release the brake by connecting the 24 VDC Connect to connector R2.MP3

power supply.
+: pin 2
Make sure the weight of the complete upper
-: pin 5
arm rests safely on the mechanical stops, the
fork lift or the lifting slings before removing the
motor.
8.
Unscrew the motors four attachment screws

and plain washers .

motor on page 103!
9.

attachment screw holes.
10. Press the motor out of position by fitting

removal tool, motor to the motor attachment
screw holes.

pairs!
11. Apply the lifting tool, motor axis 2 ,3, 4 to the

motor.
12. Lift the motor to get the pinion away from the
gear.
13. Remove the motor by gently lifting it straight
Make sure the motor pinion is not
out and disconnect the brake release voltage. damaged!
3HAC 16247-1
105

Location of motor
below.
A
B
C
xx0200000186
Motor axis 3
Required equipment
106
Equipment, etc.
Note
Motor axis 3, 175/

2.55
3HAC 15882-1

Motor axis 3, 225/

2.55, 175/2.8, 125/
3.2 and 200/2.75
3HAC 15885-1

O-ring
Grease
3HAB 3537-1
3HAC 15521-1 For guiding the motor.

pinion
3HAC 17105-1 Used to rotate the motor pinion

brakes are released with 24 VDC
power supply.
For lubricating the o-ring.
3HAC 16247-1

Equipment, etc.
Note
Power supply
24 VDC, max. 1.5 A.

Circuit Diagram

part 2.
Standard toolkit

below.
Refitting, motor

motors or gears!
is used!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of the motor is seated properly.
Lightly lubricate it with grease .

on page 106!
2.
Fit the lifting tool, motor axis 2, 3, 4 to the Art no. specified in Required equipment
motor.
on page 106!
3.
Fit the two guide pins in the two lower

motor attachment holes.
4.
Lift the motor and guide it onto the guide

pins, as close to the correct position as
possible without pushing the motor pinion
into the gear.
5.
Remove the lifting tool and allow the

motor stay on the guide pins.
6.
In order to release the brake, connect the Connect to connector R2.MP3

+: pin 2

on page 106!
on page 106!
3HAC 16247-1
-: pin 5
107

Step
7.
Action
Note/Illustration

motor pinion when mating it to the gear!
Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 3.

on page 106!
Make sure the motor pinion does not
get damaged!
Make sure the motor is turned the right
direction, i.e. the cables facing forwards.
xx0200000165

A: Rotation tool.
8.
9.
Secure the motor with four attachment

screws and plain washers.
10.
11.
Reconnect all connectors beneath the

motor cover.
Connect in accordance with markings

on connectors.
12.
Refit the cable gland cover at the cable

exit with its two attachment screws.
Make sure the cover is tightly sealed!

on page 106!
13.
Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
14.
Remove the equipment used to unload

the upper arm:
Fork lift
Lifting slings
Mech stop
4 pcs: M10 x 40, tightening torque: 50

Nm.
15.
16.

17.
it is vital that:
108
3HAC 16247-1

Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
A
B
xx0200000202
Motor, axis 4
Required equipment
Equipment, etc.
Power supply
24 VDC, 1.5 A.
Removal tool, motor

M10
3HAC 14972-1 Always use the removal tools in

pairs!
Guide pin, M8 x 150

Always use the guide pins in
pairs.
Circuit Diagram

part 2.
Standard toolkit

below.
3HAC 16247-1
Note
109

Removal, motor

motors or gears!
is used!
Step
Action
Note/Illustration
1.
Run the robot to a position where the upper arm

is pointed straight up.
This position enables the motor to be replaced
without draining the gear oil, which in turn saves
time.
2.
Remove the cable gland cover at the cable exit Shown in the figure Location of
of the motor by unscrewing its two attachment
motor on page 109!
screws.
3.

4.

cover.
5.

VDC power supply.

+: pin 2
110
-: pin 5
6.
Unscrew the motors four attachment screws and Shown in the figure Location of
plain washers.
motor on page 109!
7.
Fit the two guide pins, M8 in two of the motor

8.
If required, press the motor out of position by fit- Art. no. specified in Required
ting removal tool, motor M10 to the motor attach- equipment on page 109!
ment screw holes.
pairs!
9.
Lift the motor to get the pinion away from the

gear and disconnect the brake release voltage.
10.
Remove the motor by gently lifting it straight out. Make sure the motor pinion is not
damaged!
3HAC 16247-1

Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
A
B
xx0200000202
Motor, axis 4
Required equipment
Equipment, etc.
Note
Motor axis 4, 175/

2.55
3HAC 15887-1

Motor axis 4, 225/

2.55, 175/2.8, 125/
3.2 and 200/2.75
3HAC 15889-1

O-ring
Grease
3HAC 3537-1
Used to lubricate the o-ring.
Guide pin, M8 x 100
3HAC 15520-1
Guide pin, M8 x 150
3HAC 15520-2

pinion
3HAC 17105-1

brakes are released with 24 VDC
power supply.
Power supply
24 VDC, max. 1,5 A.

Circuit Diagram
3HAC 16247-1
3HAC 13347-1

part 2.
111

Equipment, etc.
Standard toolkit
Note
3HAC 15571-1

below.
Refitting, motor

motors or gears!
is used!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference Art. no. specified in Required equipof the motor is seated properly. Lightly lubri- ment on page 111!
cate the o-ring with grease .
2.
In order to release the brakes, connect the Connect to connector R2.MP4

+: pin 2
112
-: pin 5
3.
Fit the two guide pins, M8 in two of the

motor attachment holes.

on page 111!
4.
Fit the motor, with guidance of the pins,

making sure the motor pinion is properly
mated to the gear of gearbox 4.

get damaged!
3HAC 16247-1

Step
5.
Action
Note/Illustration

motor pinion when mating it to the gear!
Fit the motor, making sure the motor pinion
is properly mated to the gear, axis 4.

get damaged!
Make sure the motor is turned the right
direction, i.e. the cables facing forwards.
xx0200000165

A: Rotation tool.
6.
7.
Secure the motor with four attachment

8.
9.
Reconnect all connectors beneath the

motor cover.
10. Refit the cover on top of the motor with its

11.

Nm.
Refit the cable gland cover at the cable exit Shown in the figure Location of motor
on page 111!
12. Perform a leak-down test if gearbox has

been drained.
13. Refill the gearbox with oil if drained.
Detailed in "Oil change, axis 4 gearbox" in the Maintenance Manual.
it is vital that:
3HAC 16247-1
113

Location of motor
The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
xx0200000204
Motor, axis 5
Upper arm tube
Wrist unit
Required equipment
Equipment, etc.
Power supply
24 VDC, 1.5 A.
3HAC 14972-1 Always use the removal tools

in pairs!
Measuring tool
6896 134-GN
Guide pin, M8 x 100

motor
Guide pin, M8 x 150

motor
Nipple
6896 134-AA
TREDO-washer
114
Note
For pressing out the pinion,

motor 5.
Use as a seal when pressing
out the pinion, motor 5.
Nipple
6896 901-282

motor 5.
Oil injector
6369 901-280

motor 5.
Circuit Diagram
3HAC 13347-1 Included in the Repair Manual, part 2
3HAC 16247-1

Equipment, etc.
Standard toolkit
Note

page 18!

below.
Removal, motor

required.

motors or gears!
is used!
Step
Action
Note/Illustration
1.

2.
Remove the wrist unit.
Detailed in section Removal of complete

wrist unit on page 47.
3.
Place the wrist unit safely on a workbench, in a fixture or similar.
4.

5.
Remove the cable gland cover at the

cable exit by unscrewing its two attachment screws.
6.
Disconnect all connectors beneath the

motor cover and remove the separate
cable of the axis 5 motor.
7.
In order to release the brake, connect the Connect to either:

- connector R4.MP5 (in the motor):
+ : pin 2
- : pin 5
- connector R3.MP5 (on the separate

cable, if not removed):
+: pin C
3HAC 16247-1
-: pin D
8.
Remove the motor by unscrewing its four

attachment screws and plain washers.
9.
Fit the two guide pins in two of the motor Art. no. specified in Required equipment
on page 114!
115

Step
116
Action
Note/Illustration
10.
If required, press the motor out of position Art. no. specified in Required equipment
by fitting removal tool, motor, M10 to the on page 114!
motor attachment screw holes.
Always use the removal tools in pairs
and diagonally!
11.
Lift the motor to get the pinion away from Make sure the motor pinion is not damthe gear and disconnect the brake
aged!
release voltage.
12.
Remove the motor by gently lifting it

straight out.
13.
Measure the distance between the motor Art. no. specified in Required equipment
flange, included eventual shims, and the on page 114!
outer surface of the pinion, with measur- Make a note of the distance.
ing tool.
14.
Press out the pinion from the dismounted

motor, with equipment specified in table
above.
The pinion is matched with the beveral
gear for axis 5. When the motor is
replaced the pinion must be removed
from the dismounted motor and mounted
onto the new motor shaft.
If the pinion is damaged the complete
wrist unit must be replaced!
Keep track of the shims between the

motor flange and the wrist housing.
Replacing the complete wrist unit is

detailed in sections Removal of complete wrist unit on page 47 /Refitting of
complete wrist unit on page 50.
3HAC 16247-1

Location of motor
The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
xx0200000204
Motor, axis 5
Upper arm tube
Wrist unit
Required equipment
Equipment, etc.
3HAC 16247-1
Note
Motor axis 5, 175/2.55 3HAC 14673-7
Does not include pinion. Use the

pinion from the motor to be
replaced.
Motor axis 5, 225/

3HAC 14673-10
2.55, 175/2.8, 125/3.2
and 200/2.75
Does not include pinion. Use the

pinion from the motor to be
replaced.
Set of shim, motor
3HAC 7941-28 Used to obtain the correct distance between motor flange and
outer surface of motor pinion.
O-ring
2152 2012430
Must be replaced when reassembling motor!
Grease
3HAC 3537-1
For lubricating the o-ring.
Isopropanol
1177 1012-208 For cleaning motor pinion and

motor pinion hole.
Mineral oil
CS 320
For lubrication of pinion shaft and

pinion hole.
Press fixture
3HAC 4850-1
For pressing the pinion on to the

new motor.
117

Equipment, etc.
Note
Measuring tool
6896 134-GN
Guide pin, M8 x 100
Guide pin, M8 x 150
Power supply
24 VDC, 1.5 A.
Circuit Diagram

part 2.
Standard toolkit

below.
Refitting, motor

Motors and gears are HOT after running the robot! Burns may result from touching the motors
or gears!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.
is used!
Step
118
Action
Note/Illustration
1.
Make sure the o-ring on the circumference Art. no. specified in Required equipof the motor is seated properly. Lightly lubri- ment on page 117!
cate the o-ring with grease.
2.
Clean the motor pinion and the motor pinion Art. no. specified in Required equiphole in the motor, with isopropanol.
ment on page 117!
3.
Apply a thin film of mineral oil to the pinion Art. no. specified in Required equipshaft and the pinion hole in order to make
ment on page 117!
the pinion run smoothly and to achieve an
even friction torque when assembling the
pinion.
4.
Place the motor and pinion in the press fixture.
5.
Press the pinion onto the new motor and

check the pressing force.
For an axis diameter of 15.5 mm, use min.
pressing force: 18.5 kN and max. pressing
force: 39.5 kN.
If the pressing force is outside the

given range or if the pinion "jumps" in
bit by bit, it must be dismounted,
checked, cleaned and oiled before it
is assembled once again!
3HAC 16247-1

Step
Action
Note/Illustration
6.
Measure the distance between the motor

flange and the outer surface of the pinion
with the measuring tool.
Modify the distance with shims in order to
obtain the same distance as measured
when dismounting the old motor (+ 0-0,05
mm).
7.
In order to release the brake, connect the 24 Connect to either:

VDC power supply.
- connector R4.MP5 (in the motor):
+: pin 2
-: pin 5
- connector R3.MP5 (on the separate

cable, if not removed):
+: pin C
- : pin D
8.
Fit the two guide pins in two of the motor

attachment holes.
9.
Fit the motor, with guidance from the pins,

mated to the gear of axis 5.

get damaged!
10. Secure the motor with four attachment

11.
4 pcs: M8 x 25; tightening torque: 24

Nm.
12. Refit the separate cable of the axis 5 motor

and reconnect all connectors beneath the
motor cover.
13. Refit the cable gland cover at the cable exit
14. Refit the cover on top of the motor with its
15. Refit the wrist unit.
Detailed in section Refitting of complete wrist unit on page 50.
16. Perform a leak-down test.

test on page 21.
17. Refill the gear with oil.

it is vital that:
3HAC 16247-1
119

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0200000222
Wrist unit
Motor, axis 6
Required equipment
Equipment, etc.
Power supply
120
Note
24 VDC, 1.5 A.
3HAC 14972-1 Always use the removal tools

in pairs!
Circuit Diagram
3HAC 13347-1 Included in the Repair Manual, part 2.
Standard toolkit

page 18!
3HAC 16247-1

Equipment, etc.

below.
Removal, motor
Note
The procedure below details how to remove the motor, axis 6.

motors or gears!
is used!
Step
Action
Note/Illustration
1.
Run the robot to a position where the motor in axis

6 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
2.
Remove the rear motor cover by unscrewing six

attachment screws.
3.
Disconnect all connectors beneath the cover.
4.
In order to release the brake, connect the 24 VDC Connect to connector R3.MP6
power supply.
+: pin 2
3HAC 16247-1
-: pin 5
5.
Remove the motor by unscrewing its four attachment screws and plain washers.
6.
If required, press the motor out of position by fitting Art. no. specified in Required
removal tool, motor to the motor attachment screw equipment on page 120!
holes.
Always use the removal tools
in pairs!
7.
Lift the motor carefully to get the pinion away from Make sure the motor pinion is
the gear and disconnect the brake release voltage. not damaged!
8.
Remove the motor by gently lifting it straight out.
121

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0200000222
Wrist unit
Motor, axis 6
Required equipment
Equipment, etc.
122
Note
Motor axis 6, 175/2.55 3HAC 15990-1

Motor axis 6, 225/

3HAC 15991-1
2.55, 175/2.8, 125/3.2
and 200/2.75

O-ring
Guide pin, M8 x 100
3HAC 15520-1
Guide pin, M8 x 150
3HAC 15520-2
3HAC 16247-1

Equipment, etc.
Note
Power supply
24 VDC, 1.5 A.
Grease
3HAB 3537-1
For lubricating the o-ring
Circuit Diagram
3HAC 13347-1
Included in Repair Manual, part

2.
Standard toolkit
3HAC 15571-1

below.
Refitting, motor

motors or gears!
is used!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art. no. specified in Required equipthe motor is seated properly. Lightly lubricate ment on page 122!
2.

VDC power supply.

+: pin 2
3HAC 16247-1
-: pin 5
3.
Fit the two guide pins in two of the motor

attachment holes.
4.
Fit the motor, with guidance from the pins,

mated to the gear of gearbox, axis 6.
Make sure the pinion on the motor

shaft is not damaged!
5.
6.
Secure the motor with four attachment screws 4 pcs: M8 x 25, tightening torque:
and plain washers.
24 Nm.
7.
8.

cover.
9.
Refit the cover on top of the motor with its six Make sure the cover is tightly
attachment screws.
sealed!
10.

123

it is vital that:
124
3HAC 16247-1

3.6.1 Removal of gearbox, axis 1
Section 3.6: Gearboxes

Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
Base incl. Frame on page 203.
xx0300000015
Gearbox, axis 1
Frame
Base
Attachment screws, base to gearbox (not shown in figure)
Required equipment
Equipment, etc.
3HAC 16247-1
Note
Standard toolkit

page 18!
Support, base and gear 1
3HAC 15535-1
Lifting device, base and

gear 1
3HAC 15560-1
3HAC 15556-1
125

Equipment, etc.
Note

Removal, gearbox

required.
The procedure below details how to remove gearbox, axis 1.
motors or gears!
is used!
The gear box weighs 155 kg! All lifting equipment used must be dimensioned accordingly!
The base (without gearbox 1) weighs 263 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Note/Illustration
Move the robot to its most stable

position, shown in the figure to the
right.
xx0300000022
126
2.
Drain the oil from gearbox 1.
3.
Disconnect all cabling in the rear of

the manipulator base and remove
the cable support plate underneath
the inside of the base.
4.
Pull the disconnected cabling up

through the center of gearbox 1.
5.
Remove the complete arm system. Detailed in section Removal of complete arm
system on page 36.
Detailed in "Oil change, gearbox, axis 1" in the

Maintenance Manual.
3HAC 16247-1

Step
Action
Note/Illustration
6.
Remove the manipulators attachment screws to unfasten the base

from the foundation.
7.
Attach the lifting device, base and

gear 1 and theand lifting tool
(chain) , to the gearbox.

page 125!
8.
Lift the manipulator base to allow

fitting the support, base and gear 1
on each sides of the base.

page 125!
9.
Fit the support, base.

Make sure the base remains in a
stable position before performing
any work underneath the base!
10.
Unscrew the 18 attachment screws

(B), and remove the 3 washers (C),
shown in the figure to the right.
A
B
C
xx0200000227
A view from below.

A: Oil drain hose
11.
B: Gearbox 1 attachment screws, 18

pcs
C: Washers, 3 pcs
Remove the cable guide in the center of gearbox 1 by unscrewing its

attachment screws.
xx0200000256
12.
3HAC 16247-1
A: Location for attachment screws,

cable guide (cable guide removed in
figure)
Lift the gearbox away with the

already mounted lifting tools.
127

3.6.2 Refitting of gearbox, axis 1
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component may be found in Foldout section Base incl. Frame on
page 203.
xx0300000015
Gearbox, axis 1
Frame
Base
Attachment screws, base to gearbox (not shown in figure)
Required equipment
128
Equipment, etc.
Note
Gearbox, axis 1
3HAC 10828-8
Includes gearbox 3HAC

10828-3.
Includes all o-rings and sealing
rings!
O-ring
3HAB 3772-54
Replace only when damaged!
O-ring
3HAB 3772-55
Sealing ring
3HAC 11581-4
Grease
3HAC 3537-1
For lubricating the o-rings
Support, base and

gear 1
3HAC 15535-1
3HAC 16247-1

Equipment, etc.
Note
Lifting device, base

and gear 1
3HAC 15560-1
3HAC 15556-1
Standard toolkit
3HAC 15571-1
Other tools may be

required as detailed in
sections to which references are made!
Refitting, gearbox

page 18!
The procedure below details how to refit gearbox, axis 1.

motors or gears!
is used!
The base (without gearbox 1) weighs 263 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
3HAC 16247-1
Action
Note/Illustration
If the base is not supported with Support, Mounting of the Support, base and
base and gear 1, this should be done first. gear 1 is detailed in section Removal of
gearbox, axis 1 on page 125.
129

Step
2.
Action
Note/Illustration
Make sure the two o-rings (C, D) on the cir- Art no. specified in Required equipcumference of the gearbox are seated
ment on page 128!
properly in their grooves respectively.
Lightly lubricate the o-rings with grease .
Make sure the small o-ring around the oil
hole is fitted properly!
A
D
C
xx0200000055
3.
A: Guide pin
C: O-ring 3HAB 3772-54
D: O-ring 3HAB 3772-55
E: Sealing ring 3HAC 11581-4
Refit the cable guide in the center of gearbox 1 with its attachment screws.
xx0200000256
130
A: Location for attachment

screws, cable guide (cable
guide removed in figure)
4.
Fit the lifting device, base and the lifting tool Art no. specified in Required equip(chain) to the gearbox.
ment on page 128!
5.
Lift the gearbox to its mounting position in

the center of the base.
6.
Make sure the guide pin in the bottom face Shown in the figure xx0200000055
of the gearbox is properly aligned with the above!
base.
3HAC 16247-1

Step
7.
Action
Note/Illustration
Secure the gearbox and the three washers M16 x 70, 12.9 quality UNBRAKO,
with the 18 attachment screws, base to
gearbox (B).
"Screw joints" before fitting.
A
B
C
xx0200000227
A view from below.

A: Oil drain hose
8.
Lift the manipulator base and gearbox 1 to

allow removing the support, base and gear.
9.
Secure the base to the mounting site.
10. Refit the complete arm system.
11.
B: Attachment screws, base to

gearbox, 18 pcs
C: Washers, 3 pcs
Detailed in "Orienting and securing the

manipulator" in the Installation Manual.
Detailed in section Refitting of complete arm system on page 39.
This is a complex task to be performed
with utmost care in order to avoid injury
or damage!
Refit the cable support plate underneath

the inside of the base and reconnect the
cabling in the rear of the manipulator base.
12. Perform a leak-down test.

test on page 21.
13. Refill the gearbox with oil.

it is vital that:
3HAC 16247-1
131

3.6.3 Removal of gearbox axis 2
Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The service work differ some between the designs. Be aware of the differences made in the
instruction.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
Frame-Lower arm 1 on page 205.
D
A
C
G
xx0200000171
132
Gearbox axis 2 (behind motor attachment, not shown in figure )
Attachment hole for locking screw, lower arm
Attachment holes inside of frame for fixture lower arm
Attachment holes for fixture lower arm
Balancing device
Motor axis 2
Rear gearbox attachment screws
3HAC 16247-1

Attachment screws, motor attachment
Additional cover
Motor attachment
Required equipment
Equipment etc.
Fixture, lower arm
3HAC 13659-1
Locking screw, lower

arm
3HAA 1001-266 M16 x 60.

Accompanying the fixture.
Lifting tool, gearbox

axis 2
3HAC 13698-1
3HAC 13056-2
For guiding the gearbox.
3HAC 13056-4

device
3HAC 15767-1
Hydraulic cylinder
3HAC 11731-1
To be used with the press tool

and the hydraulic pump, when
unloading the balancing
device.
Hydraulic pump
3HAC 13086-1
To be used with the press tool

and the hydraulic cylinder,
when unloading the balancing
device.
Standard toolkit
3HAC 15571-1

page 18!

below.
Removal, gearbox
Note
Includes locking screw for
securing the lower arm.
The procedure below details how to remove the gearbox, axis 2.
motors or gears!
is used!
3HAC 16247-1
133

Step
Action
Note/Illustration
1.
Remove any equipment fitted to the turning

disk.
2.
Run the robot to the calibration position. The

upper arm can be directed in three different
ways, shown in the figure to the right.
The lowered position, as in figure A, is recommended as it gives the least load on the
tool.
A
C
xx0200000260
3.
If the manipulator is fitted with moveable

mechanical stops on axis 2 (not stock equipment), these must be removed at this point.
The attachment holes of the mechanical
stops are used to attach the fixture, lower
arm.
4.
The locking screw for the lower arm is

attached to the fixture tool, remove it from
there (positioned as A in figure below).
Secure the lower arm to the frame by inserting the locking screw into a specific attachment hole.
5.
Fit the fixture, lower arm to prevent the lower

arm from falling.
Make sure that both adjusters (B) on
the fixture are screwed back.

Shown in the figure Location of gearbox on page 132!

Attachment holes for the fixture are
shown in the figure Location of gearbox on page 132!
Align the fixture with the frame and
Make sure the fixture is pressed
lower arm.
tightly against the lower arm before
Tighten the four M16 bolts (C) on the
securing with screws!
inside of the frame, in attachment
E
A B D
holes , with tightening torque: 220
Nm.
Screw in the two adjusters (B) until

they rest against the flats on the
lower arm. Tighten by hand.
Lock, using the two ring nuts (D).
Tighten the two M12 bolts (E) in the

attachment holes, fixture lower arm
with tightening torque: 91 Nm.
C
xx0200000261
134
A: Locking screw, lower arm
B: Adjusters
C: M16 bolts (4 pcs)
D: Ring nuts (2 pcs)
E: M12 bolts (2 pcs)
3HAC 16247-1

Step
Action
Note/Illustration
6.
Unload the balancing device shaft by using

press tool, balancing device.

Detailed in section Unloading the balancing device on page 89!
7.
Drain the gearbox, axis 2.
Notice! Time-consuming activity!

2" in Maintenance Manual.
8.
Detailed in section Removal of motor

axis 2 on page 97.
9.
Remove the 33 rear gearbox attachment

screws from inside the lower section of the
lower arm.
10. Remove the motor attachment.

In the early design this is done by unscrewing the 24 front gearbox attachment screws.
In the later design this is done by unscrewing the 15 attachment screws, motor attachment.
Read more about the variations in

design in Different designs on page
132.
11. If the robot is equipped with the later design

of the motor attachment; now remove the 24
front gearbox attachment screws (C), shown
xx0200000166
A: Holes for guide pins, sealing ax 2/3
B: Rear gearbox attachment

screws (33 pcs)
C: Front gearbox attachment

screws (24 pcs)
12. Fit two guide pins in 180relation to each

Art. no. specified in Required equipother in the empty holes of the front gearbox ment on page 133!
attachment screws.
3HAC 16247-1
135

Step
Action
Note/Illustration
13. If required, apply two M12 screws to the

holes (A), shown in the figure to the right, to
press it free.
A
xx0200000172
A: M12 holes for pressing the

gearbox out.
14. Fit the lifting tool, gearbox axis 2 to the gear- Art. no. specified in Required equipbox.
ment on page 133!
15. Remove the gearbox axis 2 using an overhead crane or similar, with guidance from the
mounted guide pins.
16. Remove the friction washer and clean it.
17. Remove the sealing from the lower arm.
136
3HAC 16247-1

3.6.4 Refitting of gearbox axis 2
Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The service work differ some between the designs. Be aware of the differences made in the
instruction.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
A more detailed view of the gearbox may be found in the Foldout section Frame-Lower arm
1 on page 205.
D
A
C
G
xx0200000171
3HAC 16247-1
Gearbox axis 2 (behind motor attachment, not shown in figure )
Attachment hole for locking screw, lower arm
Attachment holes inside of frame for fixture, lower arm
Attachment holes for fixture, lower arm
Balancing device
Motor axis 2
Rear gearbox attachment screws
137

Attachment screws, motor attachment
Additional cover
Motor attachment
Required equipment
Equipment
Note
Gear, axis 2
3HAC 10828-12
Includes gearbox 3HAC 1082811 and all o-rings!

Does not include "Sealing, axis
2/3"!
O-ring
3HAB 3772-68 2 pcs
O-ring
3HAB 3772-69 O-rings in the additional cover.

3HAB 3772-70 Should be replaced if damaged!
Sealing, axis 2/3
3HAC 12443-2 A new sealing must be used on

each assembly!
Grease
3HAB 3537-1
Lifting tool, gearbox

axis 2
3HAC 13698-1
3HAC 13056-2
3HAC 13056-3
Guide pin, sealing

axis 2/3, 80 mm
3HAC 14628-1 For guiding the sealing!
Guide pin, sealing

axis 2/3, 100 mm
3HAC 14628-2 For guiding the sealing!
Gearbox crank
3HAC 16488-1 Used to turn the gear in correct

position.
Standard toolkit

below.
Refitting, gearbox
For lubricating o-rings.
The procedure below details how to refit gearbox axis 2.

motors or gears!
is used!
138
3HAC 16247-1

Step
1.
Action
Note/Illustration
Make sure the both o-rings (A) are fitted to

the gearbox as shown in the figure to the
right. Lightly lubricate them with grease.
xx0200000173
2.
Fit the lifting tool, gearbox axis 2 to the

gearbox.
3.
Fit the guide pins, sealing axis 2/3 on the

gearbox, axis 2.
Use the attachment holes (A) shown in the
figure to the right!
A: O-rings (2 pcs), gearbox

axis 2.
xx0200000166
3HAC 16247-1
A: Holes for guide pins, sealing axis 2/3 on the gearbox.
B: The gearboxes rear attachment screws (33 pcs)
C: The gearboxes front

attachment screws (24 pcs)
139

Step
140
Action
Note/Illustration
4.
Fit the new sealing, axis 2/3 on the gearArt. no. specified in Required equipbox, axis 2, and on to the guide pins.
ment on page 138!
Do not remove the guide pins for the sealing
until the rear gearbox attachment screws
are secured.
5.
Fit two guide pins, M12 in 180relation to Art. no. specified in Required equipeach other in the frame, in the screw holes ment on page 138!
for the gearboxes front attachment screws.
6.
Fit the cleaned friction washer onto the

guide pins, M12.
7.
Lift the gearbox to its mounting position and

slide it onto the guiding pins attached in the
frame, through the front attachment screw
holes.
8.
Align the gearbox attachment screw holes

to the hole patterns in the lower arm, with
help from the guide pins, sealing axis 2/3.
If necessary, use a gearbox crank to turn
the gear!
Use the gearbox crank with caution! The
gearbox may be damaged if the crank is
inserted too far into the gear!
9.
Fit the gearbox with guidance from the

guide pins and slide it into position.
If necessary, use the front gearbox attachment screws to press the gearbox into
place.
10.
Remove the lifting tool from the gearbox

Choose correct instruction depending
and continue refitting the motor attachment on which motor attachment the robot
as described below.
is equipped with. Read more about
the variations in Different designs on
page 137.
11.
Early design of motor attachment: Lift the

motor attachment and slide it on to the
guide pins.
If necessary, use a plastic mallet to knock
the motor attachment into place.
12.
Insert and secure 22 of the 24 front gearbox Shown in the figure xx0200000166
attachment screws.
above!
13.
Remove the guide pins, M12 and tighten the

two remaining screws as detailed above.
14.
Later design of the motor attachment:

Art. no. specified in Required equipLubricate the o-ring at the rear of the motor ment on page 138!
attachment with grease.
Replace if damaged.
15.
Later design of the motor attachment:

Refit the motor attachment by pressing it
against the frame.
16.
Later design of the motor attachment: Refit Shown in the figure Location of gearthe attachment screws, motor attachment. box on page 137.
Nm.
3HAC 16247-1

Step
Action
Note/Illustration
17.
Insert and secure 31 of the 33 rear gearbox Shown in the figure Location of gearattachment screws on the inside of the
box on page 137!
lower arm.
M12 x 50, 12.9 quality UNBRAKO,
18.
Remove the guide pins, sealing axis 2/3,

and tighten the two remaining screws as
detailed above.
19.
Refit the motor.
Detailed in section Refitting of motor

axis 2 on page 100.
20.
21.

22.
Detailed in section Restoring the balancing device on page 91!
23.
Remove the fixture, lower arm.
24.
Remove the locking screw, lower arm, and

re-attach it to the fixture tool.
25.
Refit any mechanical stops if such were

removed during disassembly.
26.
Refit any equipment to the turning disc if

such was removed during disassambly.
27.
it is vital that:
3HAC 16247-1
141

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
xx0200000194
Gearbox, axis 3 (sealing, axis 2/3 between lower arm and gearbox 3)
Motor, axis 3
Upper arm
Gearbox attachment screws (24 pcs)
Required equipment
Equipment, etc.
142
Mech stop axis 3
3HAC 12708-1
Washers for Mech

stop axis 3
3HAA 1001-186
Note
Used to secure the upper arm.
Use attachment screws 3HAB
3409-86 (M16 x 60).
3HAC 16247-1

Equipment, etc.
3HAC 13056-3

Guides are to be used in pairs.
3HAC 13056-4

Lifting eye, M12
3HAC 14457-3
Standard toolkit
3HAC 15571-1

below.
Removal, gearbox
Note

motors or gears!
is used!
Step
1.
Action
Note/Illustration
Secure the upper arm in a horizontal posi- Art. no. specified in Required equiption using a mechanical stop.
ment on page 142.
Fit the mechanical stop to the third and
final attachment hole (A), below the fixed
mechanical stop (B) in the upper arm,
shown in the figure to the right.
Tightening torqure: 115 Nm.
B
A
xx0300000051
3HAC 16247-1
2.
Detailed in section Removal of motor,

axis 3 on page 103.
Note! When removing the motor axis
3, the brake on axis 3 is released. Make
sure the upper arm is secured and
enabled to move!
3.
Remove the upper arm.
Detailed in section Removal of upper

arm on page 54.
143

Step
Action
Note/Illustration
4.
Remove the sealing, axis 2/3 between

gearbox and lower arm.
On reassembly a new sealing must be

used!
5.
Place the upper arm safely on a workbench, in a fixture or similar.
6.
Remove the gearbox attachment screws.
7.
Fit the two guide pins, M12 in 180relation Art. no. specified in Required equipto each other in the gearbox attachment ment on page 142!
screw holes.
8.
If required, apply M12 screws to the holes

(A) shown in the figure to the right to press
the gearbox free.
Shown in the figure Location of gearbox

on page 142!
xx0200000201
144
9.
Fit the lifting eye, M12 to the gearbox, in

one of the upper attachment screw holes
that attaches the gearbox to the lower
arm.
10.
Remove the gearbox, with guidance from

the guide pins, using an overhead crane or
similar.
A: M12 holes for pressing the

gearbox out
B: Gearbox attachment screw

holes
C: Upper attachment screw

holes, gearbox - lower arm
3HAC 16247-1

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
xx0200000194
Gearbox, axis 3 (sealing, axis 2/3 between lower arm and gearbox 3)
Motor, axis 3
Upper arm
Gearbox attachment screws
Required equipment
Equipment, etc.
Note
Gearbox, axis 3
3HAC 10828-12
Includes gearbox 3HAC

10828-11
Includes all o-rings!
Does not include "Sealing, axis
2/3"!
O-ring
3HAC 16247-1
3HAB 3772-68 2 pcs.
145

Equipment, etc.
Note
Grease
3HAB 3537-1
Sealing, axis 2/3
3HAC 12443-2 A new sealing must be used on

each assembly!
Lifting eye, M12
3HAC 14457-3
3HAC 13056-3 For guiding the gearbox.

3HAC 13056-4 For guiding the gearbox.

Guide pin, sealing axis

2/3, 80 mm
3HAC 14628-1 For guiding "Sealing, axis 2/3".

Guide pin, sealing axis

2/3, 100 mm
3HAC 14628-2 For guiding "Sealing, axis 2/3".

Standard toolkit

page 18!

below.
Refitting, gearbox
For lubricating the o-rings.

motors or gears!
is used!
Step
146
Action
Note/Illustration
1.
Turn the upper arm in such a position that

the gear mating surface faces upwards.
2.
Fit two guide pins in 180relation to each

Art. no. is specified in Required equipother in the gearbox attachment holes in the ment on page 145!
upper arm.
3.
Fit the lifting eye, M12 to the gearbox.
Art. no. is specified in Required equipment on page 145!
3HAC 16247-1

Step
4.
Action
Note/Illustration
Make sure the o-rings are fitted to the gear- Art. no. is specified in Required equipbox. Apply grease to the o-rings to make
ment on page 145!
sure they stick in their grooves during
A
assembly.
xx0100000136
A: O-rings, gearbox ax 3
5.
Lift the gearbox to its mounting position.
6.
Turn the gearbox to align the attachment

screw holes with those in the upper arm.
7.
Fit the gearbox onto the guide pins and slide Make sure the gearbox and o-ring are
it into position.
seated properly and correctly oriented!
8.
Remove the lifting tool.
9.
Secure the gearbox with 22 of the 24 gearbox attachment screws.

Remove the guide pins and tighten the
remaining two screws.
24 pcs: M12 x 60.

10. Refit the upper arm with a new sealing, axis Art. no. is specified in Required equip2/3 .
ment on page 145!
Detailed in section Refitting of upper
arm on page 57!
11. Refit the motor.
Detailed in section Refitting of motor,

axis 3 on page 106.
12. Remove the mechanical stop used to secure

the upper arm.
3HAC 16247-1
147

it is vital that:
148
3HAC 16247-1

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions result in two different designs of the gearbox.
A
D
B2
B1
xx0200000219
Gearbox, axis 6
B1
Attachment screws and washers, gearbox for robot version 175/2.55 (8 pcs)
B2
Attachment screws and washers, gearbox for robot version 225/2.55, 175/2.8, 125/
3.2 and 200/2.75 (18 pcs)
Oil plug, draining
Oil plug, filling
O-ring (not shown in figure)
Required equipment
Equipment, etc.
Standard toolkit

See references to
these procedures in
the step-by-step
instructions below.
3HAC 16247-1
Note
149

Removal, gearbox
motors or gears!
is used!
Step
Action
Note/Illustration
1.
Drain the oil from gearbox, axis 6.

2.
Remove the turning disc.
Detailed in section Removal of

turning disk on page 42.
3.
Remove the gearbox by unscrewing its 8 or 18 Shown in the figure Location of

attachment screws and washers (amount
gearbox on page 149!
depends on robot version).
4.
If required, apply M8 screws to the holes shown

in the figure beside to press the gearbox out
(not available in robot version 175/2.55).
A
xx0200000220
5.
150
A: M8 holes for pressing

the gearbox out
Remove the gearbox axis 6 by lifting it out care- Be careful not to damage the motor
fully.
pinion!
3HAC 16247-1

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions result in two different designs of the gearbox.
D
B2
B1
xx0200000219
Gearbox, axis 6
B1
Attachment screws and washers, gearbox for robot version 175/2.55 (8 pcs)
B2
Attachment screws and washers, gearbox for robot version 225/2.55, 175/2.8, 125/
3.2 and 200/2.75 (18 pcs)
Oil plug, draining
Oil plug, filling
O-ring (not shown in figure)
Required equipment
3HAC 16247-1
Equipment, etc.
Note
Gear axis 6, 175/2.25
3HAC 10828-10
Includes o-ring 3HAB 377258.
Gear axis 6, 225/2.55,

175/2.8, 125/3.2 and
200/2.75
3HAC 10828-13
Includes o-ring 3HAB 377257.
Washers
3HAA 1001-172
O-ring
3HAB 3772-58/57 Must be replaced when reassembling gearbox!
Grease
3HAB 3537-1
Not included in gearbox!

For lubricating o-ring.
151

Equipment, etc.
Standard toolkit
Note
3HAC 15571-1

See references to
Refitting, gearbox

page 18!
required.

motors or gears!
Step
1.
Action
Note/Illustration
Make sure the o-ring is fitted to the Art. no. specified in Required equipment on
rear of the gearbox. Lightly lubricate page 151!
A
xx0100000132
2.
152
Insert the gearbox, axis 6 into the

wrist unit.
A: O-ring, gearbox axis 6

page 151!
Shown in the figure Location of gearbox on
page 151!
Make sure the gears of the gearbox mate with
those of the motor!
3HAC 16247-1

Step
Action
Note/Illustration
3.
Secure the gearbox with the attach- Shown in figure above!

ment screws and washers.
8 pcs or 18 pcs (depending on robot version):
M8 x 40, 12.9 quality UNBRAKO, tightening
torque: 30 Nm.
Reused screws may be used, providing they
are lubricated as detailed in Screw joints on
page 15 before fitting.
4.
Refit the turning disc.
Detailed in section Refitting of turning disk on

page 44.
5.
Detailed in section Performing a leak-down

test on page 21.
6.
Detailed in "Oil change, gearbox axis 6" in the

Maintenance Manual.
7.

Manual.
it is vital that:
3HAC 16247-1
153

154
3HAC 16247-1
4 Repair activities, controller cabinet

4.0.1 Introduction
Chapter 4: Repair activities, controller cabinet

4.0.1 Introduction
Definitions
This chapter details all repair activities recommended for the controller.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refitting of a certain component in the controller. Each unit contains all information required to
perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into:
3HAC 16247-1
Removal instructions for all components
Refitting instructions for all components
Remaining instructions
155

4.1.1 Replacement of battery unit, controller
Section 4.1: Complete controller cabinet

Location of battery unit
The battery unit is located at the bottom of the controller.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000103
Battery unit
Required equipment
Equipment, etc.
Spare part no. Art no.
Note
Battery unit
3HAC 5393-2
To be replaced as a complete
unit
Standard toolkit

section "Standard toolkit"!

See references to
Removal, battery
unit
The procedure below details how to remove the battery unit.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
156
3HAC 16247-1

Step Action
Note/Illustration
1. Remove the battery unit by unscrewing

its attachment screws (1).
X1
X1
X1
X2
X2
X1
X1
X2
X2
X2
X3
Rectifier
A0
xx0200000004
2. Pull the battery unit out.

3. Disconnect the three cables from the
battery unit.
xx0200000005
Refitting, battery
unit
The procedure below details how to refit the battery unit.
Step Action
3HAC 16247-1
Note/Illustration
1. Place the battery unit close to its position.
Art. no. is specified above!

See illustration above!
2. Reconnect the cables and push the unit into position.
3. Secure it with the attachment screws.
157

4.1.2 Replacement of I/O and gateway units
Location of I/O
and gateway units
The I/O and gateway units are located as shown in the figure below.
I/O-4
I/O-3
I/O-1
I/O-2
xx0200000009
I/O and gateway units located on the panel shutter on the left side of the cabinet.
Four available slots for I/O and gateway units
Required equipment
Equipment, etc.
158
Note
Digital 24 VDC I/O
3HAB 7229-1
DSQC 328
Analog I/O
3HNE 00554-1
DSQC 355
AD Combi I/O
3HAB 7230-1
DSQC 327
Digital 120 VAC I/O
3HAB 7231-1
DSQC 320
Digital I/O with relays
3HAB 9669-1
DSQC 332
Gateway for Allen-Bradley, RIO
3HNE00025-1
DSQC 350
Gateway for Interbus-S
3HNE00006-1
DSQC 351
Gateway for Profibus DP, slave

unit
3HNE00009-1
DSQC 352
Standard toolkit
3HAC 15571-1
The contents are

defined in section
"Standard toolkit"!
3HAC 16247-1

Removal
The procedure below details how to remove an I/O or gateway board.

Step Action
Note/Illustration
1. Disconnect any connectors from the unit. The actual number of connectors vary
Note which connector goes where, to facil- depending on type of unit.
itate reassembly.
2. Lift the unit until the upper claw, that holds
the unit to the rail, is released. Use:
a screwdriver when replacing I/O
units (position 2a in the figure).
2a
3a
2b
3b
by hand when replacing a gateway

unit (position 2b in the figure).
xx0200000010
3. With the upper claw released, tip the unit

away from the mounting rail and remove it
(positions 3a and 3b in the figure).
Refitting
The procedure below details how to refit an I/O or gateway board.

Step Action
Note/Illustration
1. Hook the unit back onto the mounting rail and snap it gently
in position.
2. Reconnect all connectors disconnected during removal.
3HAC 16247-1
159

4.1.3 Replacement of bleeder resistor
Location of
bleeder resistor
The bleeder resistor is located behind the air outlet device, as shown in the figure below.
xx0200000007
Bleeder resistor unit
Air outlet device
Required equipment
Removal
Equipment, etc.
Bleeder resistor
3HAC 4560-5
Note
The procedure below details how to remove the bleeder resistor.

Step Action
Note/Illustration
1. Remove the air outlet divice in the back of

the controller by loosening the six M5
screws (pos B).
160
3HAC 16247-1

Step Action
Note/Illustration
2. Disconnect the cable secured on top of

the bleeder resistor unit (see position 1 in
the figure).
xx0200000015
3. Push down and pull out the bleeder resistor unit to release the bleeder resistor unit
from the enclosure. (see position 2 and 3
in the figure).
Refitting
The procedure below details how to refit the bleeder resistor.

Step Action
Note/Illustration
1. Fit the bleeder resistor into position and secure it with

the spring.

Also see the figure above!
2. Secure the cable disconnected during disassembly.

3. Refit the air outlet device.
4. Tightening the M5 screws.
3HAC 16247-1
161

4.1.4 Putting the computer unit in the service position
Location of computer unit
The computer unit is located as shown in the figure below.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000105
Opening
Computer unit
The procedure below details how to open the computer unit.

or gears!
Step Action
Note/Illustration
1. Make sure the ESD-wrist band is worn

and connected to ground.
2. Turn the exenter to the left to release the See following figure.
computer unit.
162
3HAC 16247-1

3. Push the locking device on the front of the

computer unit to the right (see position 1
in the figure).
4. Pull the computer unit out of the cabinet

until locked in its end position. Then swing
it to the left as shown in the figure.
xx0200000018
5. If work is to be performed on the computer

unit while in the service position, it must
be locked in this position. This is done by
placing the puck (located on the lower left
side) on the metal bar. Alternatively, the
computer unit may be lifted straight up
and placed on a work bench.
3HAC 16247-1
163

Closing
The procedure below details how to close the computer unit.

or gears!
Step Action
Note/Illustration
1. Swing the computer unit back into position and

secure it by swinging the exenter to th right.
164
See the figure above!

Also see the procedure above!
3HAC 16247-1

4.1.5 Replacement of mass storage memory
Location of mass
storage memory
The mass storage memory is located in the computer system, which is shown in the figure
below.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000105
Computer system
Required equipment
Equipment, etc.
Mass storage memory, 64 MB
3HAC 7519-2
Note
Mass storage memory, 128 MB 3HAC 7519-3

Standard toolkit
3HAC 15571-1 The contents are

defined in section
"Standard toolkit"!
Other tools and procedures may

be required. See references to
these procedures in the step-bystep instructions below.
Removal
These procedures
include references to
the tools required.
The procedure below details how to remove the mass storage memory.
Step Action
Note/Illustration
1. Put the computer unit in service position.
3HAC 16247-1
Detailed in section "Putting the computer in the service position".
165

Step Action
Note/Illustration
2. Open the cover on the right side of the computer system by unsnapping the two snaps
(item 1 in the figure).
xx0200000019
3. Disconnect the connectors X1 and X2 from

the front of the mass storage memory (items
2 and 3 in the figure).
4. Remove the mass storage memory by

unscrewing its M4 attachment screws as
shown in the figure (item 1 in the figure).
Refitting
See figure above!
The procedure below details how to refit the mass storage memory.
Step Action
Note/Illustration
1. Fit the mass storage memory in position and Art. no. is specified above!
secure it with its M4 attachment screw (item
1 in the figure)
1
xx0200000019
2. Reconnect connectors X1 and X2 to the front See the figure above!

of the computer unit (items 2 and 3 in the figure).
166
3HAC 16247-1

Step Action
Note/Illustration
3. Close the cover on the right side of the computer unit and secure it with the snaps (item
1 in the figure).
4. Put the computer system back in regular

operation position.
3HAC 16247-1
Detailed in section "Putting the computer in the service position".
167

4.1.6 Replacement of internal cooling fan
Location of internal cooling fan
The internal cooling fan is located in the computer system, which is shown in the figure
below.
X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
A0
xx0200000105
Computer system
Required equipment
Equipment, etc.
Note
Internal cooling fan
3HAC 6655-1
Two fans required

below.
Removal
The procedure below details how to remove the internal cooling fan.
Step Action
Note/Illustration
1. Put the computer unit in service position.
168
Detailed in "Putting the computer in

the service position".
3HAC 16247-1

Step Action
Note/Illustration
2. Disconnect the connector E5 or E6 respectively, depending on which fan is to be

replaced.
A
E
xx0200000020
3. Remove the internal cooling fan inwards by

gently pressing the locking tabs upwards.
Refitting
A: Upper fan
B: Lower fan
C: Locking tabs
D: Connector E5
E: Connector E6
See the figure above!
The procedure below details how to refit the internal cooling fan.
3HAC 16247-1
169

Step Action
Note/Illustration
1. Tip the internal cooling fan with its top towards the cabinet wall and fit it into the hole (see the figure). Art. no.
specified above!
xx0200000021
A: Push direction
2. With the wall between the upper lock spring hooks, push See the figure above!
the fan unit up and in until the locking tab snaps to the
wall.
3. Reconnect the connector E5 or E6 respectively, depending on which fan was replaced.
4. Put the computer unit back in regular operation position. Detailed in "Putting the
computer in the service
position".
170
3HAC 16247-1

4.1.7 Replacement of drive units and rectifier
Location of drive
units and rectifier
The drive units and rectifier are located as shown in the figure below.
B
A
xx0200000007
Rectifier (drive unit)
Drive units
Power supply unit
Required equipment
Equipment, etc.
Note
Drive unit (rectifier)
3HAB 8101-17
DSQC 545A
Drive unit, axes 1-6
3HAB 8101-18
DSQC 546A

See references to
Removal
The procedure below details how to remove the drive units.

3HAC 16247-1
171

Step Action
Note/Illustration
1. Swing the panel shutter out of the way.

(pos A in figure).
2. Disconnect connectors X1 and X2,

four connectors each (see position 1 in
the figure).
X1
X1
X1
X1
X2
X2
X2
X2
1
X1
2
X2
X3
X2
A0
Rectifier
xx0200000013
3. Remove the power supply bar in front See figure above!

of the drive units (see position 2 in the
figure).
4. Lift the spring to release the drive unit
and pull it slightly outwards (see position 3 in the figure).
xx0200000014
5. Tip it out and remove it (see position 4 See figure above!

in the figure).
Refitting
The procedure below details how to refit the drive units.

172
3HAC 16247-1

Step Action
Note/Illustration
1. Fit the unit into position and secure it with the spring.
Also see figure above!
2. Refit the power bar in front of the unit.

3. Reconnect all connectors X1 and X2.
4. Swing the power supply unit back into position.
3HAC 16247-1
Detailed in section
"Replacement of power
supply unit"
173

4.1.8 Replacement of system fan unit
Location of system fan unit
The system fan unit is located under the bleeder resistor unit, in the back of the controller as
shown in the figure below.
xx0200000007
Air outlet device
Bleeder resistor unit
System fan unit
Required equipment
Equipment, etc.
System fan unit
3HAC 15449-1

required. See references to these
procedures in the step-by-step
instructions below.
Removal
Note
These procedures
include references
to the tools required.
The procedure below details how to remove the system fan unit.
Step Action
174
Note/Illustration
1. Remove the Air outlet device.
Pos. A in previous illustration.
2. Remove the bleeder resistor unit.
Detailed in
"Replacement of bleeder resistor".
3HAC 16247-1

Step Action
Note/Illustration
3. Disconnect the cable (see position 1 in

the figure).
A0
Rectifier
xx0200000008
4. Pull the back of the system fan unit

upwards to free it and then tip it out of
the enclosure (see position 2 in the figure).
Refitting
The procedure below details how to refit the system fan unit.
Step Action
Note/Illustration
1. Fit the system fan unit into position and secure it (see
position 2 in the figure above).
2. Reconnect the cable disconnected during disassembly

(see position 1 in the figure above).
3HAC 16247-1
3. Refit the bleeder resistor unit.
Detailed in section
"Replacement of bleeder
resistor".
4. Refit the Air outlet device.
Pos. A in previous illustration.
175

4.1.9 Replacement of power supply unit
Location of power
supply unit
The power supply unit is located as shown in the figure below.
xx0200000011
Power supply unit
Power supply unit locking spring
Required equipment
Equipment, etc.
Note
Power supply unit
3HAB 4297-1
DSQC 506

may be required. See references to these procedures in
the step-by-step instructions
below.
Removal
These procedures
include references to
the tools required.
The procedure below details how to remove the power supply unit.
Step Action
Note/Illustration
1. Push the locking spring to the right to free the panel Shown in previous figure!
shutter, and Swing it out of the way.
176
2. Remove the M5 Torx screw.
See pos. 2 in previous figure.
3. Disconnect the connectors.
See pos. 1 in previous figure.
3HAC 16247-1

Step Action
Note/Illustration
4. Lift the unit straight up to release it from the hooks

in the back and remove it outwards.
Refitting
The procedure below details how to refit the power supply unit.
Step Action
Note/Illustration
1. Fit the power supply unit into position onto its hooks and Art. no. is specified above!
secure it with the attachment screw (see position 2 in the
section Removal).
2. Reconnect all connectors disconnected during removal. See position 1 in figure.
3. Swing the panel shutter back in possition and secure it
with the locking spring.
3HAC 16247-1
177

4.1.10 Replacement of Peltier Cooler power supply
Location of power
supply unit
The Peltier cooler power supply unit is located as shown in the figure below.
1
2
Cover
M5 screw
Extended Power supply
Required equipment
Equipment, etc.
Extended Power supply
3HAB 13398-1

Removal
Note
required.
The procedure below details how to remove the power supply unit.
Turn off all electric power supplies to the cabinet!
Step Action
Note/Illustration
1. Remove the M5 Torx screw.
See pos. 2 in previous illustration.
2. Remove the cover
3. Disconnect the wires.
178
3HAC 16247-1

Step Action
Note/Illustration
4. Remove the Power supply from the mounting

rail.
Refitting
The procedure below details how to refit the power supply unit.
Turn off all electric power supplies to the cabinet!
Step Action
Note/Illustration
1. Fit the power supply unit onto the mounting rail.

2. Reconnect the wires disconnected during removal.
3. Refit the cover and secure with M5 screws.
3HAC 16247-1
See pos. 1 and pos. 3. in

previous illustration.
179

180
3HAC 16247-1
5 Appendix 1: Part Lists

5.0.1 Introduction
Chapter 5: Appendix 1: Part Lists

5.0.1 Introduction
This chapter is an appendix to the manual and contains part lists with item numbers, refering
to the Appendix 2: Foldouts.
The part list for the manipulator sometimes differ for robot versions 225/2.25- 175/2.8 and
175.2.25. In case of difference, the version is stated in the title.
3HAC 16247-1
181

5.0.1 Introduction
Section 5.1: Part List, Manipulator IRB 6600/6650
182
Item Qty
Art. number
Description
Dimension/Note
3HAC 12812-2
Mechanical stop ax 1,
assembly
See Mechanical stop ax 1,

3HAC 12812-2 on page 183.
101
3HAC 12685-1
Base incl frame ax 1
See Base incl frame ax 1,

3HAC 12685-1 on page 183.
102
3HAC 10746-3
Axis 3-4, (175/2.55)
See Axis 3-4, (robot v. 175/

2.55), 3HAC 10746-3 on
page 184.
102
3HAC 10746-1
Axis 3-4, (225/2.55, 175/2.8, See Axis 3-4, (robot v. 225/

125/3.2, 200/2.75)
2.55, 175/2.8, 125/3.2, 200/
2.75), 3HAC 10746-1 on
page 184.
102
3HAC 10746-5
Axis 3-4, Foundry (175/

2.55)
102
3HAC 10746-4
Axis 3-4, Foundry (225/2.55, See Axis 3-4, Foundry (robot

175/2.8, 125/3.2, 200/2.75) v. 225/2.25, 175/2.8, 125/3.2,
200/2.75), 3HAC 10746-4 on
page 185.
103
3HAC 8114-1
Wrist (175/2.55)
See Wrist (robot v. 175/2.55)

3HAC 8114-1 on page 189.
103
3HAC 8114-3
Wrist (225/2.55, 175/2.8,

125/3.2, 200/2.75)
See Wrist (robot v. 225/2.55,

175/2.8, 125/3.2, 200/2.75)
3HAC 8114-3 on page 189.
103
3HAC 8114-6
Wrist Foundry (175/2.55)
See Wrist Foundry (robot v.

175/2.55) 3HAC 8114-6 on
page 189.
103
3HAC 8114-5
Wrist Foundry (225/2.55,

175/2.8, 125/3.2, 200/2.75)
See Wrist Foundry (robot v.

225/2.55, 175/2.8, 125/3.2,
200/2.75) 3HAC 8114-5 on
page 190.
104
3HAC 14678-1
Balancing Device F (175/

2.55, 225/2.55, 175/2.8 )
104
3HAC 16189-1
Balancing Device G (125/

3.2, 200/2.75)
104
3HAC 17117-2
Balancing Device A (175/

2.55, 225/2.55, 175/2.8 )
104
3HAC 17117-3
Balancing Device B (125/

3.2, 200/2.75)
105
3HAC 10141-1
Lower arm (175/2.55, 225/

2.55, 175/2.8 )
105
3HAC 13940-1
Lower arm (125/3.2, 200/

2.75)
106
3HAC 14940-1
Cable harness, man. ax1-4

(175/2.55, 225/2.55, 175/2.8
)
106
3HAC 16331-1
Cable harness, man ax 1-4

(125/3.2, 200/2.75)
108
3HAC 13263-1
Material set manipulator
See Axis 3-4, Foundry (robot

v. 175/2.55), 3HAC 10746-5
on page 185.
See Material set manipulator, 3HAC 13263-1 on

page 194.
3HAC 16247-1

5.1.1 Mechanical stop ax 1, 3HAC 12812-2
Item Qty
Art. number
Description
Dimension/Note
109
3HAC 13264-1
Material set ax 1-2
See Mtrl.set ax 1-2, 3HAC

13264-1 on page 195.
110
3HAC 13265-1
Mtrl.set balancing device
See Mtrl set balancing

device, 3HAC 13265-1 on
page 198.
111
3HAC 12311-4
Arm extension set 250mm

(175/2.8)
See Arm extension set, 250

mm, 3HAC 12311-4 on
page 199.
111
3HAC 12311-5
Arm extension set 450mm

(125/3.2)
See Arm extension set, 450

mm, 3HAC 12311-5 on
page 199.
112
3HAC 12129-1
Cover plate
t=1,5 mm
112
3HAC 12129-1
Cover plate
t=1,5 mm
113
9ADA 618-56
Torx pan head screw
M6x16
113
9ADA 618-56
Torx pan head screw
M6x16
114
3HAC 13416-1
Protection cover
Shell size 16
5.1.1 Mechanical stop ax 1, 3HAC 12812-2
Item
Qty
Art. number
Description
5.1
3HAC 12812-1
Mech stop
5.2
9ABA 142-92
Spring pin, slotted
Dimension
10x30
5.1.2 Base incl frame ax 1, 3HAC 12685-1
Item
Qty Art. number
Description
Dimension/Note
101.1
3HAC 13054-2
Base machining
See Base, machining, 3HAC

13054-2 on page 183!
101.2
3HAC 12684-1
Frame incl ax 1 gearbox
See Frame incl ax 1 gearbox,

3HAC 12684-1 on page 184!
101.3
3HAC 11732-2
Washer
T=3
101.4
18
3HAB 7700-5
Hex socket head cap screw M16x70
101.5
3HAC 11529-1
Rubber lined clip D=28
101.6
3HAC 14453-1
Hose with flange
101.7
3HAC 14453-2
Plug
101.8
3HAC 4428-2
Hose Clip
D=23-27
101.9
9ADA 618-56
Torx pan head screw
M6x16
Base, machining,
3HAC 13054-2
Item
3HAC 16247-1
Qty
Art. number
Description
101.1.1 1
3HAC 13054-1 Base, casting
101.1.2 5
3HAC 4836-7
Protection plug
Dimension
16x12,3x9x7
183

5.1.3 Axis 3-4, (robot v. 175/2.55), 3HAC 10746-3
Item
Frame incl ax 1
gearbox, 3HAC
12684-1
Art. number
Description
101.1.3 1
3HAC 1383-2
Protection Cover compl.
101.1.4 1
3HAC 14024-1 Protection screw
Item
Qty
Qty
Dimension
Art. number
Description
Dimension
101.2.1 1
3HAC 15866-1
Frame machining
101.2.2 1
3HAC 10828-8
RV 320C-224,26 assembly
101.2.3 24
3HAB 7700-73
Hex socket head cap screw
101.2.4 24
3HAA 1001-134 Washer
M12x70
13x19x1,5
5.1.3 Axis 3-4, (robot v. 175/2.55), 3HAC 10746-3
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4
See Material set ax 4, 3HAC

13350-1 on page 185!
102.2 1
3HAC 10139-1
Tube shaft 2,55
See Tube shaft 2,55, 3HAC

10139-1 on page 187!
102.3 1
3HAC 13351-2
Axis 3
See Axis 3, 3HAC 13351-2/1

on page 187!
102.4 1
3HAC 14753-1
Rot ac motor incl gearbox
See Rot ac motor incl gearbox, 3HAC 14753-1 on page

188!
5.1.4 Axis 3-4, (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-1
184
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4

13350-1 on page 185!
102.2 1
3HAC 10139-1
Tube shaft 2,55
See Tube shaft 2,55, 3HAC

10139-1 on page 187!
102.3 1
3HAC 13351-1
Axis 3
See Axis 3, 3HAC 13351-2/1

on page 187!
102.4 1
3HAC 14752-1

189.
3HAC 16247-1

5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5
5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4

13350-1 on page 185!
102.2 1
3HAC 15859-1
Tube shaft 2,55 foundry
102.3 1
3HAC 13351-2
Axis 3
102.4 1
3HAC 14753-1
Rot ac motor incl gearbox See Rot ac motor incl gearbox, 3HAC 14753-1 on page
188.
See Axis 3, 3HAC 13351-2/1

on page 187!
5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4
Item Qty
Art. number
Description
Note
102.1 1
3HAC 13350-1
Material set ax 4

13350-1 on page 185!
102.2 1
3HAC 15859-1
Tube shaft 2,55 foundry
102.3 1
3HAC 13351-1
Axis 3
See Axis 3, 3HAC 13351-2/1

on page 187!
102.4 1
3HAC 14752-1

189!
Material set ax 4,
3HAC 13350-1
3HAC 16247-1
Item
Qty
Art. number Description
Dimension/Note
102.1.1
3HAC 12261-1 Gear Z4 /4
102.1.3
9ADA 183-37
M8x25
102.1.4
9ADA 312-7
Plain washer
8,4x16x1,6
102.1.5
3HAC 12259-1 Wheel unit ax4 225kg
102.1.6
3HAA 1001-99 Wedge
102.1.7
3HAC 12560-1 Stud bolt
M8x65
102.1.8
12
9ADA 334-7
Spring washer, conical
8,4x18x2
102.1.9
9ADA 267-7
Hexagon nut
M8
See Wheel unit ax 4, 225

kg, 3HAC 12259-1 on page
186!
102.1.10 3
3HAB 3409-63 Hex socket head cap screw
M10x110
102.1.11 3
9ADA 334-8
10,5x23x2,5
102.1.12 1
3HAC 13564-1 Damper axis 4
102.1.13 1
3HAA 1001-17 Stop, Axis 4, Casting
See Damper axis 4, 3HAC

13564-1 on page 187!
185

Item
Qty
Dimension/Note
102.1.14 1
3HAC 11925-1 Mechanical stop head
102.1.15 2
M16x35
102.1.16 1
3HAA 1001-98 Gasket
T=1
102.1.17 1
3HAC 12149-4 Cover ax4 with sealing
See Cover axis 4 with sealing, 3HAC 12149-4 on

page 187!
102.1.18 14
9ADA 618-56
M6x16
102.1.20 1
3HAC 12126-1 Set of shims
102.1.21 1
3HAC 12060-1 Thrust washer
102.1.22 1
9ABA 135-45
Retaining ring, shaft
170
102.1.23 2
2213 253-5
Ball bearing
170x215x22
102.1.24 1
2216 261-18
Sealing
170x200x15
102.1.25 1
2216 0086-4
Sealing (Nilos)
180x215x4
102.1.26 1
3HAB 4317-1
SEALING
102.1.27 1
3HAC 3774-7
Spacer ring
102.1.28 1
3HAB 3772-27 O-ring
170x5
102.1.29 1
9ABA 107-56
10x20
Torx pan head screw
Parallel pin
102.1.30 8100 1171 2016-604 Lubricating oil

ml
Wheel unit ax 4,
225 kg, 3HAC
12259-1
102.1.31 30 g
3HAB 3537-1
Bearing grease
102.1.32 1 ml
3HAB 7116-1
Locking liquid
102.1.33 1 ml
3HAB 7116-2
Locking liquid
102.1.34 1
3HAC 16721-1 Magnetic plug
Item
Qty
R 1/2
Art. number
Description
Dimension/Note
102.1.5.1 1
3HAC 11742-1
Intermediate hub, machine
102.1.5.2 1
3HAC 12259-2
Gear unit Z2, 3/4
See Gear unit Z2, 3/4,

3HAC 12259-2 on page
186!
102.1.5.3 1
2126 2851-104
Lock nut
M20X1
102.1.5.4 1
2213 3802-11
Taper roller bearing
40x68x19
102.1.5.5 1
3HAA 1001-129
Taper Roller Bearing
102.1.5.6 1 ml
3HAB 7116-2
Locking liquid
Gear unit Z2, 3/4,

3HAC 12259-2
186
Item
Qty
Art. number
Description
102.1.5.2.0
3HAC 12259-3
Pinion Z3 /4
102.1.5.2.0
3HAC 12259-4
Gear Z2 /4
Dimension
3HAC 16247-1

Damper axis 4,
3HAC 13564-1
Cover axis 4 with

sealing, 3HAC
12149-4
Item
Qty Art. number
Description
102.1.12.2
Plate for damper
Item
Qty Art. number
Description
102.1.17.1
3HAC 12149-3
Cover ax4 with gasket
102.1.17.2
3HAA 1001-628 Sealing
3HAC 13564-2
Dimension
Dimension
Tube shaft 2,55,

3HAC 10139-1
Item
Protection Cover
compl., 3HAC
1383-2
Qty
Art. number
Description
102.2.1 1
3HAC 10139-2 Tube shaft 2,55, casting
102.2.2 1
3HAC 1383-2
Protection Cover compl.
Note
See Protection Cover
compl., 3HAC 1383-2 on
page 187!
Item
Qty Art. number Description
Dimension
102.2.2.1
9ADA 624-69
M8x20
102.2.2.2
3HAB 3772-66 O-ring
102.2.2.3
3HAC 1383-1
Protection Cover
102.2.2.4
3HAC 1383-3
Gasket
Torx counters. head screw
8x2
Axis 3, 3HAC
13351-2/1
3HAC 16247-1
Item
Qty
Art. number
Description
102.3.1
3HAC 10133-1
Axis 4 housing
102.3.2
3HAC 10828-12 RV 410F-270,176

assembly
See RV 410F-270, 176

assembly, 3HAC 1082812 on page 188!
102.3.3
24
3HAB 3409-71
M12x60
102.3.4
24
13x19x1,5
102.3.5
3HAC 14750-1
Rot ac motor incl pinion

(225/2.55, 175/2.8, 125/
3.2, 200/2.75)
See Rot ac motor incl pinion, 3HAC 14750-1 on

page 188.
102.3.5
3HAC 14751-1
Rot ac motor incl pinion,

(175/2.55)
See Rot ac motor incl pinion, 3HAC 14751-1 on

page 188.
Hex socket head cap

screw
Dimension/Note
187

Item
Qty
Art. number
Description
Dimension/Note
102.3.6
3HAB 3409-50
Hex socket head cap

screw
M10x40
102.3.7
3HAB 4233-1
Washer
102.3.8
3HAC 16721-1
Magnetic plug
102.3.9
2500 ml 3HAC 16843-1
102.3.10 1
RV 410F-270, 176
assembly, 3HAC
10828-12
Rot ac motor incl

pinion, 3HAC
14751-1
Rot ac motor incl

pinion, 3HAC
14750-1
Rot ac motor incl

gearbox, 3HAC
14753-1
188
R 1/2
Lubricating oil, RMO 150
9ABA 142-92
Spring pin, slotted
10x30
Description
Dimension
Item
Qty
Art. number
102.3.2.1
3HAC 10828-11 RV 410F, i=270,176
102.3.2.2
3HAB 3772-68
O-ring
276 x 3,53
Item
Qty
Art. number
Description
102.3.5.1
3HAC 14673-6
Rotational ac motor M6
102.3.5.2
3HAC 10122-15 Input gear RV 410F-270,17
102.3.5.3
2152 2012-430
O-ring
89,5x3
102.3.5.4
9ADA 183-444
M8x130
102.3.5.5
3 ml
3HAB 7116-1
Locking liquid
Item
Qty
Art. number
Description
102.3.5.1
3HAC 14673-9
102.3.5.2
102.3.5.3
2152 2012-430
O-ring
89,5x3
102.3.5.4
9ADA 183-444
M8x130
102.3.5.5
3 ml
3HAB 7116-1
Locking liquid
Item
Qty
Art. number
Description
102.4.1 1
3HAC 14673-7
102.4.2 1
3HAC 12260-1
Pinion Z1 /4
102.4.3 0
2152 2012-430
O-ring
Dimension
Dimension
Dimension
89,5x3
3HAC 16247-1

5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1
Rot ac motor incl

gearbox, 3HAC
14752-1
Item
Qty
Art. number
Description
102.4.1 1
3HAC 14673-10 Rotational ac motor M10
102.4.2 1
3HAC 12260-1
Pinion Z1 /4
102.4.3 0
2152 2012-430
O-ring
Dimension
89,5x3
5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1
Item
Qty
Dimension/Note
103.1
3HAC 8114-4
See Material set, 3HAC

8114-4 on page 190!
103.2
3HAC 7941-29 Rot ac motor incl gearbox
See Rot ac motor incl.

gearbox, 3HAC 7941-29
on page 192!
103.3
M16x80
103.4
3HAC 9744-1
See Axis 6 complete,

3HAC 9744-1/16032-1 on
page 192!
103.5
3HAC 12732-1 Label
Material set
Axis 6 complete
5.1.8 Wrist (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-3
Item
Qty
Dimension/Note
103.1
3HAC 8114-4

8114-4 on page 190!
103.2
See !
103.3
M16x80
103.4
3HAC 13890-1 Axis 6 complete
See !
103.5
3HAC 12732-3 Label
Material set
5.1.9 Wrist Foundry (robot v. 175/2.55) 3HAC 8114-6
3HAC 16247-1
Item
Qty
Dimension/Note
103.1
3HAC 8114-4

8114-4 on page 190!
103.2
Material set

gearbox, 3HAC 7941-29 on
page 192!
189

5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5
Item
Qty
Dimension/Note
103.3
M16x80
103.4
3HAC 16032-1 Axis 6 complete Foundry

3HAC 9744-1/16032-1 on
page 192!
103.5
3HAC 12732-2 Label
Item
Qty
Dimension/Note
103.1
3HAC 8114-4

8114-4 on page 190!
103.2

gearbox, 3HAC 7941-29 on
page 192!
103.3
M16x80
103.4
3HAC 13890-2 Axis 6 complete Foundry

3HAC 13890-2/1 on page
193!
103.5
3HAC 12732-1 Label
Material set
Material set,
3HAC 8114-4
190
Item
Qty
103.1.1
3HAC 7956-1
103.1.2
3HAC 7941-28 Set of shim, motor
103.1.3
3HAC 7941-19 Set of shim, bevel gear
103.1.4
9ADA 183-37
Hex socket head cap

screw
M8x25
103.1.5
9ADA 312-7
Plain washer
8,4x16x1,6
103.1.6
3HAA 2166-11 VK-Cover
D=80 B=10
103.1.7
3HAC 4334-3
50x90x20
103.1.8
3HAC 12560-1 Stud bolt
103.1.9
3HAB 7116-2
Locking liquid
103.1.10
16
9ADA 334-7
8,4x18x2
103.1.11
9ADA 267-7
Hexagon nut
M8
103.1.12
3HAA 1001-99 Wedge
103.1.13
3HAB 7299-1
103.1.14
3HAA 2166-23 VK-Cover
D=120, B=12
103.1.15
3HAC 7941-32 Support shaft inc bearing
See Support shaft incl.

bearing, 3HAC 7941-32 on
page 191!
103.1.16
9ADA 183-39
Hex socket head cap

screw
M8x35
103.1.17
3HAB 4337-2
Damper axis 5
103.1.18
3HAC 9953-1
Syncplate with nonie
Dimension/Note
Wrist housing, 225kg
Cylindrical roll. bearing
Sealing
M8x65
Di=115 Dy=140 B=12
T=1,5
3HAC 16247-1

Support shaft
incl. bearing,
3HAC 7941-32
Interm.wheel unit/
5 225kg, 3HAC
7941-6
Gear Unit Z4-Z5/5

225 kg, 3HAC
7941-12
Item
Qty
Dimension/Note
103.1.19
3HAC 16721-1 Magnetic plug
R 1/2
103.1.21
27
9ADA 618-56
Torx pan head screw
M6x16
103.1.22
9ADA 334-6
Plain washer
6,4x14x1,5
103.1.23
3HAB 7116-1
Locking liquid
103.1.24
3HAC 14139-1 Manip. Harness ax 5
103.1.25
6700
ml
1171 2016-604 Lubricating oil
103.1.26
3HAC 7941-6
Interm.wheel unit/5 225kg
See Interm.wheel unit/5

225kg, 3HAC 7941-6 on
page 191!
103.1.27
3HAA 1001266
Screw
M16x60
103.1.28
3HAC 7941-21 Gear wheel unit z6/5 225
103.1.29
3HAC 8081-8
Cover with gasket, 225kg
103.1.30
3HAC 8081-3
Cable cover
103.1.31
3HAC 14140-1 Manip. Harn. ax 5/6
103.1.32
2166 2055-3
Item
Description
103.1.15.1 1
3HAC 14731-1
Shaft
103.1.15.2 1
3HAB 3643-11
Groove ball bearing
130x165x18
103.1.15.3 3
9ADA 618-56
Torx pan head screw
M6x16
103.1.15.4 1 ml
3HAB 7116-1
Locking liquid
Qty Art. number
Description
Dimension
Dimension/Note
103.1.26.1 1
3HAC 7946-1
103.1.26.2 2
3HAA 1001-130 Taper Roller Bearing
103.1.26.3 1
3HAC 7941-12
Gear Unit z4-z5/5 225kg
See Gear Unit Z4-Z5/5 225

kg, 3HAC 7941-12 on page
191!
103.1.26.4 1
3HAC 13142-1
Washer
17x30x6
103.1.26.5 1
3HAC 7941-11
Locking Nut
103.1.26.6 1 ml
3HAB 7116-2
Locking liquid
Item
Qty
103.1.26.3.1 1
3HAC 16247-1
4,8x208
Art. number
Item
Qty
Cable straps, outdoors
See Gear wheel unit z6/5

225, 3HAC 7941-21 on
page 192!
Hub ax5, machining

3HAC 7941-7
Dimension
Pinion z5/5 225kg
191

Item
Qty
103.1.26.3.2 1
Gear wheel unit

z6/5 225, 3HAC
7941-21
Rot ac motor incl.

gearbox, 3HAC
7941-29
Rot ac motor incl.

gearbox, 3HAC
7941-30
Axis 6 complete,
3HAC 9744-1/
16032-1
192
Item

3HAC 7941-5
Qty
Dimension
Gear z4/5 225kg
103.1.28.1 1
3HAC 7941-8
Gear z6/5 225kg
103.1.28.2 1
3HAB 4271-1
Groove ball bearing
103.1.28.3 1
3HAB 6686-1
Support ring
103.1.28.4 1 ml
3HAB 7116-2
Locking liquid
110x150x20
Item
Qty
Art. number
103.2.1
3HAC 14673-7 Rotational ac motor M7
103.2.2
3HAC 7941-1
103.2.3
2152 2012-430 O-ring
89,5x3
Item
Qty
Art. number
Description
Dimension/Note
103.2.1
3HAC 1467310
103.2.2
3HAC 7941-1
Bevel gear set unit z1-3/5
103.2.3
2152 2012-430 O-ring
Item
Qty
Art. number
Description
103.4.1
3HAC 9744-5
Turning disc, diam. 200
103.4.2
3HAC 10828-10 RV 40E-81 assembly
103.4.3
3HAC 9744-3
Tilt housing, machining

RV40
103.4.3
3HAC 16009-2
Tilt housing, machining

RV40, foundry
103.4.4
3HAC 14755-1
Description
Dimension
Dimension/Note
Bevel gear set unit z1-3/5
89,5x3
Dimension/Note
See RV 40E-81 assembly, 3HAC 10828-10 on
page 193!

pinion, 3HAC 14754-1
on page 194 below!
3HAC 16247-1

RV 40E-81 assembly, 3HAC 1082810
Rot ac motor incl.

pinion, 3HAC
14755-1
Item
Qty
Art. number
Description
Dimension/Note
103.4.5
9ADA 312-7
Plain washer
8,4x16x1,6
103.4.6
9ADA 183-37
103.4.7
8,4x13x1,5
103.4.8
2522 122-1
Magnetic plug
R1/4
103.4.9
300 ml
3HAC 16843-1
103.4.10 1 ml
3HAB 7116-1
Locking liquid
103.4.11 1
3HAB 3772-65
O-ring
131x2
103.4.12 6
2152 0431-20
O-ring
15,5x1,5
103.4.13 1
3HAC 6862-2
Syncplate 175 kg
103.4.14 6
2121 2518-577
103.4.15 8
3HAB 7700-55
103.4.18 2
9ADA 618-32
Torx pan head screw
103.4.20 1
3HAC 14263-1
Protection Cover
103.4.21 1
9ADA 624-69
M8x20
Item
Art. number
Description
Dimension
103.4.2.1 1
3HAC 10828-5
RV 40E, i=81
103.4.2.2 1
3HAB 3772-58
O-ring
Item
Qty
Art. number
Description
103.4.4.1
3HAC 14673-8
103.4.4.2
3HAC 10122-24 Pinion RV 40E-81
103.4.4.3
2152 2012-430
O-ring
89,5x3
103.4.4.4
9ADA 183-20
M5x45
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
Item
Qty
Art. number
Description
103.4.1
3HAC 13752-1
Turning disc, diam. 200
103.4.2
3HAC 10828-13 RV 40E-81 assembly
103.4.3
3HAC 16009-1
Tilt housing RV70, foundry
103.4.3
3HAC 11522-2
Tilt housing RV70
103.4.4
3HAC 14754-1
Qty
M4x8
151,99x3,53
Dimension
Axis 6 complete,
3HAC 13890-2/1
3HAC 16247-1
Dimension/Note
See RV 40E-81 assembly, 3HAC 10828-13 on
page 194!

on page 194!
193

5.1.11 Material set manipulator, 3HAC 13263-1
RV 40E-81 assembly, 3HAC 1082813
Rot ac motor incl.

pinion, 3HAC
14754-1
Item
Qty
Art. number
Description
Dimension/Note
103.4.5
9ADA 312-7
Plain washer
8,4x16x1,6
103.4.6
9ADA 183-37
103.4.7
8,4x13x1,5
103.4.8
2522 122-1
Magnetic plug
R1/4
103.4.9
300 ml
3HAC 16843-1
103.4.10 1 ml
3HAB 7116-1
Locking liquid
103.4.11 1
3HAB 3772-64
O-ring
150,0x2,0
103.4.12 6
3HAB 3772-61
O-ring
13,1x1,6
103.4.13 1
3HAC 16862-1
Syncplate 175 kg
103.4.14 12
3HAB 7700-65
103.4.15 18
3HAB 7700-55
103.4.18 2
9ADA 618-32
Torx pan head screw
103.4.20 1
3HAC 14263-1
Protection Cover
103.4.21 1
9ADA 624-69
M8x20
Item
Art. number
Description
Dimension
Qty
M4x8
103.4.2.1 1
3HAC 10828-14 RV 70F, i=125,8
103.4.2.2 1
3HAB 3772-57
Item
Qty
Art. number
Description
103.4.4.1
3HAC 14673-8
103.4.4.2
3HAC 11173-3
Pinion RV 70F.125,8
103.4.4.3
2152 2012-430
O-ring
89,5x3
103.4.4.4
9ADA 183-415
M5x55
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
O-ring
164,69x3,53
Dimension
5.1.11 Material set manipulator, 3HAC 13263-1
Item
194
Qty
Art. number
Description
108.201 2
3HAC 17212-1
Sealing axis 2/3
108.202 66
3HAB 7700-69
108.203 3
3HAC 12703-1
Washer axis3
Dimension/Note
M12x50
3HAC 16247-1

5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1
Item
Qty
Art. number
Description
Dimension/Note
108.204 33
13x19x1,5
108.206 12
3HAB 7700-69
M12x50
108.207 12
108.210 1
3HAC 14300-1
Cable protector
108.212 1
3HAC 11771-1
Cable guide, end part
108.213 1
3HAC 13960-1
Connection plate, ax3
108.214 2
3HAC 12320-1
Damper axis 3
108.215 2
3HAC 12991-1
Damper axis 2
108.216 2
9ADA 624-65
M6x60
108.217 2
9ADA 334-7
8,4x18x2
108.218 2
9ADA 618-57
Torx pan head screw
M6x20
108.220 2
3HAC 9953-1
Syncplate with vernier
T=1,5
108.222 1
3HAC 12719-1
Syncplate with vernier ax3
T=1,5
108.223 2
9ADA 183-48
M10x16
108.224 1
3HAC 12844-1
Cable cover
108.225 14
9ADA 618-56
Torx pan head screw
108.228 1
3HAC 3261-1
Cover
108.229 1
3HAC 15431-1
Cable protection
108.230 1
3HAC 14880-1
Cable fixing bracket
t=3
108.232 4
3HAC 16721-1
Magnetic plug
R 1/2
108.234 3
9ADA 618-56
Torx pan head screw
M6x16
Art. number
Description
Dimension/Note
109.301 1
3HAC 17271-1
RV 410F-270,176 assembly
See RV 410F-270,176
assembly, 3HAC 172711 on page 197!
109.302 1
3HAC 16295-1
Cover, machining
109.302 1
3HAC 16829-1
Cover, machining
109.303 1
3HAC 14699-1
Friction washer
294x333x1,0
109.304 24
3HAB 3409-71
M12x60
109.305 24
13x19x1,5
109.306 1
3HAC 14749-1
See Rot ac motor incl

on page 197!
109.307 1
3HAC 14751-1
Rot ac motor incl pinion (175/

2.55)

on page 197!
109.307 1
3HAC 14750-1

(225/2.25, 175/2.8, 125/3.2,
200/2.75)

on page 197!
109.308 8
3HAB 3409-50
M10x40
109.309 8
3HAB 4233-1
Washer
109.310 1
3HAC 12252-1
Bottom plate
13x19x1,5
t = 4 mm
M6x16
5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1
Item
3HAC 16247-1
Qty
T=3
195

5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1
Item
196
Qty
Art. number
Description
Dimension/Note
109.311 1
3HAC 14131-1
Connection plate, base
t=3 mm
109.312 1
3HAC 11774-3
Adapter, complete
See Adapter, compl.,

197!
109.313 1
3HAC 11769-1
Cable guide, ax.1
109.314 1
3HAC 16295-3
Cover
109.315 29
9ADA 183-39
M8x35
109.316 29
9ADA 312-7
Plain washer
8,4x16x1,6
109.317 1
3HAB 3772-68
O-ring
276x3,53
109.318 1
3HAB 3772-69
O-ring
378x4
109.319 1
3HAB 3772-70
O-ring
340x3,5
109.320 1
3HAC 12671-5
Profile with sync scale
109.321 1
3HAC 12671-6
109.322 1
3HAC 14024-1
Protection screw
See Protection screw,

198!
109.324 24
9ADA 618-56
Torx pan head screw
M6x16
109.325 3
9ADA 618-57
Torx pan head screw
M6x20
109.326 1
3HAC 16014-1
Serial measurement unit
109.327 1
3HAC 14692-3
Cover SMB and BRU
See Cover SMB and

BRU, 3HAC 14692-3 on
page 198!
109.328 1
3HAC 16831-1
Battery pack
34x102x63
109.329 1
3HAC 13151-1
Cable battery/SMB
L=35020
109.330 2
3HAC 11526-1
Stud screw
M6x150
109.332 1
3HAC 14791-3
Cover battery box
See Cover battery box,

198!
109.334 4
9ADA 618-53
Torx pan head screw
M6x8
109.335 1
3HAA 2166-23
VK-Cover
D=120, B=12
109.336 1
3HAC 13915-1
Attachment plate
109.337 2
3HAC 12625-1
Strap, Velcro
25x450
109.338 1
3HAC 14792-1
Bracket
T=3
109.339 1
3HAC 15619-1
Cable, FB7-SMB 1.7
109.341 7300 3HAC 16843-1

ml
109.342 4600 3HAC 16843-1

ml
109.344 1
3HAB 7116-1
Locking liquid
109.345 1
9ADA 298-4
Prev. torque nut, non-met.
109.346 1
3HAC 16035-1
BU w. buttons DSQC 563
109.347 1
3HAC 6499-1
Push button guard
109.348 4
9ADA 629-56
Torx pan head roll. screw
M6x16
109.349 2
9ADA 618-58
Torx pan head screw
M6x25
109.350 1
3HAC 4813-1
Cover, push button guard
109.351 10
9ADA 618-44
Torx pan head screw
M6
M5x12
3HAC 16247-1

5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1
RV 410F-270,176
assembly, 3HAC
17271-1
Rot ac motor incl

pinion, 3HAC
14749-1
Rot ac motor incl

pinion, 3HAC
14751-1
Rot ac motor incl

pinion, 3HAC
14750-1
Item
Qty Art. number
Description
109.301.1 1
3HAC 10828-11 RV 410F, i=270,176
109.301.2 2
3HAB 3772-68
Item
Qty Art. number
O-ring
276x3,53
Description
Dimension
109.306.1 1
3HAC 14673-6
109.306.2 1
3HAC 11350-1
Pinion RV 500C & RV 320C
109.306.3 0
2152 2012-430 O-ring
Item
Qty Art. number
Dimension
Description
89,5x3
Dimension
109.307.1 1
3HAC 14673-6
109.307.2 1
109.307.3 0
2152 2012-430
O-ring
89,5x3
109.307.4 1
9ADA 183-444
M8x130
109.307.5 3 ml 3HAB 7116-1
Locking liquid
Item
Description
Qty Art. number
Dimension
109.307.1 1
3HAC 14673-9
109.307.2 1
109.307.3 0
2152 2012-430
O-ring
89,5x3
109.307.4 1
9ADA 183-444
M8x130
109.307.5 3 ml 3HAB 7116-1
Locking liquid
Adapter, compl.,
3HAC 11774-3
3HAC 16247-1
Item
Qty
Art. number
Description
109.312.1
3HAC 11774-1
Adapter, machined
109.312.2
2152 2012-428
O-ring
109.312.3
1 ml
1234 0011-125
Acrylate adhesive
Dimension
79,5x3
197

5.1.13 Mtrl set balancing device, 3HAC 13265-1
Protection screw,
3HAC 14024-1
Item
Cover SMB and

BRU, 3HAC
14692-3
Cover battery
box, 3HAC 147913
Qty
Art. number
Description
109.322.1 1
3HAC 13582-1
Protection Screw
109.322.2 1
3HAB 3772-32
O-ring
Item
Art. number
Description
109.327.1 1
3HAC 14692-1
Cover, casting
109.327.2 1
3HAC 14692-2
Gasket
109.327.3 1
3HAC 14692-4
Rubber cloth
Item
Art. number
Description
Dimension
109.332.1 1
3HAC 14791-1
Cover
T=4
109.332.2 1
3HAC 14791-2
Gasket
T=3
109.332.3 1
3HAC 16977-1
Warning label battery
Qty
Qty
Dimension
17x3
Dimension
5.1.13 Mtrl set balancing device, 3HAC 13265-1
198
Item
Qty
Art. number
Description
Dimension
110.401
3HAC 12441-2
Spherical roller bearing
65x120x38
110.402
3HAC 12481-1
Thrust washer
110.403
3HAC 12627-1
Bushing
110.404
9ABA 135-31
Retaining ring, shaft
110.405
3HAC 12480-1
Shaft
110.406
3HAC 4836-7
Protection plug
16x12,3x9x7
110.407
3HAB 7700-5
M16x70
110.408
9ABA 107-56
Parallel pin
10x20
110.409
3HAC 12548-1
Protection washer
T=1
110.410
3HAC 12534-1
Shaft, Balancing device
110.411
3HAA 1001-186
Washer
110.412
50 ml
3HAA 1001-294
Grease
110.413
3HAC 4836-1
Protection plug
20x14,6x7,5x5,5
110.414
9ADA 183-490
M16x180
110.415
9ADA 312-10
Plain washer
17x30x3
65
17x25x3
3HAC 16247-1

5.1.14 Arm extension set, 250 mm, 3HAC 12311-4
Item
Qty
Art. number
Description
Dimension
111.501 1
3HAC 9760-3
Arm extender 250mm
111.501 1
3HAC 15859-2
Arm extender 250mm,

Foundry
111.503 12
3HAB 7700-69
111.504 12
13x19x1,5
111.505 1
9ABA 107-56
Parallel pin
10x20
111.506 1
3HAC 9760-9
Cable cover 250mm
111.507 4
9ADA 618-56
Torx pan head screw
M12x50
M6x16
Item
3HAC 16247-1
Qty Art. number
Description
Dimension
111.501 1
3HAC 9760-7
Arm extender, 450mm
111.501 1
3HAC 15859-3
Arm extender, 450mm,

Foundry
111.503 12
3HAB 7700-69
111.504 12
13x19x1,5
111.505 1
9ABA 107-56
Parallel pin
10x20
111.506 1
3HAC 9760-10
Cable cover 450mm
111.507 6
9ADA 618-56
Torx pan head screw
M12x50
M6x16
199

200
3HAC 16247-1
6 Appendix 2: Foldouts
6.0.1 Introduction
Chapter 6: Appendix 2: Foldouts

6.0.1 Introduction
Definitions
This chapter is an appendix to the manual and contains detailed views of the components on
the manipulator.
The numbered details are specified with item numbers in the Appendix 1: Part List.
The foldouts are divided into:
3HAC 16247-1
Base, incl. frame
Frame-Lower arm 1
Frame-Lower arm 2
Upper arm
Wrist complete
201
6.0.1 Introduction
202
3HAC 16247-1
6.0.2 Base incl. Frame
101.2.1
101.2.2
101.1
101.5
101.9
101.6 101.8 101.7
101.2.4
101.2.3
101.3
101.4
xx0200000329
3HAC 16247-1
203
204
3HAC 16247-1
6.0.3 Frame-Lower arm 1
6.1
.30
109
6.3
.30
109
6.2
.30
109 .303
109
1.1
.30
109
5
.30
109
4
.30
109
8
.31
109
302
109. 15
3
109. 6
9
31
109.
.31
109
4
.31
109 317
.
109 32
.2
108
7.1
.30 3
109 .307.
109 .308
109 .309
109
xx0200000334
3HAC 16247-1
205
206
3HAC 16247-1
40
0.
4
40
0.
11 1
40
0.
2
11
11
108.201, 108.204
110.410
110.414
110.415
11
0.
40
3
11
0.
40
108.202
xx0200000335
3HAC 16247-1
207
208
3HAC 16247-1
6.0.5 Upper arm
6.0.5 Upper arm
.1
02
5
.5.
xx0200000337
3HAC 16247-1
209
6.0.5 Upper arm
210
3HAC 16247-1
6.0.6 Wrist complete
xx0200000336
3HAC 16247-1
211
212
3HAC 16247-1

S4CPlus-Repair Manual Part 1 IRB6600

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Repair Manual, part 1

Repair Manual, part 1, IRB 6600/6650, M2000A

The information in this manual is subject to change without notice and

Copyright 2003 ABB All rights reserved.

1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.1.1 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.1.1 Removal of cable harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.2.1 Removal of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.3.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Section 3.4: Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.4.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.5.1 Removal of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.6.1 Removal of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

4.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.1.1 Replacement of battery unit, controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

5.1.1 Mechanical stop ax 1, 3HAC 12812-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

This manual should be used during repair work.

Who Should Read

This manual is intended for:

repair personnel in the user's organization.

repair personnel in other organizations.

The reader should...

be a trained repair craftsman

have the required knowledge of mechanical repair work OR

have the required knowledge of electrical repair work.

The information product is organized in the following chapters:

Circuit Diagrams, Manipulator

Circuit Diagrams, Controller

Manual completed with version IRB 6650.

0.0.2 Product Documentation

0.0.2 Product Documentation

The Installation and Commissioning Manual contains the following information:

Installation of controller software

System directory structure

If there is any, model specific information

The Repair Manual contains the following information:

Remove/Refitting instructions for all manipulator details considered spare parts

If there is any, model specific information

The Maintenance Manual contains the following information:

If there is any, model specific information

0.0.2 Product Documentation

In addition, spare part information is supplied for the complete option.

Chapter 1: Safety, service

The chapter "Safety, service" is divided into the following sections:

Section 1.1: General information

1.1.2 Limitation of Liability

1.1.3 Related information

The list below specifies documents which contain useful information:

Installation of safety devices

Installation and Commissioning

Changing robot modes

Restricting the working space

Installation and Commissioning

On-site installation Manipulator

Section 1.2: Safety risks

1.2.2 Safety risks related to tools/workpieces

1.2.3 Safety risks related to pneumatic/hydraulic systems