IRC5-IRB6600 Prod Man 3HAC020938-001 Procedures RevC en

Product manual (part 1 of 2), procedures
Articulated robot
IRB 6600 - 225/2.55 type A
IRB 6600 - 175/2.8 type A
IRB 6600 - 175/2.55 type A
IRB 6650 - 200/2.75 type A
IRB 6650 - 125/3.2 type A
M2000, M2004,M2000A

Product manual (part 1 of 2), procedures

IRB 6600 - 225/2.55 type A
IRB 6600 - 175/2.8 type A
IRB 6600 - 175/2.55 type A
IRB 6650 - 200/2.75 type A
IRB 6650 - 125/3.2 type A
M2000
M2000A
M2004
Document ID: 3HAC 020938-001
Revision: C
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.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
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 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Vsters
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Safety
15
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.3 Emergency release of the robots arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2.4.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3.3 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 39
1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3.6 WARNING - Mixed oils may cause severe damage to gearbox! . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Installation and commissioning
45
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.2.3 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.3.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3.3 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3.5 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3.6 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3.7 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.3.8 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.3.9 Installation of chip and dust protection (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.3.10 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3HAC 020938-001 Revision: C
Table of Contents
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
93
95
97
99
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.5.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3 Maintenance
107
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.9 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.10 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.11 Inspection, additional mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.12 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.13 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.14 Inspection, signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
116
119
121
123
125
127
134
138
140
142
144
146
150
3.4 Replacement/changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3 Oil change, gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.7 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.8 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
152
156
160
164
167
170
173
176
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.5.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3.7 Service Information System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

3.7.2 Description of Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.7.3 SIS system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.7.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.7.5 Reading the SIS output logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.7.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4 Repair
195
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Table of Contents
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4.3.2 Replacement of cable harness, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.4.1 Replacement of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.4.2 Replacement of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.4.3 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
4.4.4 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.4.5 Replacement of lower arm shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.4.6 Securing the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.5 Frame and base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.5.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

4.5.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.5.3 Replacement of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
4.5.4 Unloading the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.5.5 Restoring the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

4.6.2 Replacement of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.6.3 Replacement of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

4.7.2 Replacement of gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5 Calibration information
337
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
6 Decommissioning
349
6.1 Environmental information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

6.2 Decommissioning of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Table of Contents
Overview
Overview
About this manual
This manual contains instructions for
mechanical and electrical installation of the manipulator
maintenance of the manipulator
mechanical and electrical repair of the manipulator.
Usage
This manual should be used during
installation, from lifting the manipulator to its work site and securing it to the
foundation to making it ready for operation
maintenance work
repair work.
Who should read this manual?

This manual is intended for:
installation personnel
maintenance personnel
repair personnel.
Prerequisites
The reader should...
be a trained maintenance/repair craftsman
have the required knowledge of mechanical and electrical installation/repair/

maintenance work.
Overview
Organization of chapters
The manual is organized in the following chapters:
Chapter
Contents
Safety
Safety information
Installation and
commissioning
Information about installation of the manipulator.
Maintenance
Information about maintenance work, including maintenance

schedules.
Repair
Information about repair work.
Calibration Information
Procedures that does not require specific calibration

equipment.
Decommissioning
Environmental information about the manipulator.
Revisions
Revision Description
-
First edition.
Replaces previous manuals:
Installation and Commssioning Manual
Maintenance Manual
Repair Manual, part 1
Repair Manual, part 2.
Changes made in the material from the previous manuals:
Previous separate Removal and Refitting sections combined to one
Replacement section.
New spare part number for the balancing device, section Replacement of
balancing device on page 263.
New spare part numbers for the motors, section Motors on page 278.
Updated instructions for calibration that describe the use of the Wyler
calibration equipment, chapter Calibration information on page 337.
Modified maintenance intervals for oil change and lubrication of
balancing device bearing, section Maintenance schedule on page 109.
Corrected information about the weight of the wrist unit, section
Replacement of complete wrist unit on page 225.
More detailed instructions of how to use special tools when removing and
refitting the lower arm shaft, new section Replacement of lower arm shaft
on page 246.
More detailed information about how to use special tools when securing
the lower arm with a fixture, new section Securing the lower arm on page
251.
Information about a cable protection at the lower arm, section Installation
of position switch, axis 2 on page 102.
Various corrections and editing made in text and figures due to technical
revisions, changes in the toolkits etc.
Model M2004 implemented.

New spare part number for axis 6 motor.
Removed section Alternative calibration.
Overview
Revision Description
B
Changes made in chapter Calibration:

Chapter Calibration is replaced with chapter Calibration information.
Chapter Safety, Service is replaced with a new Safety chapter.
New lubricating oil in the gearboxes. Changes are made in the chapter:
Maintenance.
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
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.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
Installation information
Repair information
Maintenance information
In addition, spare part information is supplied for the entire option.
10
Product documentation, M2004

General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
RAPID Overview: An overview of the RAPID programming language.
RAPID reference manual part 1: Description of all RAPID instructions.
RAPID reference manual part 2: Description of all RAPID functions and data types.
Technical reference manual - System parameters: Description of system

parameters and configuration workflows.
11
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
The purpose of the application (what it does and when it is useful)
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
How to use the application
Examples of how to use the application
Operators manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
Operators manual - IRC5 with FlexPendant
Operators manual - RobotStudio Online
Trouble shooting manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
12
Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)
How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material etc. The references are read as
described below.
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an procedure.
Step Action
Note/Illustration
8.
Shown in the figure Location of

gearbox on page xx.
Remove the rear attachment screws, gearbox.
References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in an procedure.
Step Action
Note/Illustration
3.
Art. no. is specified in Required

equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed. Read more in chapter Safety on page
15.
13
14
1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 16.
specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 36.
15
1 Safety
1.2.1. Introduction
1.2 General safety information

1.2.1. Introduction
Definitions
This section details general safety information for service personnel i.e. personnel performing
installation, repair and maintenance work.
Sections
The general safety information is divided into the following sections:
1. General information contains lists of:
Safety, service
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 during service work on robot
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.
16
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
Signal lamp (optional)
1 Safety
1.2.2.1. Safety, service
1.2.2. General information

1.2.2.1. Safety, service
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.
17
1 Safety
1.2.2.2. Limitation of Liability
1.2.2.2. Limitation of Liability

General
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
have been complied with.
18
1 Safety
1.2.2.3. Related information
1.2.2.3. Related information

General
The list below specifies documents which contain useful information:
Documents
Type of information
Detailed in document
Section
Installation of safety devices
Product manual for the

manipulator
Installation and commissioning
Changing robot modes
Users Guide
Start-up
Restricting the working space Product manual for the

manipulator
Installation and commissioning
19
1 Safety
1.2.3.1. Safety risks during service work on robot
1.2.3. Safety risks

Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.
20
1 Safety
Complete robot
Safety risk
Description
Hot components!
Caution!
Motors and gears are HOT after running the robot!

Touching the motors and gears may result in burns!
Removed parts may result in
collapse of robot!
Warning!
Take any necessary measures to ensure that the robot

does not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.
Cabling
Safety risk
Description
Cable packs are sensitive to

mechanical damage!
Caution!
The cable packs are sensitive to mechanical damage!

They must be handled with care, especially the
connectors, in order to avoid damaging them!
Gearboxes and motors

Safety risk
Description
Gears may be damaged if

excessive force is used!
Caution!
Whenever parting/mating motor and gearbox, the gears

may be damaged if excessive force is used!
21
1 Safety
Balancing device
Safety risk
Description
Dangerous balancing device!
Warning!
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!
22
1 Safety
1.2.3.2. Safety risks related to gripper
1.2.3.2. Safety risks related to gripper

CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
23
1 Safety
1.2.3.3. Safety risks related to tools/workpieces
1.2.3.3. 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.
24
1 Safety
1.2.3.4. Safety risks related to pneumatic/hydraulic systems
1.2.3.4. Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
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.
Safe design
25
1 Safety
1.2.3.5. Safety risks during operational disturbances
1.2.3.5. Safety risks during operational disturbances

General
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.
Qualified personnel
Extraordinary risks
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.
26
1 Safety
1.2.3.6. Safety risks during installation and service
1.2.3.6. Safety risks during installation and service

General risks during installation and service
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.
Nation/region specific regulations

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.
Non-voltage related risks
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
parallel arm.
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 part
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.
To be observed by the supplier of the complete system
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.
27
1 Safety
1.2.3.7. Risks associated with live electric parts
1.2.3.7. Risks associated with live electric parts

Voltage related risks, general
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 robot's working space.
Voltage related risks, controller

A danger of high voltage is associated with the following parts:
Be aware of stored electrical energy (DC link) in the controller.
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, robot

A danger of high voltage is associated with the robot in:
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)
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.
28
1 Safety
1.2.4.1. Safety fence dimensions
1.2.4. Safety actions

1.2.4.1. Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
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.
29
1 Safety
1.2.4.2. Fire extinguishing
1.2.4.2. Fire extinguishing

NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!
30
1 Safety
1.2.4.3. Emergency release of the robots arm
1.2.4.3. Emergency release of the robots arm

Description
In an emergency situation, any of the robots axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
Manually releasing the brakes on page 67.
The robot 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, further increasing any injury!
31
1 Safety
1.2.4.4. Brake testing
1.2.4.4. 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.
32
1 Safety
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!
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.
33
1 Safety
1.2.4.6. Safe use of the Teach Pendant Unit
1.2.4.6. Safe use of the Teach Pendant Unit

NOTE!
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:
34
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 robot's working space. This is to prevent anyone else taking control over
the robot without the programmer knowing.
1 Safety
1.2.4.7. Work inside the manipulators working range
1.2.4.7. Work inside the manipulators working range

WARNING!
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 robot's 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 speed" may 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 32.
35
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions

General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
A brief description of what will happen if the operator/service personnel does not
eliminate the danger.
An instruction of how to eliminate the danger to facilitate performing the activity at

hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol
Designation
Signification
DANGER
Warns that an accident will occur if the instructions

are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height etc.
WARNING
Warns that an accident may occur if the instructions

are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height etc.
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol

indicates electrical hazards which could result in
severe personal injury or death.
CAUTION
Warns that an accident may occur if the instructions

are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
danger
warning
Electrical shock
caution
36
1 Safety
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates

DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE
Note symbols alert you to important facts and

conditions.
TIP
Tip symbols direct you to specific instructions, where

to find additional information or how to perform a
certain operation in an easier way.
Note
Tip
37
1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
1.3.2. DANGER - Moving manipulators are potentially lethal!

Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.
Elimination
Step
38
Action
Info/Illustration
1.
Before attempting to run the manipulator,

Emergency stop equipment such as
make sure all emergency stop equipment gates, tread mats, light curtains, etc.
has been correctly installed and connected.
2.
If possible, use the hold-to-run button

whenever possible.
The hold-to-run button is used in manual
mode, not in automatic mode.
3.
Make sure no personnel is present within

the manipulator working range before
pressing the start button.
How to use the hold-to-run control in

RobotWare 5.0 is detailed in section
How to use the hold-to-run switch in
the Operators Manual, IRC5.
How to use the hold-to-run control in
RobotWare 4.0 is detailed in section
The Teach Pendant unit in the Users
Guide.
1 Safety
1.3.3. WARNING - The brake release buttons may be jammed after service work
1.3.3. WARNING - The brake release buttons may be jammed after service work
Description
The brake release unit has push buttons for brake release of each axis motor. When service
work is performed inside the SMB recess that includes removal and refitting of the brake
release unit, the brake release buttons may be jammed after refitting!
In case the power is turned on while a brake release button is jammed in depressed position,
the affected motor brake is released! This may cause serious personal injuries and damage to
the robot!
Elimination
To eliminate the danger after service work has been performed inside the SMB recess, follow
the procedure below:
Step
Action
1.
Make sure the power is turned off.
2.
Remove the push button guard, if necessary.
3.
Check the push buttons of the brake release unit by pressing them down, one by
one.
Make sure none of the buttons are jammed in the tube.
4.
If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes!
39
1 Safety
1.3.4. WARNING - The unit is sensitive to ESD!
1.3.4. WARNING - The unit is sensitive to ESD!

Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not connected to ground potential may transfer
high static charges. This discharge may destroy sensitive electronics.
Elimination
Step
40
Action
Note/Illustration
1.
Use a wrist strap
Wrist straps must be tested frequently to

ensure that they are not damaged and are
operating correctly.
2.
Use an ESD protective floor mat.
The mat must be grounded through a currentlimiting resistor.
3.
Use a dissipative table mat.
The mat should provide a controlled discharge

of static voltages and must be grounded.
1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!
Warnings and elimination
Warning
Description
Elimination / Action
Changing and draining

Make sure that protective gear
gearbox oil may require
like goggles and gloves are
handling hot oil of up to 90 C! always worn during this activity.
Hot oil!
When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
-
Possible pressure build

up in gearbox!
Do not overfill!
Overfilling of gearbox oil can

lead to internal over-pressure
inside the gearbox which in
turn may:
damage seals and
gaskets
completely press out
seals and gaskets
prevent the manipulator
from moving freely.
Make sure not to overfill the

gearbox when filling with oil!
After filling, check the correct oil
level.
Mixing types of oil may cause

severe damage to the
gearbox!
When filling gearbox oil, do not

mix different types of oil unless
specified in the instruction.
Always use the type of oil
specified by the manufacturer!
Warm oil drains quicker than

cold oil.
When changing gearbox oil, first

run the robot for a time to heat
up the oil.
Do not mix types of oil!
Heat up the oil!
41
1 Safety
Warning
Specified amount
depends on drained
volume!
42
Description
Elimination / Action
The specified amount of oil is After refilling, check the oil level.
based on the total volume of
the gearbox. When changing
the oil, the amount of refilled oil
may differ from the specified
amount, depending on how
much oil has previously been
drained from the gearbox.
1 Safety
1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!

Description
The six gearboxes of the robot are historically filled with different types of oil. When refilling
a gearbox it is extremely important to fill with exactly the same type of oil that is currently
used! In case the gearbox oil is contaminated with an other type of oil, the gearbox may be
severely damaged and must therefor be rinsed.
Shell Tivela S 150 mixed with Optimol Optigear RMO 150
The procedure below details how to rinse the contaminated gearbox if the oil types Shell
Tivela S 150 and Optimol Optigear RMO 150 are mixed.
Step
Action
1.
Flush the gearbox properly three times with the correct type
of oil. Use a service program when flushing.
2.
Refill the gearbox with the correct type of oil.
Note
Shell Tivela S 150 mixed with Mobil Gearlube X320

The procedure below details how to rinse the contaminated gearbox if the oil types Shell
Tivela S 150 and Mobil Gearlube X320 are mixed.
Step
Action
1.
If the gearbox should contain Tivela S 150 and is

contaminated with Gearlube X320:
Flush the gearbox properly three times with Tivela S
150. Use a service program when flushing.
Refill the gearbox with Tivela S 150.
2.
If the gearbox should contain Gearlube X320 and is

contaminated with Tivela S 150:
Drain the gearbox.
Flush the gearbox once with Gearlube X320. Use a
serviceprogram when flushing.
Drain the gearbox properly! It is important to allow all
the oil be drained from the gearbox!
Refill the gearbox with Gearlube X320.
Note
43
1 Safety
44

2.1. Introduction

2.1. Introduction
General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
45

2.2.1. Pre-installation procedure
2.2 Unpacking
General
This section is intended for use when unpacking and installing the robot for the first time. It
also contains information useful during later re-installation of the robot.
Checking the pre-requisites for installation
The checklist below details what must be observed before proceeding with the actual
installation of the robot:
1. Make sure only qualified installation personnel conforming to all national and local codes
are allowed to perform the installation.
2. Visually inspect the robot to make sure it is not damaged.
3. Make sure the lifting device used is suitable to handle the weight of the robot as specified
in Weight, robot on page 46.
4. If the robot is not installed directly, it must be stored as described in Storage conditions,
robot on page 47.
5. Make sure the expected operating environment of the robot conforms to the specifications
as described in Operating conditions, robot on page 47.
6. Before taking the robot to its installation site, make sure the site conforms to Loads on
foundation, robot on page 47, Requirements on foundation, robot on page 47 and
Protection classes, robot on page 48.
7. Before moving the robot, please observe Risk of tipping / stability on page 53 regarding
risk of tipping!
8. When these prerequisites are met, the robot may be taken to its installation site as
described in section On-site installation on page 54.
Weight, robot
The table below shows the weights of the different models:
46
Robot model
Weight
IRB 6600 - 175/2.55
1700 kg
IRB 6600 - 225/2.55
1700 kg
IRB 6600 - 175/2.8
1700 kg
IRB 6650 - 125/3.2
1725 kg
IRB 6650 - 200/2.75
1700 kg

Loads on foundation, robot

The table below shows the various forces and torques working on the robot during different
kinds of operation.
Note! These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum simultaneously!
Force
Endurance load (operation)
Max. load (emergency stop)
Force xy
10.1 kN
20.7 kN
Force z
18.0 13.8 kN
18.0 22.4 kN
Torque xy
27.6 kNm
50.6 kNm
Torque z
7.4 kNm
14.4 kNm
Requirements on foundation, robot

The table below shows the requirements for the foundation where the robot is installed:
Requirement
Value
Min. levelity
0.5 mm
Max. tilt
Min. resonance frequency
22 Hz
Note
The limit for the maximum load on the robot
is reduced if the robot is tilted.
Contact ABB for further information about
acceptable loads.
Storage conditions, robot

The table below shows the allowed storage conditions for the robot:
Parameter
Value
Min. ambient temperature
-25 C
Max. ambient temperature
+55 C
Max. ambient temperature (less than 24 hrs)
+70 C
Max. ambient humidity
Max. 95% at constant temperature
Operating conditions, robot

The table below shows the allowed operating conditions for the robot:
Parameter
Value
Min. ambient temperature
+5 C
Max. ambient temperature
+50 C
Max. ambient humidity
Max. 95% at constant temperature
47

Protection classes, robot

The table below shows the protection class of the robot:
48
Equipment
Protection class
robot
IP 67

2.2.2. Working range

Working range
This section details the working ranges of the manipulator models.
IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55
The illustration below shows the unrestricted working range of IRB 6600 - 175/2.55 and IRB
6600 - 225/2.55:
xx0200000025
49

IRB 6600 - 175/2.8

The illustration below shows the unrestricted working range of IRB 6600 - 175/2.8:
xx0200000026
50

IRB 6650 - 125/3.2

xx0200000338
51

IRB 6650 - 200/2.75

xx0200000339
52

2.2.3. Risk of tipping / stability
2.2.3. Risk of tipping / stability

Risk of tipping
When the robot is not fastened to the foundation and standing still, the robot is not stable in
the whole working area. Moving the arms will displace the center of gravity, which may cause
the robot to tip over. Do not change the robot position before securing it to the foundation.
Stabililty
The figure below shows the robot in its shipping position, which also is its most stable
position.
xx0100000103
WARNING!
The robot is likely to be mechanically unstable while not secured to the foundation!
53

2.3.1. Lifting robot with fork lift
2.3 On-site installation

General
The robot may be moved using a fork lift, provided that available special aids are used.
This section describes how to attach the fork lift equipment to the robot.
Different designs
There are two different versions of the fork lift that fit one design of the frame respectevily.
The different designs of the frame and of the fork lift attachments are shown in the figure
below. Determine which fork lift set fits the current robot.
Note! The distance between the attachment holes for the fork lift pockets, shown in the figure
below, are different depending on the design of the frame. This means that the fork lift sets
are unique for one type of frame and not compatible!
Except for the shorter distance between the attachment holes, the later design of the frame
also includes an extra oil plug, located as shown in the figure below.
xx0200000386
54
Frame version without an oil plug, use the fork lift set: 3HAC 0604-2
Frame version with an oil plug (C), use the fork lift set: 3HAC 0604-1
Attachment holes, fork lift 3HAC 0604-2
Attachment holes, fork lift 3HAC 0604-1
Oil plug

Attachment points
The attachment points for the fork lift equipment are shown in the figure below.
xx0400000707
Attachment points, spacer and horizontal attachment screws
Attachment points, horizontal attachment screws
Attachment points, vertical attachment screws
Attachment points, horizontal attachment screws
Required equipment
To determine which fork lift set to use, see the section Different designs on page 54.
Equipment, etc.
Art. no.
Note
Fork lift set, incl. all required 3HAC 0604-2

hardware
See the figure Fork lift set, 3HAC 0604-2

on page 56.
Fork lift set, incl. all required 3HAC 0604-1

hardware
See the figure Fork lift set, 3HAC 0604-1

on page 57.
Standard toolkit
The contents are defined in section

Standard toolkit in the Product manual,
reference information!
3HAC 1557-1
55

Fork lift set, 3HAC 0604-2

The fork lift set, 3HAC 0604-2, is fitted to the robot as shown in the figure below.
xx0100000102
56
Vertical attachment screws (4 pcs / fork lift pocket)
Fork lift pockets (2 pcs)
Spacer (2 pcs)

Fork lift set, 3HAC 0604-1

The fork lift set, 3HAC 0604-1, is fitted to the robot as shown in the figure below.
xx0200000379
Fork lift pocket (2 pcs, different from each other)
Spacer (2 pcs)
Horizontal attachment screws (4 pcs / fork lift pocket)
Vertical attachment screws (2 pcs)
57

Lifting the robot with fork lift

The section below details how to secure the fork lift set to the robot in order to lift and move
the robot using the fork lift ONLY!
Step
Action
Info/Illustration
1.
If a cooling fan for the axis 1 motor is used,

it must be removed in order to use the fork
lift device!
2.
Position the robot as shown in the figure to Release the brakes if required as
the right!
detailed in section Manually releasing
Note! No load is permitted on the robot if the brakes on page 67.
the fork lift set 3HAC 0604-2 is used!
xx0200000079
When using fork lift set 3HAC 0604-2,

no load is permitted on the robot!
3.
Fit the two spacers to the robot and

secure.
Attachment points on the robot are

shown in the figure Attachment points
on page 55.
4.
Caution!
Caution!
The fork lift pocket weighs 60 kg!
58

Step
5.
Action
Info/Illustration
Secure the longer fork lift pocket to the

spacers with four of the horizontal
attachment screws and washers.
Note! The vertically and the horizontally
attached screws are identical, but
tightened with different torques!
Make sure the original screws are

always used (or replacements of
equivalent quality: M16, quality 12.9)!
on page 55.
xx0400001068
6.
A: horizontal attachment
screws, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
B: spacers, 2 pcs.
Make sure the securing screw is removed

from the fork lift pocket!
It is only used for robot model IRB 6650S.
xx0400000977
A: securing screw
59

Step
7.
Action
Info/Illustration
Secure the fork lift pocket to the robot with

the two vertical attachment screws and
washers.
(only valid for the fork lift set 3HAC 0604-1)
Note! The vertically and the horizontally
attached screws are identical, but
tightened with different torques!
xx0300000464
A: vertical attachment screws, 2

pcs, M16x60; tightening torque:
270 Nm.
on page 55.
8.
Caution!
Caution!
The fork lift pocket weighs 22 kg!
9.
Secure the shorter fork lift pocket on the

other side of the robot with the four
remaining horizontal attachment screws.
4 pcs, M16x60; tightening torque: 60

Nm.
on page 55.
10. Double-check that the pockets are

properly secured to the robot! Insert the
fork lift forks into the pockets.
xx0200000380
Reposition the harness, if any, before

using a fork lift!
60

Step
Action
Info/Illustration
11.
Caution!
Caution!
The robot weighs 1725 kg! All lifting
equipment used must be dimensioned
accordingly!
12. Carefully lift the robot and move it to its
installation site.
13.
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under the
suspended load!
61

2.3.2. Lifting robot with roundslings

General
The robot may be lifted with roundslings according to the illustration below. The illustration
is identical with the label attached to the robots lower arm.
Attachment points
The figure below shows how to attach the roundslings to the robot.
xx0200000282
62
Chain sling with shortener
Roundsling, manipulator
Roundsling, upper arm Note! Do not stretch!

Sling specification
Sling type
Qty
Lifting capacity
Length / Note
Chain sling with shortener
3 pcs
4 250 kg
0.47 m
0.54 m
0.76 m
Roundsling, manipulator
3 pcs
2 000 kg
2m
Roundsling, upper arm
2 pcs
2 000 kg
Note! Do not stretch!
Lifting with roundslings

Step
1.
Action
Note
Attach the roundslings to the robot according to the

figure Attachment points on page 62.
2.
Caution!
Caution!
The robot weighs 1725 kg! All lifting equipment used
must be dimensioned accordingly!
3.
Warning!
WARNING!
Personnel must not, under any circumstances, be
present under the suspended load!
63

2.3.3. Lifting robot with lifting slings

General
This section contains a general overview of how to lift the complete robot using special lifting
equipment. More detailed instructions are included with the equipment.
Illustration, lifting slings
The figure below shows how to lift the complete robot with lifting slings.
Note the recommended robot position shown in the figure below and in the instruction!
Attempting to lift a robot in any other position may result in the robot tipping over, causing
severe damage or injury!
xx0200000153
64
Load hook
Swivelling lifting eyes, 4 pcs
Shortening hook
Chain
M12 lifting eye
Lifting devices eye

Lifting slings, 4 pcs
Hook
Required equipment
Equipment
Art. no.
Note
Lifting device, manipulator
3HAC 15607-1
Includes
user instructions (3HAC 15971-2).
Slings attached directly onto robot

The section below details how to lift and move the robot using lifting slings when these are
attached directly onto the robot frame.
Step
Action
1.
Run the overhead crane to a position

above the robot.
2.
Make sure the robot is positioned as

shown in the figure on the right. If it is
not, position it that way.
Note
Release the brakes if required as detailed

in section Manually releasing the brakes
on page 67.
xx0100000103
3.
Fit the lifting device, manipulator to the Art. no. is specified in Required
robot as described in the enclosed
equipment on page 65!
instruction!
4.
Caution!
Caution!
The robot weighs 1725 kg! All lifting
accordingly!
65

Step
Action
Note
5.
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under the
suspended load!
6.
66
Raise the overhead crane to lift the

robot.
Make sure all hooks and attachments

maintain their correct positions while
lifting the robot!
Always move the robot at very low
speeds, making sure it does not tip.

2.3.4. Manually releasing the brakes

General
This section details how to release the holding brakes of each axis motor.
Location of brake release unit
The internal brake release unit is located at the frame, as shown in the figure below.
xx0300000044
Internal brake release unit with push buttons
Releasing the brakes

The procedure below details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Step
1.
Action
Info/Illustration
The internal brake release unit is equipped with six

buttons for controlling the axes brakes. The buttons are
numbered according to the numbers of the axes.
If the robot is not connected to the controller, power must
be supplied to the connector R1.MP according to section
Supplying power to connector R1.MP on page 68.
The buttons are shown

in the figure Location of
brake release unit on
page 67
2.
Danger!
When releasing the holding brakes, the robot axes may
move very quickly and sometimes in unexpected ways!
Make sure no personnel is near the robot arm!
67

Step
3.
Action
Info/Illustration
Release the holding brake on a particular robot axis by

pressing the corresponding button on the internal brake
release panel and keeping it depressed.
The brake will function again as soon as the button is
released.
Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector R1.MP in
the robot base in order to enable the brake release buttons on the robot.
Step
Action
Note/Illustration
1.
Danger!
Incorrect connections, such as
supplying power to the wrong pin, may
cause all brakes to be released
simultaneously!
2.
Supply 0V on pin 12 and 24V on pin

11.
xx0300000565
68

2.3.5. Lifting the base plate
2.3.5. Lifting the base plate

General
This section details how to lift the base plate
Equipment
Art. no.
Note
Lifting eye, M16
3HAC 14457-4
3 pcs
Lifting slings
3 pcs
Length: approx. 2 m
Hole configuration
xx0200000096
Attachment holes for lifting eyes (x3)
Lifting the base plate

Step
Action
Info/Illustration
1.
Caution!
The base plate weighs 353 kg! All lifting equipment
used must be dimensioned accordingly!
2.
Fit the lifting eyes in the three lifting holes.
3.
Fit the lifting slings to the eyes and to the lifting

device.
Shown in the figure Hole

configuration on page 69!
69

2.3.6. Securing the base plate

General
This section details how to secure the base plate.
Base plate, dimensions
xx0100000105
70

xx0400000715
Note1
Four holes for alternative clamping

71

Base plate, grooves and holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.
xx0300000045
Guide sleeve holes (2 pcs)
Orienting grooves (3 pcs)
Levelling bolts, attachment holes (4 pcs)
Required equipment
Equipment
Art. no.
Note
Base plate
3HAC 12937-8
Includes
guide sleeves, 3HAC 12937-3
levelling screws, 9ADA 120-79
attachment screws and
washers for securing the
manipulator to the base plate.
A drawing of the base plate itself may
be ordered from ABB Robotics!
Standard toolkit
3HAC 15571-1

Other tools and procedures may

be required. See references to
these procedures in the step-bystep instructions below.
72
These procedures include references

to the tools required.

Recommendations, quality
The table specifies any recommendations made by ABB:
Variable
Recommendation
Recommended foundation quality 1
Steel fibre reinforced concrete foundation, 30 kg/m3,

class K30, t=250 mm
Recommended foundation quality 2
Sturdy concrete foundation, double reinforced by 10

mm steel bars, distance 140 mm, class K25, t=250
Recommended bolt quality and

dimension
Hilti HDA-P, M20 x 250/50 (maximum thickness of

base plate = 50 mm)
Hilti HDA-P, M20 x 250/100 (maximum thickness of
base plate = 100 mm)
Base plate
This section details how to secure the base plate to the foundation.
CAUTION!
The base plate weighs 353 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Info/illustration
1.
Make sure the foundation is level.
2.
Orient the base plate in relation to the robot

work location using the three grooves in the
base plate.
Shown in the figure Base plate,

grooves and holes on page 72.
3.
Lift the base plate to its mounting position.
Detailed in section Lifting the base

plate on page 69.
4.
Use the base plate as a template and drill 16 If possible, observe the
attachment holes as required by the selected recommendations specified in
bolt dimension.
section Recommendations, quality
on page 73. ABB does not assume
any responsibility for other
foundation qualities, due to great
variations in the foundation
properties.
5.
Fit the base plate and use the levelling bolts Shown in the figure Base plate,
to level the base plate.
6.
If required, fit strips of sheet metal

underneath the base plate to fill any gaps.
7.
Secure the base plate to the foundation with

screws and sleeves.
8.
Recheck the four manipulator contact

Max. allowed deviation: 0.5 mm
surfaces on the base plate to make sure they
are level and flat.
If they are not, pieces of sheet metal or
similar may be used to bring the base plate to
a level position.
73

2.3.7. Orienting and securing the robot

General
This section details how to orient and secure the robot to the base plate in order to run the
robot safely. The requirements made on the foundations are shown in the following tables and
figures.
Illustration, robot fitted to base plate
The illustration below shows the robot base fitted to the base plate.
xx0300000566
Robot attachment bolts and washers, 8 pcs (M24 x 140)
Orienting grooves in the robot base and in the base plate
Levelling screws
Base plate attachment screws
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
robot to the base plate/foundation.
74
Suitable screws, lightly lubricated:
M24 x 140
Quality:
Quality 8.8
Suitable washer:
Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque:
725 Nm

Securing the robot

The procedure below details how to secure the robot to the base plate after fitting the plate to
the foundation.
Step
Action
Info/Illustration
1.
Lift the robot.
Detailed in section Lifting robot with

lifting slings on page 64.
2.
Move the robot to the vicinity of its

installation location.
3.
Fit two guide sleeves to the guide sleeve

holes in the base plate.
Shown in the figure Base plate,

Note that one of the guide sleeve holes
is elongated!
4.
Guide the robot gently using two M24

screws while lowering it into its mounting
position.
Make sure the robot base is correctly

fitted onto the guide sleeves!
5.
Fit the bolts and washers in the base

attachment holes.
Specified in Attachment screws on

page 74.
Shown in the figure Illustration, robot
fitted to base plate on page 74!
Note! Lightly lubricate the screws
before assembly!
6.
Tighten the bolts in a criss-cross pattern to

ensure that the base is not distorted.
Hole configuration, base

The illustration below shows the hole configuration used when securing the robot.
xx0200000029
75

Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes.
xx0100000109
76

2.3.8. Fitting equipment on robot

General
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional cabling,
equipment, etc., fitted by the robot user. Make sure the required mounting holes are accessible
when planning the robot cell.
Under certain conditions, mounting holes may be added on the robot.
Illustration, fitting of extra equipment on lower arm
The illustration below shows the mounting holes available for fitting extra equipment on the
lower arm.
Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra
equipment. Always use appropriate attachment screws!
xx0200000195
77

xx0300000571
xx0300000572
78

Illustration, fitting of extra equipment on upper arm

upper arm.
xx0300000573
xx0200000196
79

Illustration, fitting of extra equipment on frame

frame.
xx0200000198
80

Illustration, fitting on mounting flange

The illustration below shows the mounting holes available for fitting equipment on the
mounting flange.
There are two different versions of the mounting flange, as shown in the illustrations below.
xx0200000397
Mounting flange for robot version IRB 6600 175/2.55. Use every other of the bolt
holes for six attachment bolts, as numbered in the figure.
81

xx0200000197
Mounting flange for robot version IRB 6600 225/2.55 and 175/2.8, IRB 6650 125/
3.2 and 200/2.75
Fastener quality
When fitting tools on the mounting flange (see the figures above), use only screws with
quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
82

2.3.9. Installation of chip and dust protection (option)

General
This section details how to install the optional chip and dust protection. It also details how to
remove the proctection, when necessary.
Illustration, equipment mounted on robot
The illustration below shows the chip and dust protection mounted on the robot.
xx0400001071
Bearing unit, lower arm shaft
Bearing unit, axis 2 motor
Stop
Shield (4 pcs)
Cover, balancing device
Sliding cover
Cover, lower arm
83

Required equipment
Equipment
Art. no.
Note
Chip and dust protection
3HAC 020529-002
Includes mounting set with

attachment screws and mounting
instruction.
Locking liquid
Loctite 577
Used to secure the attachment
screws of the rear cover at the
end of the balancing device.
Standard toolkit
3HAC 15571-1
The contents are defined in

section Standard toolkit in the
Product manual, reference
information.
Installation
The procedure below details how to install the chip and dust protection to the robot.
Step
1.
Action
Illustration
Fit the bearing unit, lower arm

shaft to the robot by inserting it
through the shaft and securing
with the washer and nut.
xx0400001077
A: Bearing unit
B: Lower arm shaft
C: Washer and nut
Also shown in the figure Illustration, equipment
mounted on robot on page 83
84

Step
2.
Action
Illustration
Remove the four attachment

screws (A) from the cover, axis 2.
Use the holes to attach the
bearing as described in next step.
xx0400001078
3.
Attach the bearing unit, axis 2

motor to the robot with the
enclosed attachment screws.
Make sure the bearing unit is
orientated correctly. The opening
must be orientated approximately
as shown in the figure to the right
(B).
xx0400001079
Attachment screws: 4 pcs, M8 x 70.

Also shown in the figure Illustration, equipment
mounted on robot on page 83
4.
Remove the securing screws that

are fitted to the bearing unit
during transport and installation.
The separate rings are now
movable.
xx0400001098
85

Step
5.
Action
Illustration
Fit the stop to the robot. Use the

xx0400001080
6.
C: Attachment screws: 2 pcs, M6x25.
Remove the rear bracket from the

upper shield.
xx0400001099
86

Step
7.
Action
Illustration
Fit the four shields to the robot

with enclosed attachment
screws. Begin with the shield at
the bottom and continue
upwards, correct order is shown
in the figure to the right.
Make sure to fit the border tabs to
eachother so that the upper
shields lift the lower ones when
the robot moves.
xx0400001082
8.
D: Attachment screws, 2 pcs, M12 x 20

E: Attachment screws, 16 pcs, M6 x 10
Remove the two upper

attachment screws (shown in the
figure to the right) from the rear
cover of the balancing device.
xx0400001086
87

Step
9.
Action
Illustration
Secure the cover, balancing

device to the robot with the
original attachment screws,
earlier removed from the rear
Use locking liquid.
Fit the enclosed clamp (I) around
the balancing device and insert it
through the holes on top of the
cover.
xx0400001085
H: Attachment screws: 2 pcs, M10 x 30,

tightening torque: 50 Nm
I: Clamp
Locking liquid is specified in Required
equipment on page 84
10.
Fit the sliding cover to the robot.
xx0400001087
88
J: Bushing
K: Hub

Step
11.
Action
Illustration
Fit the rubber cloth of the sliding

cover between the upper shield
and the rear bracket (earlier
removed from the upper shield).
Attach the rear bracket with
xx0400001100
12.
L: Rubber cloth
M: Upper shield
N: Rear bracket
Fit the cover, lower arm to the

robot, using the enclosed screws.
If the attachment holes are used
for other equipment, the cover
may be fitted beneath the
equipment.
xx0400001088
O: Attachment screws, 2 pcs, M12 x 20
Removing parts
In case the chip and dust protection must be removed, for example in order to perform certain
repair activities, read and follow the information below. If removing the complete protection,
follow the removal order below. If only removing some parts, follow the actions detailed for
the specific part.
Part to be removed
Action
Cover, lower arm
Sliding cover
Cover, balancing device
1.
2.
3.
4.
Shields
Stop
Remove the sliding cover.

Remove the clamp from the balancing device.
Remove the cover, balancing device.
Refit the attachment screws to the rear cover of the
balancing device end, using locking liquid.
89

Part to be removed
90
Action
Bearing unit, lower arm shaft
1. Remove all the shields.

2. Remove the bearing unit.
Bearing unit, axis 2 motor
1. Remove all the shields.

2. Remove the bearing unit.
3. Refit the original attachment screws to the cover,
axis 2.

2.3.10. Loads
2.3.10. Loads
General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operational stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in Users
Guide (RobotWare 4.0), or Operators manual (RobotWare 5.0).
Stop time and braking distances
Robot motor brake performance depends on any loads attached. For further information about
brake performance, please contact ABB.
91

2.4.1. Introduction
2.4 Restricting the working range

2.4.1. Introduction
General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited.
The working range of following axes may be restricted:
Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
switch)
switch)
As standard configuration, axis 1 is allowed to move 180. The working range may however
be increased to 220 with option 561-1 "Extended working range axis 1". Notice that this
option also requires installation of a position switch on axis 1.
This section describes how to install hardware that restricts the working range.
Notice that adjustments must be made also in the software, references to software manuals
are given in following installation procedures.
92

2.4.2. Mechanically restricting the working range of axis 1

General
The working range of axis 1 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation in both directions.
Mechanical stops, axis 1
The illustration below shows the mounting position of the mechanical stops on axis 1.
xx0300000049
Additional mechanical stop
Fixed mechanical stop
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop for axis 1, 7.5
3HAC 11076-1
Includes attachment screws and an

assembly drawing.
Mechanical stop for axis 1, 15
3HAC 11076-2
Includes attachment screws and an

assembly drawing.
Standard toolkit
3HAC 15571-1

Standard toolkit in the Product
manual, reference information!
Users Guide (RobotWare 4.0)

Operator's manual (RobotWare5.0)
Art. no. is specified in section

Document references in the Product
manual, reference information.
93

Installation, mechanical stops axis 1

The procedure below details how to fit the mechanical stops of axis 1 on to the robot. An
assembly drawing is also enclosed with the product.
Step
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Fit the additional mechanical stop on the

frame according to the figure Mechanical
stops, axis 1 on page 93.
3.
The software working range limitations must

be re-defined to correspond to the changes
in the mechanical limitations of the working
range.
How to define the range of movement

in RobotWare 4.0 is detailed in the
Users Guide - chapter System
Parameters - topic Manipulator.
How to define the range of movement
in RobotWare 5.0 is detailed in the
Operator's manual - chapter
FlexPendant - section ABB menu subsection Control panel.
4.
Warning!
If the mechanical stop has been deformed
after a hard collision, it must be replaced!
94


General
adding up to six additional mechanical stops with 15 graduation in respective direction.
xx0300000047
Additional mechanical stops
Required equipment
Equipment, etc.
Art. no.
Mechanical stop set, axis 2
3HAC 13787-1 Includes six stops, 3HAC 13786-1, each

one restricting the working range by 15.
Includes attachment screws.
Standard toolkit
3HAC 15571-1 The contents are defined in section

Users Guide (RobotWare 4.0) Operator's manual

(RobotWare 5.0)
Note
Art. no. is specified in section Document

references in the Product manual,
reference information.
95


The procedure below details how to fit the mechanical stops for axis 2, on to the robot. An
Step
Action
Note/Illustration
1.
Danger!
2.
Fit and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop.
Shown in the figure Mechanical stops,
axis 2 on page 95.
3.
The software working range limitations

must be re-defined to correspond to the
changes in the mechanical limitations of
the working range.
How to define the range of movement in

RobotWare 4.0 is detailed in the Users
Guide - chapter System Parameters topic Manipulator.
RobotWare 5.0 is detailed in the
4.
Warning!
96


General
adding additional mechanical stops with 20 graduation in respective direction.
xx0300000048
Additional mechanical stops
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop set, axis 3
3HAC 13128-1
Includes six stops, one with 80

restriction, 3HAC 12708-3 (use
when limitation angle >=80), and five
with 20, 3HAC 12708-1.
Includes attachment screws.
Standard toolkit

Users Guide (RobotWare 4.0)

Operator's manual (RobotWare 5.0)
Art. no. is specified in section

Document references in the Product
manual, reference information.
97


The procedure below details how to fit the mechanical stops for axis 3 on to the robot. An
Step
Action
Note/Illustration
1.
Danger!
2.
Mount and tighten the additional stops in a Shown in the figure Mechanical stops,
row, starting from the fixed stop.
axis 3 on page 97
3.
The software working range limitations

must be re-defined to correspond to the
changes in the mechanical limitations of
the working range.

RobotWare 4.0 is detailed in the Users
Guide - chapter System Parameters topic Manipulator.
RobotWare 5.0 is detailed in the
4.
Warning!
98

2.4.5. Position switches

General
Position switches can be installed on axes 1-3. The position switches include cams as shown
in the figures below.
The position switch kits may be delivered in one of two ways:
Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and
locked by the user. For axis 1, the cover for the cams must also be fitted.
As kits to be completely fitted to the robot and adjusted by the user.
Required equipment
Description
Art. no.
Position switch, axis 1 complete
3HAC 14118-1
3HAC 15710-1
3HAC 15709-1
Connector kit R1.SW1
3HAC 17252-1
Connector kit R1.SW2/3
3HAC 17253-1
Axis 1
The illustration below shows the position switch for axis 1:
xx0100000158
Position switch, axis 1
Cam
Set screw, cam (cam stop)
99

Protection sheet
Rail
Rail attachment
Axis 2
xx0100000159
100
Cam
Rail
Rail Attachment

Axis 3
xx0100000160
Cam
Rail
Rail attachment
Specifications
Maximum voltage/current for the position switches:
Parameter
Value
Voltage
Max. 50 VDC
Current
Max. 1 A
101

Connections
The position switches may be connected to different points on the robot system:
XT8, screw terminal in the controller cabinet when position switch cables are used.
R1.SW1 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 99!
R1.SW2/3 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 99!
Further information about the cables and connection points, see section Robot cabling and
connection points on page 104.
Installation of position switch, axis 2
Later designs of the robot are equipped with a cable protection at the lower arm that must be
removed before fitting the positions switch for axis 2:
Step
Action
1.
Remove the cable protection from the lower arm.
2.
Fit the rail by pushing it against the support surface on the lower arm and tightening
the two screws.
3.
Fit the cam and the position switch unit.
4.
Refit the cable protection to the lower arm with two screws.
Fitting and adjusting cams and stops

The instruction below details how to fit and adjust the parts of the position switches:
Step
102
Action
Info/Illustration
1.
Cut the cam to a suitable length.
Use a sharp knife and rubber

hammer or similar.
2.
Cut the edge of the cam edge to max 30!
Shown in Illustration, cutting

the cam on page 103.
If the angle is larger, this
may damage the position
switch!
3.
Cut the part of the cam running in the profile to 90!

Also see Illustration, cutting the cam on page 103
below!
4.
Make sure the ends of the profile are chamfered to

enable the cam to run through the profile.
5.
Fit the cam with the M5 screw and nut. Tighten the M5 Shown in Illustration, adjust
screw to secure the cam.
and secure cams on page
103.

Illustration, adjust and secure cams

The illustration below show how to adjust and secure the position switch cams and profiles.
xx0100000113
Cam stop, M5 nut and M5 x 6 set screw
Adjustable cam
Profile
Illustration, cutting the cam

The illustration below show how to cut the position switch cam.
xx0100000114
Remove the gray section
103

2.5.1. Robot cabling and connection points
2.5 Electrical connections

General
Connect the robot and controller to each other after securing them to the foundation. The lists
below specify which cables to use for each respective application.
Main cable categories
All cables between the robot and control cabinet are divided into the following categories:
Cable category
Description
Robot cables
Handles power supply to and control of the robots motors

as well as feedback from the serial measurement board.
Specified in table Robot cables on page 104
Position switch cables (option)
Handles supply to and feedback from any position

switches and cooling fans on the robot.
See the product manual for the controller.
Specified in table Position switch cables (option) on page
105.
Customer cables (option)
Handles communication with equipment fitted on the robot

by the customer, including databus communication,low
voltage signals and high voltage power supply + protective
earth.
See the product manual for the controller.
Art. no. is specified in section Document references in the
Product manual, reference information.
External axes cables (option)
Handles power supply to and control of the external axes

motors as well as feedback from the servo system.
See the product manual for external axes.
Art. no. is specified in section Document references in the
These categories are divided into sub-categories which are specified below:
Robot cables
These cables are included in the standard delivery. They are completely pre-manufactured
and ready to plug in.
Cable sub-category Description
104
Connection
Connection
point, cabinet point, robot
Robot cable, power
Transfers drive power from the XS1

drive units in the control cabinet
to the robot motors.
R1.MP
Robot cable, signals
Transfers resolver data from the XS2

serial measurement board and
power supply to the SMB.
R1.SMB

Robot cable, power

Cable
Art. no.
Robot cable, power, 7 m
3HAC 11818-1
3HAC 11818-2
3HAC 11818-4
Cable
Art. no.
Robot cable, signal, shielded, 7 m
3HAC 7998-1
3HAC 7998-2
3HAC 7998-3
3HAC 7998-4
Robot cable, signals
Position switch cables (option)

These cables are not included in the standard delivery, but are included in the delivery if the
position switch option is ordered. The position switches can also be ordered without cables.
The cables are completely pre-manufactured and ready to plug in.
Cable
Art. no.
Connection
Connection
point,
point, robot
cabinet
Position switch cable, axis 1, 7 m
3HAC 13175-1
XS8
R1.SW
3HAC 13175-2
XS8
R1.SW
3HAC 13175-4
XS8
R1.SW
Position switch cable, axes 2 and 3, 7 m
3HAC 13176-1
XS8
R1.SW2/3
Position switch cable, axes 2 and 3, 15 m 3HAC 13176-2
XS8
R1.SW2/3
Position switch cable, axes 2 and 3, 30 m 3HAC 13176-4
XS8
R1.SW2/3
105

106
3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
Structure of this chapter
This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including periodicity and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, e.g. required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Make sure
to read through the chapter Safety on page 15.
107
3 Maintenance
3.2.1. Specification of maintenance intervals
3.2 Maintenance schedule and expected component life

3.2.1. Specification of maintenance intervals
Description
The intervals may be specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the robot:
108
Calendar time: specified in months regardless of whether the robot system is run or not
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
SIS: specified by the robot's SIS (Service Information System). A typical value is
given for a typical work cycle, but the value will differ depending on how hard each
part is run. The SIS is further detailed in section Service Information System on page
183
3 Maintenance
3.2.2. Maintenance schedule

General
The robot must be maintained regularly to ensure proper function. The maintenance activities
and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Values for these are specified in Expected component life on page 112.
Activities and intervals, standard equipment
The table below specifies the required maintenance activities and intervals:
Maintenance
Equipment
activity
Interval
Detailed in section
Cleaning
Robot
Cleaning, robot on page

181
Inspection
Axis 1 gear, oil level
12 mths
1)
Inspection, oil level

gearbox axis 1 on page
113
Inspection
12 mths
1)

116
Inspection
12 mths
1)

119
Inspection
12 mths

121
Inspection
12 mths
Inspection, oil level,

123
Inspection
12 mths
Inspection
Balancing device
12 mths
Inspection, balancing
device on page 127
Inspection
Robot harness
12 mths
Inspection, cable
harness on page 134
Inspection
Information labels
12 mths
Inspection, information
labels on page 138
Inspection
Damper axes 2-5
12 mths
Inspection, damper axes

2-5 on page 144
Inspection
Mechanical stop, axis 1 12 mths
Inspection, mechanical
stop, axis 1 on page 140
Changing
Axis 1 gear, oil: Optimol 12 000 h

Optigear RMO 150
Changing
Axis 1 gear oil: Shell

Tivela S 150
- 7)
1)
1)

125
Oil change, gearbox axis

1 on page 156
-
109
3 Maintenance
Maintenance
Equipment
activity
110
Interval
Detailed in section
1)
Changing

Optigear RMO 150
Changing

Tivela S 150
Changing

Optigear RMO 150
Changing

Tivela S 150
- 7)
Changing
Axis 4 gear, oil
12 000 h
1)
Oil change, gearbox, axis

4 on page 167
Changing
Axis 5 gear, oil
12 000 h
1)

5 on page 170
Changing

Optigear RMO 150 7)
1)

6 on page 173
Changing

Tivela S 150
- 7)
Replacement
Axis 1 gearbox
As specified by the SIS, Replacement of gearbox,

or typically 96 mths
axis 1 on page 308
Replacement
Axis 2 gearbox
As specified by the SIS, Replacement of gearbox

axis 2 on page 316
Replacement
Axis 3 gearbox

axis 3 on page 324
Replacement
Axis 4 gearbox 5)
96 mths
2)
Replacement of upper
arm on page 231
Replacement
Axis 5 gearbox 6)
96 mths
2)
Replacement of
complete wrist unit on
page 225
Replacement
Axis 6 gearbox

axis 6 on page 330
Replacement
Robot harness
See note below 3)
Replacement of cable
harness, axes 1-4 on
page 200
Replacement of cable
harness, axes 5-6 on
page 209
Replacement
SMB Battery pack
36 mths
Replacement of SMB
battery on page 176
Lubrication
Balancing device
bearing
12 000 h
- 7)

2 on page 160
-
1)

3 on page 164
-
4)
Lubrication, balancing
device bearing on page
179
3 Maintenance
1)
2)
The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see
expected life in section Expected component life on page 112.
3)
4)
5)
It is recommended to replace the complete upper arm house, instead of only

replacing the gearbox.
6)
It is recommended to replace the complete wrist unit, instead of only replacing the
gearbox.
7)
If the robot is run at ambient temperatures higher than 50C, the equipment may
require maintenance more frequently.
Replace when damage is detected or when approaching life limit as specified in

Expected component life on page 112.
The interval is the same as the interval for changing axis 2 gear oil because of the
similarity of the type and degree of operation. Always lubricate the front eye bearing
after refitting the balancing device shaft!
In case the gearbox is lubricated with Shell Tivela S 150, no preventive maintenance
in terms of changing the gear oil is needed. Read more about the different types of oil
in section Oil in gearboxes on page 152.
Activities and intervals, optional equipment

The table below specifies the required maintenance activities and intervals for common
optional equipment. Maintenance of other external equipment for the robot is detailed in
separate documentation.
Maintenance activity
Equipment
Inspection
Signal lamp
Inspection
Mechanical stop
axes 1-2-3
12 mths
Inspection, additional
mechanical stops on page
142
Inspection
Position switches,
axes 1-2-3
12 mths
Inspection, position switch

axes 1, 2 and 3 on page 146
Interval
Detailed in section
Inspection, signal lamp on
page 150
111
3 Maintenance
3.2.3. Expected component life
3.2.3. Expected component life

General
The expected life of a component can vary greatly depending on how hard it is run.
Expected life
Component
Expected life
Note
Cabling for robot, 7th axis, axis 2/3

position switch and fan
4,000,000 cycles axis 1 180

2,000,000 cycles axis 1 220
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000h
See note 3)
1)
The expected life can also be affected by assemblage of cabling other than standard options.
The given life is based on a test cycle that for every axis starts from the calibration position
to minimum angle to maximum angle and back to the calibration position. Deviations from
this cycle will result in differences in expected life!
2)
The given life for the balancing device is based on a test cycle that starts from the initial
position and goes to maximum extension, and back. Deviations from this cycle will result in
differences in expected life!
3)
The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spot
welding application. Depending on the actual application, the life of individual gearboxes
may vary greatly from this specification. The Service Information System (SIS), integrated
in the robot software, keeps track of the gearbox life in each individual case and will notify
the user when a service is due. The SIS is described in section Service Information System,
SIS.
112
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
3.3 Inspection activities

Location of gearbox
The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the
figure below.
xx0200000228
Gearbox axis 1
Oil plug, inspection
Motor, axis 1
Oil plug, filling
113
3 Maintenance
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001
Optimol Optigear RMO 150 /

Shell Tivela S 150 (001A9646)
Do not mix the oils! Check which
oil is currently filled in the
gearbox, as detailed in section
Which type of oil does the
gearbox contain? on page 154!
Standard toolkit
3HAC 15571-1

section Special tools in the
information.

These procedures include

references to the tools required.
Inspection, oil level gearbox, axis 1

The procedure below details how to inspect the oil level in gearbox axis 1.
Step
Action
Note/Illustration
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 41.
2.
Danger!
114
3.
Open the oil plug, inspection.
4.
Required oil level: max. 10 mm below the oil

plug hole!
5.
Add oil if required.

gearbox on page 113!

Further information about how to
fill the oil may be found in section
Filling, oil on page 158.
3 Maintenance
Step
6.
Action
Refit the oil plug, inspection.
Note/Illustration
7.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 43!
115
3 Maintenance

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 correct oil level varies, depending on the design of the motor attachment.
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.
xx0200000229
116
Gearbox axis 2 (behind motor attachment and cover)
Oil plug, filling and inspection
Oil plug, draining
Vent hole, gearbox axis 2
3 Maintenance
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
3HAC 16483-1 /
3HAC 021469-001

Standard toolkit
3HAC 15571-1
Other tools and procedures may be

required. See references to these
procedures in the step-by-step
instructions below.

Inspection, oil level gearbox 2

Step
Action
Note/Illustration
1.
Warning!
safety information in section WARNING Safety risks during work with gearbox oil on
page 41.
2.
Danger!
3.
Open the oil plug, filling.

4.
Measure the oil level at the oil plug, filling.

Required oil level with the early designof the
motor attachment: approx. 65 mm 5 mm.
Required oil level with the later designof the
motor attachment: max. 10 mm below the oil
plug hole.

Read more about the variations in
design in Different designs on page
116.
117
3 Maintenance
Step
Action
Note/Illustration
5.

Filling of oil is detailed further in
section Filling, oil on page 162.
6.
Refit the oil plug, filling.
7.
Warning!
118
3 Maintenance

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
xx0200000230
Gearbox axis 3
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001

Standard toolkit
3HAC 15571-1

information!
119
3 Maintenance
Equipment, etc.
Art. no.

Note

The procedure below details how to inspect the oil level in the gearbox axis 3.
Step
Action
Note/Illustration
1.
Warning!
risks. Before proceeding, please observe
the safety information in section WARNING
- Safety risks during work with gearbox oil on
page 41.
2.
Move the robot to the calibration position.
Detailed in section Calibration scales

and correct axis position on page 340.
3.
Danger!
4.

5.
Required oil level: max 10 mm below the oil

plug hole.
6.

Further information about how to fill
the oil may be found in section Filling,
oil on page 166.
7.
8.
Warning!
Do not mix the oil types! If wrong oil is
refilled, the gearbox must be rinsed as
detailed in section WARNING - Mixed oils
may cause severe damage to gearbox! on
page 43!
120
3 Maintenance

Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
xx0200000231
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
1171 2016-604
Mobil Gearlube X320

This is a common oil that can be
replaced with an equivalent oil from
another manufacturer!
Standard toolkit
3HAC 15571-1



121
3 Maintenance

Step
Action
Note/Illustration
1.
Warning!
2.
Run the manipulator to the calibration position.
Shown in section Calibration

scales and correct axis position
on page 340.
3.
Danger!
4.

5.
Required oil level: max 10 mm below the oil plug

hole.
6.

equipment on page 121.
Further information about how to
fill the oil may be found in section
Filling, oil on page 169.
7.
Refit the oil plug.
8.
Warning!
122
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5

Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000232
Oil plug, filling
Oil plug, draining
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
1171 2016-604
Mobil Gearlube X320

This is a common oil that can be
replaced with an equivalent oil from
another manufacturer!
Standard toolkit
3HAC 15571-1



123
3 Maintenance

Step
Action
Note/Illustration
1.
Warning!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 41.
2.
Danger!
3.
Turn the wrist unit so that the both oil plugs face
upwards.
4.
5.
Measure the oil level.

Required oil level: 30 mm to the oil plug hole.
6.

Further information about how
to fill the oil may be found in
section Filling, oil on page 172.
7.
Refit the oil plug.

8.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 43!
124
3 Maintenance

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
xx0200000233
Gearbox axis 6
Oil plug, filling
Oil plug, draining
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001

Standard toolkit
3HAC 15571-1

information!

instructions below.

125
3 Maintenance

Step
Action
Note/Illustration
1.
Warning!
page 41.
2.
Danger!
3.
Make sure the oil plug, filling is facing

upwards and open it.

4.
Measure the oil level.

Required oil level: 55 mm 5 mm to oil plug
hole, filling.
5.

Further information about how to fill
the oil may be found in section Filling,
oil on page 175.
6.
7.
Warning!
Do not mix the oil types! If wrong oil is
refilled, the gearbox must be rinsed as
detailed in section WARNING - Mixed oils
may cause severe damage to gearbox! on
page 43!
126
3 Maintenance
3.3.7. Inspection, balancing device

General
Several points are to be checked on the balancing device during the inspection. This section
details how to perform the inspection regarding:
dissonance
damage
leakage
contamination / lack of free space.
Action at detected faults

If any faults are detected during the inspection, a maintenance may be performed according
to specific maintenance kits.
If the balancing device is an older model, it must in some cases be upgraded instead! The
instruction for the current inspection details if a fault requires a maintenance / upgrade and
the table below specifies the different models and which of the two actions they require.
The article number of the balancing device is located on a label at the rear cover, shown in
the figure Inspection points, balancing device on page 128.
Balancing device, art. no.
Action at detected faults
3HAC 12604-1
Upgrade
3HAC 14678-1
Maintenance
3HAC 16189-1
Maintenance
3HAC 17117-2
Maintenance
3HAC 17117-3
Maintenance
127
3 Maintenance
Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure below. The
figure also shows the inspection points, further detailed in the instructions.
xx0300000580
128
Balancing device
Piston rod (inside)
Shaft, including securing screw
Ear, bearing and o-rings
Label with article number
Inspect the surroundings
Bearing, balancing device attachments
3 Maintenance
Required equipment
The table below specifies the equipment used if damage is detected on the balancing device.
See section Action at detected faults on page 127 to determine whether to perform
maintenance or upgrade!
Equipment, etc.
Spare part no.
Art. no.
Maintenance kit,
complete
3HAC 16195-1 3
For maintenance of balancing

device 3HAC 14678-1 and 3HAC
16189-1.
Includes
complete kit including the
kit with bearings and seals
instructions for
maintenance, 3HAC
15864-5.
Maintenance kit,
complete
3HAC 021592-001

17117-3.
Includes:
complete kit including the
kit with bearings and seals
instructions for
maintenance.
Maintenance kit,
bearings and seals
3HAC 16194-1

16189-1.
Includes
kit with bearings, o-rings
and seals only
instructions for
maintenance, 3HAC
15864-4.
Maintenance kit,
bearings and seals
3HAC 021593-001

17117-3.
Includes:
kit with bearings, o-rings
and seals only
instructions for
maintenance.
Upgrade kit
3HAC 16196-1
Includes
kit with piston rod, support
shaft etc.
instruction for conversion,
3HAC 15864-6.
Securing screw
Toolkit for
maintenance
Note
Securing screw in the shaft.

M16 x 180
Locking liquid must be used when
fitting the screw (Loctite 245)!
3HAC 15943-2
129
3 Maintenance
Equipment, etc.
Spare part no.
Art. no.
Note
Puller for separator
4552-2
(Bahco)
Used for removing the spherical

roller bearings.
Separator
4551-C
(Bahco)
Used for removing the spherical

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

information!
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.

Check for dissonance

The check points are shown in the figure Inspection points, balancing device on page 128.
Step
130
Check for dissonance from...
If dissonance is detected...
1.
bearing at the ear

bearings at the balancing devices
attachments.
... perform maintenance or upgrade

according to given instructions in
Maintenance kit, bearings and seals /
Upgrade kit.
Art. no. for the kit and the
documentation are specified in section
Required equipment on page 129.
To decide whether to perform
maintenance or upgrade, see section
Action at detected faults on page 127.
2.
cylinder (a tapping sound, caused ...replace the balancing device or

by the springs inside the cylinder). consult ABB Robotics.
How to replace the device is detailed in
section Replacement of balancing
device on page 263. This section also
specifies the spare part number!
3.
piston rod (squeaking may indicate

worn plain bearings, internal
contamination or insufficient
lubrication).
... perform maintenance or upgrade

Maintenance kit, complete / Upgrade
kit.
3 Maintenance
Check for damage

Check for damages, such as scratches, general wear, uneven surfaces or incorrect positions.
The check points are shown in the figure Inspection points, balancing device on page 128.
Step
Check for damage on...
1.
2.
If damage is detected...
the piston rod (part of the piston rod ... perform maintenance or upgrade
that is visible at the front of the
balancing device).
Maintenance kit, complete / Upgrade
kit.
the securing screw in the front ear ...replace.

shaft.
Dimension is specified in section
Also check the tightening torque (50 Nm). Required equipment on page 129.
131
3 Maintenance
Check for leakage

The front ear of the balancing device is lubricated with grease. After filling, excessive grease
may normally be forced out between the shaft and the sealing spacer. This is normal
behaviour and must no be confused with incorrect leaks from the ear.
Leaks at the o-rings, however, are not acceptable and must be attended to immediately in
order to avoid any damage to the bearing!
Check the o-rings in the front ear of the balancing device for leaks, as shown and detailed
below.
xx0300000284
O-rings at the front ear
Sealing spacer
Shaft
Step
132
Action
1.
Clean the area at the front ear from old grease.
2.
Run the manipulator for some minutes, in order

to move the balancing device piston.
Note
3 Maintenance
Step
Action
Note
3.
Danger!
4.
Check the o-rings at the front ear for leakage.

Replace the o-rings, if any leaks are detected.
Excessive grease from between the shaft and
the sealing spacer is normal and is not
considered as a leak!
The o-rings are included in the

Maintenance kit, bearings and
seals, already assembled with
sealing spacers and sealing
rings.
Art. no. for the kit is specified in
Required equipment on page
129!
Check for contamination / lack of free space

Step
Action
1.
Danger!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 128.
Keep the areas around the balancing device clean and free from objects, such as
service tools.
133
3 Maintenance
3.3.8. Inspection, cable harness

Location of cable harness, axes 1-4
The manipulator cable harness, axes 1-4, is located as shown in the figure below.
xx0200000097
Lower arm
Cables attached with velcro straps and mounting plate
Connectors at cable harness division point, R2.M5/6
Connectors at base
Required equipment
134
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1


These procedures include references to

the tools required.
Circuit diagram
See chapter Circuit diagram in the

3 Maintenance
Inspection, cable harness 1-4

The procedure below details how to inspect the cable harness of axes 1-4.
Step
Action
Note
1.
Danger!
2.
Make an overall visual inspection of the cable

harness, in order to detect wear and damage.
3.
Check the connectors at the division point

and at the base.

cable harness, axes 1-4 on page
134!
4.
Check that velcro straps and the mounting

plate are properly attached to the frame. Also
check the cabling, leading into the lower arm.
Make sure it is attached by the straps and not
damaged.
Location is shown in the figure

Location of cable harness, axes 1-4
on page 134!
A certain wear of the hose at the
entrance to the lower arm is natural.
5.
Replace the cable harness if wear or damage Detailed in section Replacement of

is detected.
200!
135
3 Maintenance
Location of cabling axes 5-6

The manipulator cable harness, axes 5-6, is located as shown in the figure below.
xx0200000234
Connectors at cable harness division point, R2.M5/6
Cable attachment, rear of upper arm
Cable attachment, upper arm tube
Inspection, cable harness, axes 5-6

The procedure below details how to inspect the cable harness of axes 5-6.
Step
Action
Note
1.
Danger!
136
3 Maintenance
Step
Action
Note
2.
Make an overall visual inspection of the cable

harness, in order to detect wear and damage.
3.
Check the attachments at the rear of the

upper arm and in the upper arm tube.
Check the connectors at the cable harness
division. Make sure the attachment plate is
not bent or in other way damaged.
4.
Replace the cable harness if wear or damage Detailed in section Replacement of

is detected.
209!

cabling axes 5-6 on page 136!
137
3 Maintenance
3.3.9. Inspection, information labels

Location of labels
The figures below show the location of the information labels to be inspected.
xx0200000236
138
Warning label "High temperature", 3HAC 4431-1 (4 pcs)
Warning sign, symbol of a flash (located on motor cover), 3HAC 1589-1 (5 pcs)
Instruction label "Safety instructions", 3HAC 4591-1
Warning label "Brake release", 3HAC 9508-1
Warning label, tools are not allowed around the balancing device during operation,
3HAC 020611-001
Warning label, "Shut off power", 3HAC 17804-1
Information labels at gearboxes and at robot base, if gearboxes are filled with Shell
Tivela S 150
3 Maintenance
xx0400000786
Instruction label "Lifting the robot", 3HAC 16487-1
Warning label "Robot can tip forward...", 3HAC 9191-1
Foundry logotype, 3HAC 8256-1
Warning label "Stored energy", 3HAC 9526-1
Required equipment
Equipment
Art. no.
Note
Labels and plate set
3HAC 8711-1
Includes all labels specified in the two

previous figures!
Label set, oil labels
3HAC 021670-002
Includes only the oil labels at the

gearboxes and at the robot base.
Are fitted to the robot if the gearboxes
include Shell Tivela S 150.
Inspection, labels
Step
Action
Note/Illustration
1.
Danger!
2.
Check the labels, located as shown in the

figures Location of labels on page 138.
3.
Replace any missing or damaged labels.

139
3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1

Location of mechanical stop
The mechanical stop axis 1 is located at the base as shown in the figure below.
xx0200000151
Mechanical stop (stop pin)
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop ax 1
3HAC 12812-2
To be replaced when damaged.

Includes spring pin.
Standard toolkit
3HAC 15571-1
The contents are defined in section Standard

toolkit in the Product manual, reference
information!
Inspection, mechanical stop

The procedure below details how to inspect the mechanical stop axis 1.
Step
Action
Note/Illustration
1.
Danger!
140
3 Maintenance
Step
Action
Note/Illustration
2.
Inspect the mechanical stop, axis 1.

mechanical stop on page 140!
3.
Make sure the mechanical stop can move in

both directions.
4.
If the stop pin is bent or damaged, it must be Art. no. is specified in Required
replaced!
141
3 Maintenance
3.3.11. Inspection, additional mechanical stops

Location of mechanical stops
The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3
(IRB 7600 shown).
xx0200000150
Additional stop
Fixed stop
Required equipment
142
Equipment etc.
Art. no.
Note
Mechanical stop axis 1
3HAC 11076-1
Limits the robot working range by 7,5.
3HAC 11076-2
Limits the robot working range by 15.
3HAC 13787-1
3HAC 13128-2
Standard toolkit
3HAC 15571-1

3 Maintenance
Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and
3.
Step
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2.
Check the additional stops on axes 1, 2 and 3 for

damage.
3.
Make sure the stops are properly attached.

Correct tightening torque: 115 Nm.
4.
If any damage is detected, the mechanical stops

Art. no. is specified in
must be replaced!
Required equipment on
Correct attachment screws (lubricated with Molycote page 142!
1000):
Axis 1: M16 x 35
Axis 2: M16 x 50
Axis 3: M16 x 60
Shown in the figure Location

of mechanical stops on page
142!
143
3 Maintenance
3.3.12. Inspection, damper axes 2-5

Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0300000040
Damper, axis 2 (2 pcs)
Damper, axis 4 (1 pc)
Required equipment
144
Equipment
Art. no.
Note
Damper axis 2
3HAC 12991-1
To be replaced if damaged!
Damper axis 3
3HAC 12320-1
Damper axis 4
3HAC 13564-1
3 Maintenance
Equipment
Art. no.
Note
Damper axis 5
3HAB 4337-2
Standard toolkit
3HAC 15571-1
The contents are defined in section Standard

toolkit in the Product manual, reference
information!
Inspection, dampers
The procedure below details how to inspect the dampers, axes 2-5
Step
Action
Note/Illustration
1.
Danger!
2.
Check all dampers for damage, and for cracks or

existing impressions larger than 1 mm.
of dampers on page 144!
To inspect the damper, axis 4, remove the two covers
on top of the upper arm!
3.
Check attachment screws for deformation.
4.
If any damage is detected, the damper must be

replaced with a new one!

page 144!
145
3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3

The illustration below shows the position switch for axis 1.
xx0100000158
146
Cam
Set screw, cam
Protection sheet
Rail
Rail attachment
3 Maintenance

xx0100000159
Cam
Set screw, cam
Rail
Rail attachment
147
3 Maintenance

xx0100000160
Cam
Set screw, cam
Rail
Rail attachment
Required equipment
148
Equipment, etc.
Art. no.
3HAC 15715-1
3HAC 16418-1
3HAC 16417-1
Note
3 Maintenance
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

information!
Other tools and procedures

may be required. See
references to these
procedures in the step-bystep instructions below.

references to the tools
required.
Inspection, position switches

The procedure below details how to inspect the position switch, axes 1, 2 and 3.
See the figures above to locate the different components to be inspected.
Step
Action
Note
1.
Danger!
2.
Check the position switch!

Check that the rollers are easy to push in and
that they roll freely.
3.
Check the rail!

Check that the rail is firmly attached with the
attachment screws.
4.
Check the cams!

Check that the rollers have not caused any
impressions on the cams.
Check that the cams are clean. Wipe them if
necessary!
Check that the set screws holding the cams in
position are firmly attached.
5.
Check the protection sheets on axis 1!

Check that the three sheets are in position and
not damaged. Deformation can result in
rubbing against the cams!
Check that the area inside of the sheets is
clean enough not to interfere the function of
the position switch.
6.
If any damage is detected, the position switch must

be replaced!

page 148!
149
3 Maintenance
3.3.14. Inspection, signal lamp

Location of signal lamp
The signal lamp is located as shown in the figure below. Note that the position can differ
depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on
the current harness for alternative positioning.
There are two different article numbers for the signal lamp. The difference is due to the
accompanying motor cover, which is either flat or vaulted.
xx0200000240
Signal lamp
Clamp
Position for cable gland
Warning label on motor cover
Warning sign on motor cover
Required equipment
150
Equipment, etc.
Art. no.
Note
Signal lamp
3HAC 10830-1
To be replaced in case of detected

damage.
(Includes vaulted motor cover.)
3 Maintenance
Equipment, etc.
Art. no.
Note
Signal lamp
3HAC 13097-1
To be replaced in case of detected

damage.
(Includes flat motor cover.)
Standard toolkit
3HAC 15571-1



Inspection, signal lamp

The procedure below details how to inspect the function of the signal lamp.
Step
1.
Action
Note/Illustration
Check that the signal lamp is lit, when the motors are
put in operation ("MOTORS ON").
2.
Danger!
3.
If the lamp is not lit, trace the fault by:

Checking whether the signal lamp is broken. If Required equipment on
page 150!
so, replace it.
Checking the cable connections.
Measuring the voltage in connectors motor
axis 3 (=24V).
Checking the cabling. Replace cabling if a
fault is detected.
151
3 Maintenance
3.4.1. Oil in gearboxes
3.4 Replacement/changing activities

Location of gearboxes
The gearboxes are located as shown in the figure below.
xx0400000798
152
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 4 gearbox
Axis 5 gearbox
Axis 6 gearbox
3 Maintenance
Type of oil
The table below specifies the types of oil used in the gearboxes of each axis. For some of the
axes, there are two different types specified. Normally, the same oil should be refilled as the
one drained. Read the sectionWhich type of oil does the gearbox contain? on page 154 in
order to determine which type of oil is currently used in the gearbox.
As the Shell Tivela S 150 is not compatible with mineral oil, contamination with other types
of oils used in the gearboxes is not accepted. Equipment used in handling of Tivela S 150
must be carefully cleaned. In case of changing the type of oil to another, the gearbox must
therefor be thoroughly rinsed! Contact ABB for further instructions.
The Shell Global Product Code for Shell Tivela S 150 is specified within parentheses in table.
Gearbox
Type of oil
Art. no.
Amount
Axis 1

3HAC 16843-1 /
Shell Tivela S 150 (001A9646) 3HAC 021469-001
7,300 ml
Axis 2

3HAC 16483-1 /
4,600 ml (later
design of motor
attachment)
1,800 ml (early
design of motor
attachment)
Axis 3

3HAC 16843-1 /
2,500 ml
Axis 4
Mobil Gearlube X320
1171 2016-604
8,100 ml
Axis 5
Mobil Gearlube X320
1171 2016-604
6,700 ml
Axis 6

3HAC 16843-1 /
300 ml (IRB 6600175/2.55)

450 ml
WARNING!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the type of oil specified by the manufacturer!
If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further
instructions!
153
3 Maintenance
Which type of oil does the gearbox contain?

The type of oil filled in the gearbox, can be identified by:
serial number of the robot
labels attached on the robot.
Serial number of robot

At delivery, the following robots are filled with Tivela S 150:
Robot
Serial number as from
Type of oil
IRB 6600/6650/6650S M2000
66-40000
Tivela S 150
IRB 6600/6650/6650S M2000A
66-34000
Tivela S 150
IRB 6600/6650/6650S M2004
66-51000
Tivela S 150
Notice that robots with earlier serial numbers might have been changed to Tivela after
delivery!
Labels on the robot
In case there are gearboxes filled with Tivela S 150, there are also labels attached to the robot.
The figures below show the labels and describe their location on the robot.
If the oil is changed to Tivela S 150 after delivery, the robot must be completed with these
labels!
xx0500001398
154
Labels located next to each oil plug on the gearbox
3 Maintenance
xx0500001396
Label at the robot base
Equipment, change of oil type

Equipment
ABB art. no.
Note
Shell Tivela S 150
3HAC 021469-001
Shell global product code: 001A9646
Label set
3HAC 021670-002
Must be fitted to the robot in case of changing

the type of oil!
155
3 Maintenance
3.4.2. Oil change, gearbox axis 1

Location of oil plugs
The axis 1 gearbox is located between the frame and base. The oil plugs for filling and
inspection are shown in the figure below. The oil is drained through a hose, available in the
rear of the manipulator base, not shown in the figure.
xx0200000228
Gearbox axis 1
Oil plug, inspection
Motor axis 1
Oil plug, filling
Required equipment
156
Equipment, etc.
Art. no.
Amount
Lubricating oil
3HAC 16843-1 /
7,300 ml
3HAC 021469-001
Note
3 Maintenance
Equipment, etc.
Art. no.
Amount
Oil collecting vessel
Note
Capacity: 8,000 ml.
Oil exchange
equipment
3HAC 021745-001

information.
Standard toolkit
3HAC 15571-1

information!
Draining
The procedure below details how to drain the oil in gearbox axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 156.
Step
Action
Note/Illustration
1.
Danger!
2.
Warning!
risks. Before proceeding, please observe
the safety information in section WARNING
- Safety risks during work with gearbox oil on
page 41.
3.
Remove the rear cover on the base by

unscrewing its attachment screws.
157
3 Maintenance
Step
4.
Action
Note/Illustration
Pull the oil draining hose out of the rear of

the base.
xx0200000237
The hose is located beneath the base,

as shown in the figure with a view from
below.
A: Oil draining hose
5.
Place an oil vessel close to the hose end.
Vessel capacity is specified in

Required equipment on page 156!
6.
Remove the oil plug, filling, in order to drain Shown in the figure Location of oil
the oil quicker!
plugs on page 156.
7.
Open the hose end and drain the oil into the Notice! The draining is timevessel.
consuming. Elapsed time depends on
the temperature of the oil.
8.
Close the oil drain hose, and put it back

inside the base.
9.
Refit the rear cover by securing it with its

attachment screws.
Filling, oil
The procedure below details how to fill the oil in gearbox axis 1.
Step
Action
Note
1.
Danger!
2.
Warning!
158
3 Maintenance
Step
Action
Note
3.

oil plugs on page 156!
4.
Refill the gearbox with lubricating oil.

The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspection, oil level
gearbox axis 1 on page 113.
Art. no. and the total amount are

specified in Required equipment
on page 156!
5.
Warning!
6.
159
3 Maintenance

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 correct amount oil varies, depending on the design of the motor attachment.
Location of oil plugs
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.
xx0200000229
160
Gearbox axis 2
Oil plug, filling
Oil plug, draining
Vent hole, gearbox axis 2
3 Maintenance
Required equipment
Equipment, etc. Art. no.
Lubricating oil
Amount
Note
3HAC 16483-1 /
4,600 ml (later
3HAC 021469-001 design of motor
attachment)
1,800 ml (early
design of motor
attachment)

Do not mix the oils! Check
which oil is currently filled in
the gearbox, as detailed in
section Which type of oil does
the gearbox contain? on page
154!
Oil collecting vessel -
Capacity: 5,000 ml.
Oil exchange
equipment
3HAC 021745-001

information.
Standard toolkit
3HAC 15571-1

information!
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
Step
Action
Note/Illustration
1.
Danger!
2.
Warning!
page 41.
3.
Remove the plug of the vent hole .
Shown in the figure Location of oil

plugs on page 160!
161
3 Maintenance
Step
Action
Note/Illustration
4.
Remove the oil plug, draining, and drain the Shown in the figure Location of oil
gearbox oil using a hose with nipple and an oil plugs on page 160!
collecting vessel.
Draining is time-consuming.
Elapsed time varies depending on
the temperature of the oil.
5.
Refit the oil plug.
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
Step
Action
Note
1.
Danger!
2.
Warning!
3.
Remove the oil plug, filling and the plug from the Shown in the figure Location of
vent hole.
oil plugs on page 160!
4.

Art. no. and total amount are
amount previously being drained. The correct oil on page 161!
5.
Warning!
162
3 Maintenance
Step
6.
Action
Note
Refit the oil plug and the plug in the vent hole.
163
3 Maintenance
3.4.4. Oil change, gearbox, axis 3

Location of gearbox
xx0200000230
Gearbox axis 3
Oil plug, filling
Oil plug, draining
Required equipment
164
Equipment, etc.
Art. no.
Amount
Lubricating oil
3HAC 16843-1 /
2,500 ml
3HAC 021469-001
Note
3 Maintenance
Equipment, etc.
Art. no.
Amount
Note
Oil exchange
equipment
3HAC 021745-001

information.
Capacity: 3,000 ml.
Standard toolkit
3HAC 15571-1

information!
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
Step
Action
Note
1.
Danger!
2.
Warning!
page 41.
3.
Remove the oil plug, draining, and drain the

gearbox oil using a hose with nipple and an
oil collecting vessel.
Remove the oil plug, filling in order to drain
the oil quicker!

Draining is time-consuming. Elapsed
time varies depending on the
temperature of the oil.
4.
Refit the oil plug.
165
3 Maintenance
Filling, oil
The procedure below details how to fill oil to the gearbox, axis 3.
Step
Action
Note
1.
Danger!
2.
Warning!
3.
Remove the oil plug, filling.

4.

amount previously being drained. The correct oil on page 164!
5.
Warning!
6.
166
Refit the oil plug.
3 Maintenance

Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
xx0200000231
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
1171 2016-604
8,100 ml
Mobil Gearlube X320

This is a common oil that can
be replaced with an equivalent
oil from another manufacturer!
Oil exchange equipment
3HAC 021745-001

information.
Capacity: 9,000 ml.
Standard toolkit
3HAC 15571-1

information!
167
3 Maintenance
Draining, oil
The procedure below details how to drain the oil in the gearbox, axis 4.
Step
1.
Action
Note
Run the upper arm -45 from the calibration

position.
2.
Danger!
3.
Warning!
page 41.
168
4.
Drain the oil from the gearbox into an vessel

by opening theoil plug, draining.
the oil quicker!

5.
Run the upper arm back to its calibration

position (horizontal position).
Shown in section Calibration scales

and correct axis position on page
340.
6.
Refit the oil plug, draining.
3 Maintenance
Filling, oil
The procedure below details how to fill the oil in the gearbox, axis 4.
Step
Action
Note
1.
Danger!
2.
Warning!
3.
Refill the gearbox with lubricating oil through the oil

plug, filling.

specified in Required
4.
Warning!
WARNING - Mixed oils may cause severe damage
to gearbox! on page 43!
5.
169
3 Maintenance

Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000232
Oil plug, filling
Oil plug, draining
Required equipment
170
Equipment, etc.
Art. no.
Amount Note
Lubricating oil
1171 2016-604
6,700 ml
Oil exchange equipment
3HAC 021745-001

information.
Capacity: 7,000 ml.
Standard toolkit
3HAC 15571-1

information!
Mobil Gearlube X320

This is a common oil that can
be replaced with an equivalent
oil from another manufacturer!
3 Maintenance
Draining, oil
The procedure below details how to change the oil in gearbox, axis 5.
Step
1.
Action
Note
Run axis 4 to a position where the oil plug,

draining, is facing downwards.
2.
Danger!
3.
Warning!
page 41.
4.
Drain the oil from the gearbox by opening the

oil plug, draining.
the oil quicker!

5.
171
3 Maintenance
Filling, oil
The procedure below details how to change the oil in gearbox, axis 5.
Step
Action
Note
1.
Warning!
page 41.
2.
Run axis 4 to a position where the oil plug,

filing, is facing upwards.
Calibration position is shown in

section Calibration scales and
correct axis position on page 340.
3.
Danger!
4.
Refill the gearbox with lubricating oil through

the oil plug, filling.
The amount of oil to be refilled depends on
the amount previously being drained. The
correct oil level is detailed in section
Inspection, oil level, gearbox axis 5 on page
123.

specified in Required equipment on
page 170.
5.
Warning!
6.
172
3 Maintenance

Location of gearbox
The different robot versions have different gearbox designs. The amount of oil in the gearbox
therefor varies depending on robot version.
xx0200000233
Gearbox axis 6
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Art. no.
Lubricating oil
3HAC 16843-1 /
300 ml (IRB
3HAC 021469-001 6600-175/2.55) Shell Tivela S 150 (001A9646)
450 ml
Do not mix the oils! Check
which oil is currently filled in
the gearbox, as detailed in
section Which type of oil does
the gearbox contain? on page
154!
Oil exchange
equipment
3HAC 021745-001

information.
Vessel capacity: 500 ml.
Standard toolkit
3HAC 15571-1

information!
Amount
Note
173
3 Maintenance
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 6.
Step
1.
Action
Note/Illustration
Run the robot to a position where the oil plug,

draining of axis 6 gearbox is facing downwards
and the oil plug, filling, is facing upwards.

2.
Danger!
3.
Warning!
174
4.
Drain the oil from gearbox into a vessel by

removing the oil plug.

173!
5.
3 Maintenance
Filling, oil
The procedure below details how to fil oil in the gearbox, axis 6.
Step
Action
Note/Illustration
1.
Danger!
2.
Warning!
3.
Remove the oil plug, filling.

4.

Art. no. and the total amount are

on page 173!
5.
Warning!
6.
Refit the oil plug.
175
3 Maintenance
3.4.8. Replacement of SMB battery

Location of SMB battery
The SMB battery (SMB = serial measurement board) is located on the left hand side of the
frame as shown in the figure below.
Note that the manipulator is shown with the SMB cover already removed!
xx0200000238
SMB battery cover
SMB battery pack
Battery cable
Required equipment
Equipment, etc. Spare part no. Art. no.
Note
Battery pack
Battery includes protection

circuits. Replace it only with given
spare part no. or an ABB approved
eqvivalent.
Standard toolkit
Circuit Diagram
176
3HAC 16831-1
3HAC 15571-1

information!
See chapter Circuit diagram in the
information.
3 Maintenance
Removal, battery
The procedure below details how to remove the SMB battery.
Step
Action
Note
1.
Danger!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 40
3.
Remove the SMB battery cover by

unscrewing its attachment screws.
Shown in the figure Location of SMB

battery on page 176!
4.
Pull out the battery and disconnect the

battery cable .

5.
Remove the SMB battery.

Battery includes protection circuits. Replace battery on page 176!
it only with the specified spare part or with
an ABB approved eqvivalent.
177
3 Maintenance
Refitting, battery
The procedure below details how to refit the SMB battery.
Step
Action
Note
1.
Danger!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
3.
Reconnect the battery cable to the SMB

battery pack and fit it to the frame.

4.
Secure the SMB battery cover with its

attachment screws.

battery on page 176
5.
Update the revolution counter.
Detailed in chapter Calibration section Updating revolution counters

on page 342.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
178
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 are 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.
3 Maintenance
3.5.1. Lubrication, balancing device bearing
3.5 Lubrication activities

Location of bearing
The figure below shows the location of the lubrication nipple etc.
Note! The balancing device must be mounted on the manipulator when lubricating the
bearing!
xx0200000109
Ear (spherical roller bearing located inside)
Lubrication nipple
Sealing spacer
Hole through which the shaft is pressed
Required equipment
Equipment, etc.
Art. no.
Note
Grease
3HAA 1001-294
Optimol PDO, max. 80 ml.

For lubrication of the spherical roller bearing.
Grease pump
179
3 Maintenance
Lubrication, balancing device bearing

The procedure below details how to lubricate the spherical roller bearing.
Step
Action
Note
1.
Danger!
180
2.
Lubricate the spherical roller bearing through

the lubrication nipple in the ear, with grease.
Fill until excessive grease is forced out
between the shaft and the sealing spacer.

bearing on page 179!
The balancing device must be
mounted on the manipulator when
lubricating the bearing!
3.
Clean the area from any excessive grease

Read more about the inspection in
and check the area once again after
section Inspection, balancing device
operation of the robot, in order to make sure - Check for leakage on page 132.
there is no incorrect leakage from the o-rings.
3 Maintenance
3.6.1. Cleaning, robot
3.6 Cleaning activities

General
The protection class is IP 67, i.e. the robot is watertight.
Activities
This instruction specifies how to clean the robot.
Periodicity
The periodicity of cleaning the robot varies a great deal depending on the actual environment
and function of the robot. Clean a contamined robot as required.
Special points
Special points to be observed are shown in the figure below:
xx0200000239
Spiral cables to motor 6
Inside of upper arm tube
Rear of upper arm tube
181
3 Maintenance
Inside of lower arm
Inside of base/axis 1
Required equipment
Equipment, etc.
Art. no.
Steam cleaner
Note
High pressure water cleaner
Water pressure at nozzle: max.

2,500 kN/m 2 (25 bar)
Type of nozzle: fan jet, min. 45
spread
Flow: max. 100 litres/min.
Water temperature: max. 80 C
Max. water pressure on enclosures:
50 kN/m 2 (0.5 bar)
Fan jet nozzle should be used, min.
45 spread
Flow: max. 100 litres/min.
Dos and donts!

The section below specifies some special considerations when cleaning the robot
Always!
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never!
Never point the water jet at bearing seals, contacts, and other seals!
Never spray from a distance closer than 0.4 m!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 6 spiral cable (item A in the figure Special points)!
Although the robot is watertight, avoid spraying connectors and similar items with a
high pressure cleaner!
Foundry versions
In working environments, e.g. foundries, where the robot may be exposed to fluids that dry
to make a crusty surface, e.g. release agents, clean the cable harnesses to prevent the crust
damaging the cables:
182
Clean the spiral wound cables to motor 6 (item A in the figure Special points on page
181) with water and a cloth!
Clean the remaining sections of the cable harnesses as detailed above!
3 Maintenance
3.7.1. Using the SIS system
3.7 Service Information System

3.7.1. Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS. Details may be
found in:
Service Information System, SIS
Defining the SIS input parameters
Setting the SIS parameters
Importing/exporting SIS data
Reading the SIS output logs
Basic procedure
Step
Action
Reference
1.
Determine which of the system functions you These are described in Description of
require.
Service Information System (SIS) on
page 184.
2.
Define what values are adequate and

suitable for your application in your
production environment.
Recommendations on how to define

these are given in SIS system
parameters on page 187.
Maintenance intervals recommended
by ABB are specified in section
Maintenance schedule on page 109.
3.
Enter these parameters in the system.
How to do this is detailed in Setting

the SIS parameters on page 189.
4.
Run the robot in normal operation.
5.
Reset the counter if a repair is made, or if a The TPU displays for resetting any
counter for any other reason is restarted.
SIS value are shown in Description of
Service Information System (SIS) on
page 184.
6.
When a time limit, set in the parameters, is

exceeded, a message may be read on the
Tech Pendant Unit (TPU).
How to access this is detailed in

Reading the SIS output logs on page
192.
7.
If the log containing the message is to be

available from an external PC, or if the SIS
parameters are to be entered from an
external PC, a set of software tools are
available to build such an application.
These are described in Exporting the

SIS data on page 193.
183
3 Maintenance
3.7.2. Description of Service Information System (SIS)

General
Service Information System (SIS) is a software function within the robot controller, which
simplifies maintenance of the robot system. It supervises the operating time and mode of the
robot, and alerts the operator when a maintenance activity is scheduled.
Maintenance is scheduled by setting the system parameters of the type SIS Parameters, see
section Setting the SIS parameters on page 189. All system parameters are described in
Technical reference manual - System Parameters.
Supervised functions
The following counters are available:
Calendar time counter, a general alarm based on calendar time
Operation time counter, a general alarm based on operational time
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
interval
interval
interval
Counters are reset when maintenance has been performed.

The counter status is displayed after running the service routine for maintenance. Status "OK"
indicates that no service interval limit has been exceeded by that counter.
184
3 Maintenance
Calendar time
This is a clock within the control system that keeps track of the service interval, based on
calendar time.
When the calendar time limit for maintenance is reached, a message is displayed on the TPU
(for M2000 robot systems) or the FlexPendant (for M2004 robot systems). How to access this
is detailed in section Reading the SIS output logs on page 192.
The following information is available about the calendar time in the service routine.
Prev service
Date when the counter was reset last time, i.e. after the last service.
Elapsed time
Elapsed time since the counter was reset the last time.
Next service
Date when next scheduled service is planned. This date is

calculated using system parameters, as detailed in section Setting
Remaining time
Remaining time to next scheduled service date.
Operation time
This is a function within the control system that keeps track of the amount of time the
"MOTORS ON" signal is active, i.e. the amount of time the robot is in the operating mode.
When the operation time limit for maintenance is reached, a message is displayed on the TPU
The following information is available about the operation time in the service routine.
Service interval
The specified service interval until another service will be required.

This parameter was entered manually as detailed in section Setting
Elapsed time
Operation time since the service interval was set the last time.
Remaining time
Remaining operation time until the time set in service interval has
expired.
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an expected
service interval for each gearbox. When service is due, a message will be shown on the TPU
The following information is available about the joint service status in the service routine.
Joint x OK
Service status for axis x, i.e. the automatically calculated time

parameter has not been exceeded.
Joint x NOK
The service interval for the axis in question has been reached.
Joint x N/A
No service time parameter calculation available.

Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
The following information is available for the axis service status in the service routine.
Consumed time
The consumed time as a percentage of the total amount of time.
Elapsed time
Operation time for axis x since calculation began.
185
3 Maintenance
Remaining time
Remaining operation time for axis x until the service time parameter
value has been reached.
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in section
Exporting the SIS data on page 193!
Service interval exceeded
When the service time has been exceeded for the selection made, an error message (Service
interval exceeded!) is displayed.
No data available
When no data is available for the selection made, a message (No data available!) is displayed
when trying to display the data.
SIS for MultiMove robot systems
SIS information is only available for IRB 66X0 and IRB 7600 robots. This means that in a
M2004 robot system with the option MultiMove, SIS information can only be displayed for
these robot models. If another robot model is part of the system, it will be displayed in the
SIS information list, but there is no information available.
186
3 Maintenance
3.7.3. SIS system parameters

General
This section details the system parameters that may be set with estimated values. The values
can be defined by the operating organization as knowledge of the robots working conditions
are accumulated.
Since the counters are to be used for purposes defined by the user, ABB cannot give any
recommendations regarding their definitions.
The figures below shows the options of parameters to be set.
en0200000049
en0400001266
Operation time limit (service level)

The number of operation hours selected as service interval.
E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating
the alarm, not counting the percentage described below.
187
3 Maintenance
Operation time warning

A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation
time "Reset" was made the last time.
Calendar time limit (service level)
The number of calendar years selected as service interval.
E.g. by setting the value "2", the SIS will save this as the nominal time for activating the
alarm, not counting the percentage described below.
Calendar time warning
A percentage of the "Calendar time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator after 90% of two years, i.e. 657
days after a calendar time "Reset" was made the last time.
Gearbox warning
A percentage of the gearbox service interval as calculated by the system.
E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service
interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate the
expected service interval of each gearbox. This is done by extrapolating data from earlier
operation into a function of time, using a formula including:
188
input and output torque
gearbox spindle speed
other variables
3 Maintenance
3.7.4. Setting the SIS parameters

General
If the SIS system is to function properly, a number of parameters must be set. This is detailed
below.
Procedure M2000
This is an instruction of how to enter SIS parameters to the M2000 robot system.
Step
Action
Rem.
1.
Open "System
parameters" using the
TPU.
Detailed in the Users Guide.
2.
Go to "System parameters/
Manipulator/types 2".
xx0200000045
en0200000046
189
3 Maintenance
Step
3.
Action
Rem.
Select "0 SIS parameters"

and press "Enter".
en0200000047
xx0100000200
4.
Select the required system

The parameter list is
displayed.
en0200000048
en0200000049
5.
190
Select the required

Available parameters are described in SIS system
parameters by stepping up parameters on page 187.
and down through the
parameter list.
3 Maintenance
Procedure M2004
This is an instruction of how to enter SIS parameters to the M2004 robot system.
Step
Action
Rem.
1.
Open system parameters

configuration in the
FlexPendants Control
Panel, or using the
Configuration in
RobotStudioOnline.
Detailed in Operators manual - IRC5 with FlexPendant

and Operators manual - RobotStudioOnline.
2.
Select the Motion topic and

then the SIS Parameters
type.
3.
Select the instance to

Available parameters are described in SIS system
define and edit the system parameters on page 187 and in Technical reference
parameters.
manual - IRC5 with FlexPendant.
191
3 Maintenance
3.7.5. Reading the SIS output logs
3.7.5. Reading the SIS output logs

General
Whenever a set condition has expired (e.g. max allowed operation time before service), a
message to this effect will be shown in the Operational log (M2000 robot system) or the event
log (M2004 robot systems).
Access to logs
How to open a log and show its contents is detailed in the Users Guide, chapter Service
(M2000 robot systems) and in Trouble shooting - IRC 5 (M2004 robot systems).
Available messages
The following messages may be shown:
Available in:
192
SIS message in
the log:
Meaning:
Calendar time
Service Message
Service is due!
X calendar days
since last service.
The manually set calendar time limit has expired.

How to set the limit is detailed in section Setting the
SIS parameters on page 189.
Proceed with the required service as detailed in
chapter Repair on page 195 or chapter
Maintenance on page 107 depending on which
type of service.
Calendar time
Service Message
X calendar days to
next service.
X number of calendar days remain until the

manually set calendar time limit expires.
How to set the value determining when the
message is to be shown, is detailed in section
Setting the SIS parameters on page 189.
Operation time
Service Message
Service is due!
X production hours
since last service.
The manually set operation time limit has expired.

How to set the limit is detailed in section Setting the
SIS parameters on page 189.
type of service.
Operation time
Service Message
X production hours
to next service.
X number of operation hours remain until the

manually set operation time limit expires.
Gearbox time
Service Message
Gearbox x requires
service!
The automatically calculated gearbox time limit has

expired.
type of service.
Gearbox time
Service Message
X% of the service
interval has expired
for gearbox x!
X percent of gearbox hours remain until the

automatically calculated gearbox time limit expires.
3 Maintenance
3.7.6. Exporting the SIS data

General
This section describes the available variables for entering SIS parameters as well as showing
any values of exceeded time limits as detected by the SIS counters.
In a M2004 robot system, the values can be read using OPC Server or RAB. The values can
also be read in RobotStudioOnline (Controller and System Properties) or on the FlexPendant
(System Info).
In a M2000 robot system, the values can be read on a PC using "Webware SDK". How to
access these variables and how to perform the actual programming sequences are detailed in
the robot system Users Guide.
Definitions
The table below defines the names and functions of all software variables available for
communication between the SIS and an external computer.
Signal
Unit
Counter type
Function
sisRestartDate
hrs*
Calendar time
The date on which the supervision was

started/reset last time.
sisCalendarT
hrs*
Calendar time
The number of hours since start/last reset.
sisTotRunT
hrs*
Operation time
Total number of operation hours since the

system was started. Corresponds to the
operating time counter on the control cabinet.
sisRunT
hrs*
Operation time
The number of operation hours since start/

last reset of the operation time counter.
Corresponds to the operating time counter on
the control cabinet.
sisL10h_1
hrs
Gearbox time
Estimated life of gearbox axis 1
sisL10h_Time_1
hrs*
Gearbox time
Operation time of gearbox axis 1
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2
hrs*
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3
hrs*
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6
hrs
Gearbox time
* For RobotWare releases earlier than 5.05, the unit is seconds.
193
3 Maintenance
194
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter
This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate procedures, each detailing a specific repair activity. Each procedure
contains all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 15 before commencing any
service work.
195
4 Repair
4.2.1. Performing a leak-down test
4.2 General procedures

4.2.1. 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.
Art. no.
Leakdown tester
3HAC 0207-1
Leak detection spray
Note
Procedure
Step
196
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 question, Art. no. is specified above!
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 pressure with the Recommended value: 0.2 knob until the correct value is shown on the
0.25 bar (20 - 25 kPa)
manometer.
4.
Disconnect the compressed air supply.
5.
Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is
be detected.
significantly 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 Art. no. is specified above!
.
Bubbles indicate a leak.
8.
When the leak has been localized: take the

necessary measures to correct the leak.
4 Repair
4.2.2. Mounting instructions for bearings
4.2.2. Mounting instructions for bearings

General
This section details how to mount and grease different types of bearings on the manipulator.
Equipment
Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Used to grease the bearings, if not

specified otherwise.
Assembly of all bearings

Follow the instructions below when mounting a bearing on the manipulator.
1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.
2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and
other contamination. Cast components must be free from foundry sand.
3. Bearing rings, inner rings and roller elements must under no circumstances be subjected
to direct impact. Furthermore, the roller elements must not be exposed to any stresses
during the assembly work.
Assembly of tapered bearings
Follow the previous instructions for assembly of all bearings, when mounting a tapered
bearing on the manipulator.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
Note! The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.
2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the
bearing.
Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
During operation, the bearing should be filled to 70-80% of the available volume.
Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
Grooved ball bearings must be filled with grease from both sides.
Tapered roller bearings and axial needle bearings must be greased in the split
condition.
197
4 Repair
4.2.3. Mounting instructions for seals

General
This sections details how to mount different types of seals to the manipulator.
Equipment
Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Used to lubricate the seals.
Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
Protect the sealing surfaces during transport and mounting.
Keep the seal in its original wrappings or protect it well before actual mounting.
The fitting of seals and gears must be carried out on clean workbenches.
Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
Step
198
Action
Note
1.
Check the seal to ensure that:

the seal is of the correct type (provided with cutting
edge).
there is no damage to the sealing edge (feel with a
fingernail).
2.
Inspect the sealing surface before mounting. If scratches or

damage are found, the seal must be replaced, as it may
result in future leakage.
3.
Lubricate the seal with grease just before fitting. (Not too
early as there is a risk of dirt and foreign particles adhering Equipment on page
to the seal.)
198.
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4.
Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in
leakage.
4 Repair
Flange seals and static seals

The procedure below details how to fit flange seals and static seals.
Step
Action
Note
1.
Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint
(without sealing compund).
If the flange surfaces are defective, the parts may not be used
beacuse leakage could occur.
2.
Clean the surfaces properly and in accordance with ABB

ROBOTICS PRODUCTS recommendations.
3.
Distribute the sealing compound evenly over the surface, preferably

with a brush.
4.
Tighten the screws evenly when fastening the flange joint.
O-rings
The procedure below details how to fit o-rings.
Step
Action
Note
1.
Ensure that the correct o-ring size is used.
2.
Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings
may not be used.
3.
Check the o-ring grooves.

Defective o-rings
The grooves must be geometrically correct and free from pores may not be used.
and contamination.
4.
Lubricate the o-ring with grease.
5.
Tighten the screws evenly when assembling.
199
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
4.3 Complete manipulator

Location of cable harness
The cable harness for axes 1-4 is located throughout the manipulator as shown in the figure
below.
xx0300000561
200
Rear cover plate
Attachment point for earth lug
Connector R1.MP
Connector R1.SMB
Cable guide in the center of the frame
Connectors at motor 1: R2.FB1 and R2.MP1
4 Repair
SMB recess
Cable gland, upper arm house
Cable fixing bracket + velcro strap
Connector R2.M5/6 at the cable division point
Connectors at motor 3: R2.FB3 and R2.MP3 (optional signal lamp: R2.H1 and
R2.H2)
Required equipment
Equipment, etc.
Spare part no. Art. no.
Cable harness axis 1-4

(IRB 6600)
3HAC 14940-1
Cable harness axis 1-4

(IRB 6650)
3HAC 16331-1
Note
Locking liquid
Standard toolkit
Loctite 638
Used to secure the
attachment screws for the
attachment plate inside the
frame.
3HAC 15571-1

section Standard toolkit in
the Product manual,
Other tools and

procedures may be
required. See references
to these procedures in the
step-by-step instructions
below.

required.
Circuit Diagram
See chapter Circuit diagram

in the Product manual,
Removal, cable harness, axes 1-4

The procedure below details how to remove the cable harness, axes 1-4.
Step
1.
Action
Note/Illustration
In order to facilitate refitting of cable harness, run Axes 2 and 3 may be tilted
the manipulator to the specified position:
slightly to improve access.
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
Axis 6: no significance
201
4 Repair
Step
Action
Note/Illustration
2.
Danger!
3.
Remove the rear cover plate on the manipulator

by removing its attachment screws.

cable harness on page 200.
4.
Disconnect the earth cable.
Attachment point is shown in the

figure Location of cable harness
on page 200!
5.
Disconnect connectors R1.MP and R1.SMB.
Attachment points are shown in

the figure Location of cable
harness on page 200.
6.
Pull the cable and connectors up through the

cable guide in the center of the frame.
7.
Disconnect all connectors at motor 1 and motor 2. Specified and shown in the figure
Location of cable harness on
page 200!
8.
Open the SMB cover carefully.

The cable between the battery and the SMB-unit
may stay connected, in order to avoid an update
of the revolution counter. 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 updating of the revolution
counter!
9.
Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 from the brake
release unit.
xx0200000118.wmf
202
4 Repair
Step
Action
Note/Illustration
10. Remove
the cable gland (A), by removing the four
attachment screws from inside the SMB
recess (B)
the attachment plate (C), by removing the
attachment screws and the velcro strap
(D).
Note! Different manipulator versions are fitted
with different versions of the attachment plate.
When replacing the cable harness, make sure the
correct one is used to avoid cable failure.
xx0300000560
A: Cable gland
B: Attachment screws,
cable gland
C: Attachment plate
D: Velcro strap
11. Remove the cable gland securing the cables

inside the lower arm.
203
4 Repair
Step
Action
Note/Illustration
12. Remove the cable gland securing the cables to

the arm house.
xx0100000143.wmf
13. Remove the velcro strap from the harness at the Shown in the figure Location of
cable fixing bracket at the arm house.
14. Disconnect connector R2.M5/6 at the cable
division point.

cable harness on page 200!
15. Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
Location of cable harness on
page 200!
16. Gently pull the cable harness out.
204
4 Repair
Refitting, cable harness, axes 1-4

The procedure below details how to refit the cable harness, axes 1-4.
Step
Action
Note/Illustration
1.
Danger!
2.
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
move 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
3.
Pull the cable and connectors down through

the cable guide in the center of the frame.
4.
Reconnect connectors R1.MP and R1.SMB at Make a note of the correct positions
the rear cover plate.
of the connectors!
figure Location of cable harness on
page 200.
5.
Reconnect the earth cable.

figure Location of cable harness on
page 200!
6.
Refit the rear cover plate on the manipulator

with its attachment screws.

7.
Reconnect all connectors at motor 1 and

motor 2.
Specified and shown in the figure

Location of cable harness on page
200!
Make sure the cables are not

twisted with each other or with
eventual customer harnesses!
Make a note of the correct positions
of the connectors!
205
4 Repair
Step
8.
Action
Note/Illustration
Secure the cable gland (A) with four

Locking liquid is specified in
attachment screws (B) from inside the SMB
recess.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws,
using locking liquid.
Refit the velcro strap (D).
Note! Different manipulator versions are fitted
with different versions of the attachment plate.
Make sure the correct one is used to avoid
cable failure.
xx0300000560
9.
A: Cable gland
B: Attachment screws, cable
gland
C: Attachment plate
D: Velcro strap
Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 to the brake
release unit.
Reconnect R1.G if it has been disconnected.
10. Secure the SMB cover with its attachment

screws.
206
4 Repair
Step
Action
Note/Illustration
11.
Warning!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 39!
12. Pull the cable harness through the lower arm.
13. Refit the cable gland securing the cables
xx0100000142
14. Refit the cable gland securing the cables to

the arm house.
Make sure not to twist the harness!
xx0100000143
15. Reconnect all connectors at motor 3 and

motor 4.
Specified and shown in the figure

Location of cable harness on page
200!
16. Reconnect the connector R2.M5/6 gently at

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

cable harness on page 200!
M6, 2 pcs.
17. Secure the cable harness to the upper arm

house by refitting the velcro strap to the cable cable harness on page 200!
bracket at the upper arm house.
18. If the connection between the SMB battery
and the SMB unit has been broken, the
revolution counters must now be updated!
Detailed in the Calibration chapter section Updating revolution

counters on page 342.
207
4 Repair
DANGER!
it is vital that:
208
4 Repair

Location of cable harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
xx0200000213
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
Connector at cable harness division point; R2.M5/6
Connectors at motor, axis 6; R3.FB6 and R3.MP6
209
4 Repair
Required equipment
Equipment, etc.
Cable harness axes 5-6
3HAC 14140-1
Cable harness axis 5
3HAC 14139-1
Standard toolkit
Note
3HAC 15571-1

the Product manual,
Other tools and

procedures may be
to these procedures in
the step-by-step
instructions below.

required.
Circuit Diagram

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 in
section Removal, cable harness, axis 5 on page 212.
Step
Action
Note/Illustration
1.
Danger!
pneumatic pressure supplies to the
robot!
2.
Remove the cover, wrist unit and the

cover, upper arm tube.
xx0200000214
210
A: cover, wrist unit

B: cover, upper arm tube
4 Repair
Step
Action
Note/Illustration
3.
Note!
Axis 5 must be oriented in the correct
position (+90) to allow the motor 6
cover to open!
4.
Remove the cover of motor, axis 6 and Specified in the figure Location of cable
disconnect all connectors beneath.
harness ax 5-6 on page 209!
5.
Loosen the cable bracket on top of the Shown in the figure Location of cable
wrist unit by undoing the three
attachment screws.
Two of the attachment screws are
visibly located at the rear attachment
and the third is located at the bottom of
the cable bracket, in the center.
xx0200000254
B: Attachment screws, rear of cable

bracket, 2 pcs
C: Attachment screw, bottom of
cable bracket, 1 pc
6.
Pick out the cabling from motor, axis 6.
7.
Loosen the cable bracket in the upper Shown in the figure Location of cable
arm tube by undoing the two screws on harness ax 5-6 on page 209!
top of the tube.
8.
Disconnect the two connectors

(R3.FB5 and R3.MP5) in the tube.
9.
Remove eventual cable straps from the

harness.
Shown in the figure Location of cable

10. Remove the cable attachment, rear.

11. Disconnect connector R2.M5/6 at the

cable harness division point.

12. Gently pull the cable harness out.
211
4 Repair
Removal, cable harness, axis 5

The procedure below details how to remove the cable, axis 5.
Step
Action
Note
1.
Danger!
2.
Remove the complete wrist unit.
Detailed in section Removal,

wrist unit on page 226.
3.
Remove the cover of motor, axis 5.
4.
Disconnect all connectors at motor, axis 5.
5.
Remove the cable gland cover at the cable exit by

unscrewing its two attachment screws.
6.
Remove the cable, axis 5.
Refitting, cable harness, axes 5-6

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 214.
Step
Action
Note/Illustration
1.
Danger!
212
2.
The manipulator is required to be positioned

in the following position:
Axis 4: 0 degrees
Axis 5: +90 degrees
3.
Gently insert the cable harness from the rear

into the upper arm.
4.
Connect the two connectors inside the

upper arm tube, R3.FB5 and R3.MP5 and
secure the cable bracket with the two
attachment screws to the tube.

4 Repair
Step
5.
Action
Note/Illustration
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.
xx0200000185
6.
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 ax 5-6 on page 209!
at the rear attachment point and the third
located on the bottom of the cable bracket, in
the center.
xx0200000254
7.
Reconnect the connectors to motor, axis 6

and refit the motor cover.
8.
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.
B: Attachment screws, rear of

cable bracket.
C: Attachment screw, bottom
of cable bracket.
xx0200000214
9.
A: cover, wrist unit

B: cover, upper arm tube
If any cable straps have been removed, refit

them to the harness.
10. Refit the cable attachment, rear.

11. Reconnect connector R2.M5/6 gently at the Shown in the figure Location of cable
rear cable division point with two screws,
M6.
213
4 Repair
Step
Action
12. Update the revolution counter!
Note/Illustration
Detailed in chapter Calibration section Updating revolution counters
on page 342.
Refitting, cable harness axis 5

The procedure below details how to refit the cable, axis 5.
Step
Action
Note
1.
Danger!
2.
Reconnect all connectors at motor, axis 5.
3.
Refit the cable gland cover at the cable exit

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

unit on page 228.
6.
Recalibrate the robot!
Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are
specified in section Document
DANGER!
it is vital that:
214
4 Repair
4.3.3. Replacement 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.
xx0200000224
Upper arm
Lower arm
Frame
Gearbox, axis 1
Base attachment screws
Balancing device
Block for calibration
Motor axis 1
215
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Lifting device, manipulator
3HAC 15607-1
Instruction 3HAC 15971-2 is enclosed!
Guide pins M12 x 130
3HAC 022637001
Used to guide the complete arm system

when refitting.
Always use the guide pins in pairs!
In order to make the refitting easier, it is
recommended to use two guide pins of
different lengths. Notice that longer
guide pins that 140 mm will not be
possible to remove from the frame
because lack of space after refitting!
Hoisting block
Used to adjust the length of the lifting

chain.
Standard toolkit
3HAC 15571-1


references to these procedures
in the step-by-step instructions
below.
216

the tools required.
4 Repair
Removal, arm system

The procedure below details how to lift and remove the complete arm system.
Step
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
2.
Make sure the manipulator is

positioned as shown in figure to the
right. If it is not, position it that way.
Release the brakes if necessary, as

detailed in section Manually releasing the
brakes on page 67.
3.
Drain the oil from gearbox axis 1.
4.
Loosen the cable connectors from the

base and pull up the cabling from the
base, through the hole in the center of
the frame.
5.
Remove the motor, axis 1.
6.
Run the overhead crane to a position

above the manipulator.
7.
Fit the lifting device and adjust it as

detailed in the enclosed instructions.
8.
Remove the block for calibration from Shown in the figure Location of arm system
the bottom of the frame.
on page 215!
xx0100000103
Detailed in section Oil change, gearbox

axis 1 on page 156.
Detailed in section Removal, motor on page

279.
Art. no. is specified in Required equipment

on page 216!
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 lifting!
217
4 Repair
Step
9.
Action
Note/Illustration
Unfasten the arm system from the

Shown in the figure Location of arm system
base by unscrewing its 24 attachment on page 215!
screws.
10. Fit the two guide pins in two opposite

screw holes.
11.
Caution!
The complete arm system weighs
1300 kg! All lifting equipment used
12. Lift the arm system carefully and
secure it in a safe area.
Always move the manipulator at very
low speeds, making sure it does not
tip.
Make sure all hooks and attachments
stay in the correct position while lifting
the arm system and that the lifting
device does not wear against sharp
edges.
Continue lifting even if the arm system
turns out to be unbalanced despite
earlier adjustments! The risk of
damaging the interfaces is bigger if the
load is lowered unbalanced!
Refitting, arm system

The procedure below details how to lift and refit the complete arm system.
Step
Action
Note/Illustration
1.
Danger!
2.
218
Fit the lifting device as detailed in enclosed Art. no. is specified in Required
instruction.
Also fit a hoisting block to the front chain,
used to adjust the balance of the arm system
in order to lift it completely level!
4 Repair
Step
Action
Note/Illustration
3.
Caution!
The complete arm system weighs 1300 kg!
All lifting equipment used must be
dimensioned accordingly!
4.
Lift the complete arm system and move it at Make sure all the hooks and
very low speed, making sure it does not tip! attachments stay in the correct
Make sure the lift is done completely level. position while lifting the manipulator!
Adjust the length of the chains as detailed in
enclosed instruction or with a hoisting block!
5.
Fit the two guide pins to the frame

Dimension is specified in Required
attachment holes, as shown in the figure to equipment on page 216.
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.
xx0300000070
The figure above shows the frame,

view from below.
A: Attachment holes for the
guide pins, M12.
B: Guiding hole for the spring
pin located in the gearbox,
axis 1.
6.
Look through the empty mounting hole of

This is a complex task to be
motor 1 to assist in aligning the assembly
performed with utmost care in order to
during refitting of the arm system.
avoid injury or damage!
The spring pin in the gearbox must be fitted
to the guiding hole of the frame (B).
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
The refitting must be made completely level!
Make sure the lifting device is adjusted prior
refitting of arm system.
7.
Refit 22 of the 24 attachment screws before

the arm system is completely lowered.
219
4 Repair
Step
Action
Note/Illustration
8.
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 215!
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 section Screw joints in the
information before fitting.
9.
Refit the block for calibration at the bottom of Shown in the figure Location of arm
the frame.
system on page 215!
10. Refit the motor axis 1.
Detailed in section Refitting, motor on

page 280.
11. Refit the cabling in the base.

12. Perform a leak-down test of the gearbox axis Detailed in section Performing a leak1.
down test on page 196.
13. Refill the gearbox axis 1 with lubricating oil. Detailed in section Oil change,
14. Recalibrate the robot.

Art. no. for the manuals are specified
in section Document references in the
information.
DANGER!
it is vital that:
220
4 Repair
4.4.1. Replacement of turning disk
4.4 Upper and lower arm

Location of turning disk
The turning disk is located in the front of the wrist housing, as shown in the figure below.
The design of the turning disk is different for robot version IRB 6600 175/2.55.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0300000473
Attachment screws (6 pcs) , turning disk for robot version IRB 6600 175/2.55
xx0200000217
Turning disk
Wrist unit
Oil plug, draining
Oil plug, filling
Attachment screws (12 pcs)turning disk for all robot versions except IRB 6600
175/2.55
221
4 Repair
Required equipment
Equipment, etc. Spare part no. Art. no.
Note
Turning disk, dia.

200 (175/2,55)
3HAC 9744-5
For robot version IRB6600 175/2.55.

O-rings are not included!
Turning disk, dia.

200
3HAC 13752-1
For all IRB 6600 and IRB 6650 robot

versions except IRB 6600 175/2.55.
O-rings are not included!
O-ring
3HAB 3772-65 For robot v. IRB 6600 175/2.55.

(1 pc)
Must be replaced when replacing
2152 0431-20 the turning disk!
(6 pcs)
O-ring
3HAB 3772-64
(1 pc)
3HAB 3772-61
(12 pcs)

versions except IRB 6600 175/2.55.
Must be replaced when replacing
the turning disk!
Grease
3HAB 3537-1
Used to lubricate the o-rings.
Standard toolkit

Other tools and

procedures may
be required. See
references to
these procedures
in the step-by-step
instructions below.

Removal, turning disk

The procedure below details how to remove the turning disk.
Step
Action
Note
1.
Danger!
222
2.
Remove any equipment fitted to the turning disk.
3.
Run the robot to a position where the oil plug,

draining of axis 6 gearbox faces downwards.

turning disk on page 221!
4.
Drain the oil from gearbox 6.
Detailed in section Oil change,

5.
Remove the turning disk by unscrewing its

attachment screws .

turning disk on page 221!
4 Repair
Refitting, turning disk

The procedure below details how to refit the turning disk.
Step
Action
Note/Illustration
1.
Danger!
2.
Lubricate the turning disk o-ring with

grease.
Fit the o-ring to the rear of the turning disk.
Fit also the 6 or 12 o-rings (depending on
robot version), when refitting the
attachment screws.
xx0200000218
A: Sealing surface, o-ring
3.
Secure the turning disk with its attachment For robot version IRB 6600 175/2.55:
screws.
6 pcs, M14 x 25, tightening torque: 175
Nm.
versions except IRB 6600 175/2.55:
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 section
Screw joints in the Product manual,
reference information before fitting.
4.
Perform a leak-down test of the gearbox

axis 6.
Detailed in section Performing a leakdown test on page 196.
223
4 Repair
Step
Action
5.
Refill the gearbox 6 with oil.
6.
Refit any equipment removed during

disassembly, to the turning disk.
Note/Illustration
axis 6 on page 173.
DANGER!
it is vital that:
224
4 Repair
4.4.2. Replacement 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.
xx0200000184
Wrist unit
Turning disk
Cover, wrist unit
Cover, upper arm tube
Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
Cable bracket
Attachment point for lifting tool, wrist unit
Wrist unit attachment screws and washers
Upper arm tube
225
4 Repair
Required equipment
Equipment etc.
Note
Wrist (175/2.55)
3HAC 16627-1
IRB 6600 175/2.55
Wrist (175/2.55, insulated 3HAC 17372-1

turning disk)
IRB 6600 175/2.55
Wrist
All IRB 6600 and IRB 6650

robot versions except IRB
6600 175/2.55.
3HAC 16626-2
3HAC 13056-3
Lifting tool, wrist unit
3HAC 13605-1
Standard toolkit
3HAC 15571-1
Always use guide pins in

pairs!
The contents are defined
in section Standard toolkit
Other tools and

procedures may be
to these procedures in the
step-by-step instructions
below.

required.
Circuit diagram
See chapter Circuit

diagram in the Product
manual, reference
information.
Removal, wrist unit

The procedure below details how to remove the complete wrist unit.
Step
Action
Note/Illustration
1.
Danger!
226
2.
Remove all equipment fitted to the turning disk.
3.
Turn axis 4 to a position where the cover, upper arm Shown in the figure Location
tube and wrist unit, faces upwards. Also turn axis 5 of wrist unit on page 225!
so that the turning disk faces to the side in order to
allow access to the motor 6 cover.
4.
Remove the cover, wrist unit.

of wrist unit on page 225!
5.
Remove the cover, upper arm tube.

6.
Remove the cover of motor, axis 6 and disconnect

all connectors beneath.
4 Repair
Step
7.
Action
Note/Illustration
Loosen the cable bracket on top of the wrist by

undoing the three attachment screws.
Two of the attachment screws are visibly located at
the rear of the bracket (B) and the third located at
the bottom of the cable bracket, in the center (C),
shown in the figure to the right.
xx0200000254
8.
Pick out the cabling from motor, axis 6 and place it

safely on the tube.
9.
Loosen the cable bracket in the upper arm tube by

undoing the two screws on top of the tube.
B: Attachment screws,
rear of cable bracket, 2
pcs
C: Attachment screw,
bottom of cable
bracket, 1 pc

10. Disconnect the motor axis 5 by disconnecting the

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

11. Fit the lifting tool to the wrist unit.

226!
12.
Caution!
The complete wrist unit weighs 130 kg! All lifting
equipment used must be dimensioned accordingly!
13. Slightly raise the wrist unit to unload the screw joint,
facilitating removing the attachment screws.
14. Remove the wrist unit attachment screws and
washers .

15. Pull the wrist unit out, lift it away and place it on a
secure surface.
227
4 Repair
Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
Step
Action
Note/Illustration
1.
Danger!
2.
Fit two guide pins, M12 in the upper arm

tube, in two of the holes for the wrist unit
attachment screws.

Shown in the figure Location of wrist
unit on page 225!
3.
Fit the lifting tool to the wrist unit.
Art. no. is specified Location of wrist

unit on page 225!
4.
Caution!
The complete wrist unit weighs 130 kg! All
lifting equipment used must be
228
5.
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 does not
get jammed.
6.
Secure the wrist unit with 10 of the 12

attachment screws and washers.
7.
Remove the guide pins and secure the two

remaining attachment screws as detailed
above.
8.
Remove the lifting tool from the wrist unit.
9.
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.

unit on page 225!
12 pcs: M12 x 50, 12.9 quality
before fitting.

unit on page 225!
4 Repair
Step
Action
Note/Illustration
10.
Note!
Axis 5 must be oriented in the correct
position (+90) to allow the motor 6 cover to
open!
11. 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.
xx0200000185
Put a loop of cable in this area with

cable straps (A), if necessary. The
cables are long enough to fit different
upper arm lengths.
12. Fasten the cable bracket at top of the wrist Shown in the figure Location of wrist
unit with three attachment screws. Two of unit on page 225!
them are visible at the rear attachment
point (B) and the third is located on the
bottom of the cable bracket, in the center
(C), shown in the figure to the right.
xx0200000254
B: Attachment screws, rear of

cable bracket
C: Attachment screw, bottom of
cable bracket
13. Reconnect the connectors to motor, axis 6

and refit the motor cover.
14. Refit the cover, upper arm tube.

unit on page 225!
15. Refit the cover, wrist unit.

unit on page 225!
16. Recalibrate the robot!

Art. no. for the manuals are specified in
section Document references in the
information.
17. Refit any equipment previously removed

from the turning disk.
229
4 Repair
DANGER!
it is vital that:
230
4 Repair
4.4.3. Replacement of upper arm

Location of upper arm
The upper arm is located on top of the manipulator as shown in the following figure. 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 following figure.
231
4 Repair
xx0200000163
232
Attachment hole for lifting eye, M12 (if wrist unit is mounted)
Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
Oil plug, draining, gearbox axis 3
Cable harness division; connector 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)

4 Repair
Required equipment
Equipment
Art. no.
Note
Sealing, axis 2/3
3HAC 12443-2
Always use a new sealing when

refitting the upper arm!
Washer, axis 3 (3 pcs)
3HAC 12703-1
To be replaced if damaged.
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
3HAC 17105-1
Used to rotate the motor shaft

beneath the motor cover, when
brakes are released with 24 VDC
power supply.
Lifting eye VLBG M12
3HAC 16131-1
Lifting device, upper arm
3HAC 15994-1
Lifting tool (chain)
3HAC 15556-1
To be used together with lifting

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

information!

instructions below.

Removal, upper arm

The procedure below details how to remove the upper arm.
Step
Action
Note
1.
Danger!
2.
Remove all equipment fitted to turning disk.
3.
Move the manipulator upper arm to a horizontal Shown in the figure Location of
position.
upper arm on page 231!
Run axis 4 so that the attachment hole for lifting
eye is faced upwards!
4.
Upper arm including wrist unit: Fit the lifting Art. no. is specified in Required
eye, VLBG M12 to the attachment hole for
lifting eye on the upper arm tube.
233
4 Repair
Step
Action
Note
5.
Upper arm including wrist unit: Fit one of the

pieces included in lifting device, upper arm to
the front attachment for lifting device on the
upper arm.
Upper arm without wrist unit: Fit the lifting
device, upper arm to the both attachments for
lifting device .

figure Location of upper arm on
page 231!
Notice the different attachment
points, depending on whether the
wrist unit is mounted or not!
6.
Fasten the lifting tool (chain) onto the lifting

eye, the lifting device and an overhead crane.

7.

gearbox, axis 3 on page 164.
8.
Disconnect connector R2.M5/6 at the cable

harness division as well as all remaining
connections between upper and lower arm.

9.
Remove the cover on top of the motors, axis 3

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

upper arm by removing their attachment screws
respectively.
11.
Caution!
The complete upper arm weighs 380 kg without
any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
12. Raise the lifting equipment to take the weight of
the upper arm.
13. In order to release the brake of the axis 3 motor, Connect to connector R2.MP3
connect the 24 VDC power supply.
+: pin 2
Note! When releasing the brake, the position of
-: pin 5
the upper arm is adjusted to the position given
by the lifting equipment.
14. Carefully remove the attachment screws and
washers, upper arm.

15. 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!
16. Remove the sealing, axis 2/3 from the lower
arm.
234

4 Repair
Refitting, upper arm

The procedure below details how to refit the upper arm.
Step
Action
Note/Illustration
1.
Danger!
2.
Fit the two guide pins, sealing axis 2/3 in Always use a new sealing when
two of the attachment screw holes on
reassembling!
gearbox 3, see figure to the right.
Guide the new sealing, axis 2/3 into
position on gearbox 3, using the guide
pins.
xx0200000166
A: Holes for the guide pins

(sealing axis 2/3).
B: Holes for the upper arm
attachment screws (33 pcs).
C: Holes for the gearbox
attachment screws (not affected
in this instruction).
3.
Upper arm including wrist unit: Fit the

lifting eye, VLBG M12 to the attachment
hole, lifting eye on the wrist unit.

Shown in the figure Location of upper
arm on page 231!
4.
Upper arm including wrist unit:Fit one of

the pieces included in the lifting device,
upper arm to the front attachment for the
lifting device on the upper arm.
Upper arm without wrist unit:Fit the
lifting device, upper arm to the both
attachments for the lifting device on the
upper arm.

Attachment points are shown in the
figure Location of upper arm on page
231!
Notice the different attachment points
depending on whether the wrist unit is
mounted or not!
235
4 Repair
Step
Action
Note/Illustration
5.
In order to release the brake of the axis 3

motor, connect the 24 VDC power supply,
after removing the motor cover.
Connect to connector R2.MP3

+: pin 2
-: pin 5
6.
Fasten the lifting tool (chain) onto the

lifting eye, the lifting device and an
overhead crane.

7.
Caution!
The complete upper arm weighs 380 kg
without any additional equipment fitted!
Use a suitable lifting device to avoid injury
to personnel!
8.
Lift the upper arm and run to its mounting

position.
Make sure the lift is done completely level!
9.
Fit in the gearbox attachment holes with

the attachment holes on the lower arm with equipment on page 233!
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
236
10. Fit the three washers to be placed

beneath the attachment screws.

arm on page 231!
11. 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 231!
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.
4 Repair
Step
Action
12. Secure the lower arm to gearbox axis 3,

with the attachment screws.
Note/Illustration
33 pcs: M12 x 50; 12.9 quality
they are lubricated as detailed in
section Screw joints in the Product
manual, reference information before
fitting.
13. Remove the guide pins and fit the two

remaining attachment screws. Tighten
them as detailed above!
14. Disconnect the brake release voltage and
remove the rotation tool from the motor.
15. Remove the lifting devices.
16. Refit any cabling removed during the
removal process.
17. Reconnect all connectors inside motors,
axis 3 and 4. Refit the motor covers.
18. Reconnect connector R2.M5/6 gently at
the cable harness division point, with 2
screws, M6.
19. Perform a leakdown test.
20. Refill the gearbox with oil.


DANGER!
it is vital that:
237
4 Repair
4.4.4. Replacement of complete lower arm

Location of lower arm
The lower arm is located as shown in the figure below.
xx0200000255
238
Lower arm
Pivot point, axis 2
Front shaft, balancing device, including securing screw
Attachment for lifting equipment, balancing device
4 Repair
Internal components, lower arm

The internal components of the lower arm are located as shown in the figure below:
The figure (1) shows a cut between the lower arm and the gearbox axis 3. The location
of the sealing axis 2/3 is identical between the lower arm and the axis 2.
The figure (2) shows a cut through the lower arm pivot point in axis 2 (item B in the
figure above!).
xx0200000031
Gearbox
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, lower arm
406
Protection plug
409
Protection washer
239
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
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 120x12
3HAA 2166-23
Mount on new lower arm or replace if

damaged.
Lifting eye M12
3HAC 14457-3
Used to lift the balancing device, if it is

equipped with a threaded hole.
Shackle, balancing device
3HAC 020997-1
Used if the balancing device is equipped

with a lifting eye.
Puller tool, balancing device 3HAC 12475-1

shaft
Lifting tool, lower arm
3HAC 14691-1
Tool that may be rent from ABB Robotics.

Includes:
two guidings, 3HAC 14446-1,
must be used for guiding the
sealing, axis 2/3.
Rotation tool
3HAC 17105-1
Used to rotate the motor pinion and gear

if necessary, when brakes are released.
Hydraulic pump, 80 MPa
3HAC 13086-1

(Glycerin)
3HAC 021563-012
Puller device, axis 2 shaft
3HAC 021563-001
Press device, axis 2 shaft
3HAC 021600-001
Press tool, axis 2 bearing
3HAC 13527-1
Retaining ring plier
Grease
3HAB 3537-1
For lubrication of the shaft hole.
Isopropanol
1177 1012-208
For cleaning of the shaft.
Standard toolkit
3HAC 15571-1


references to these
240
The use of the tool is detailed in section

Replacement of lower arm shaft on page
246.

the tools required.
4 Repair
Removal, lower arm

The procedure below details how to remove the complete lower arm.
Step
Action
Note/Illustration
1.
Danger!
2.
Remove the upper arm.
Detailed in section Removal, upper

arm on page 233.
3.
Disconnect and remove the cables from

Release any cable attachments.
Detailed in section Removal, cable

harness, axes 1-4 on page 201.
4.
Apply the lifting eye, M12orshackle to the

balancing device and raise to unload the
weight of the device.

Attachment is shown in the figure
Location of lower arm on page 238.
5.
Unload the balancing device in order to make Detailed in sectionUnloading the

the piston rod and front ear adjustable when balancing device on page 271.
pulling the front shaft out.
6.
Remove the securing screw from the

balancing device front shaft.
Shown in the figure Location of lower

arm on page 238.
7.
Apply the puller tool, balancing device shaft

to the shaft of the balancing device, through
the hole in the frame.
The shaft has a M20 thread diameter, as
Pull the shaft out using the puller tool and the
hydraulic pump.
xx0300000056
Note! The dimension of the shaft

puller tool is M20. Do not mix up with
the shaft press tool used when
mounting the shaft.
8.
Lower the balancing device until it rests

safely against the bottom of the frame.
241
4 Repair
Step
9.
Action
Note/Illustration
Move the lower arm backwards to the lowest

position possible.
xx0300000015
10. Apply the lifting tool to the lower arm.

11. Drain the oil from gearbox 2.

12.
Caution!
The lower arm weighs 160 kg! All lifting
accordingly!
13. Raise the tool to unload the lower arm.
14. Remove the lower arm shaft and all additional
components, as detailed in section Removal,
lower arm shaft on page 248!
15. Remove the attachment screws and
washers that attach the lower arm to the
gearbox axis 2.
Shown in the figure Internal

components, lower arm on page 239!
16. Lift the lower arm and place it on a secure

surface.
17. Remove the bearing and thrust washer from Shown in the figure Internal
the shaft hole in the lower arm.
On reassembly a new bearing must
be used!
18. Remove the both sealings, axis 2/3 from the Shown in the figure Internal
lower arm.
On reassembly new sealings must
be used!
242
4 Repair
Refitting, lower arm

The procedure below details how to refit the lower arm.
Step
Action
Note/Illustration
1.
Danger!
2.
Fit a new VK-cover on a new lower arm or

replace the existing if damaged.
Part no. is specified in Required

3.
Fit two guidings in the attachment holes of

the lower arm.

xx0200000262
A: Attachment holes for the two

guidings
4.
Fit the new sealing, axis 2/3 on the guidings. Always use a new sealing when
reassembling!
5.
Apply the lifting tool to the lower arm.

6.
Caution!
The lower arm weighs 160 kg! All lifting
accordingly!
7.
Lift the lower arm and move it to its mounting

position.
243
4 Repair
Step
8.
Action
Note/Illustration
In case the hole pattern of the lower arm and Connect power supply to connector
the gearbox axis 2 does not match, use power R2.MP2
supply to release the motor axis 2 brakes and
+: pin 2
rotate the pinion and gear with the rotational
-: pin 5
tool.
xx0200000165
The rotation tool (A) is used beneath

the motor cover, directly on the
motor shaft as shown in figure
above.
9.
Disconnect the power supply, if used.
10. Secure the lower arm with 31 of the 33

33 pcs: M12 x 50, 12.9 quality
attachment screws and washers in gearbox, UNBRAKO, tightening torque: 120
axis 2.
Nm.
detailed in section Screw joints in
the Product manual, reference
Shown in the figure Internal
components, lower arm on page
239!
11. Remove the guidings and secure the two
remaining screws as detailed above!
12. Refit the lower arm shaft and all additional
components, as detailed in section Refitting,
13. Remove the lifting tool from the lower arm.
14. Refit and restore the balancing device.
Detailed in section Refitting,

15. Refit the upper arm.
Detailed in section Refitting, upper

arm on page 235.
16. Perform a leak-down test.
Detailed in section Performing a

leak-down test on page 196.

18. Refit and reconnect all cables inside the lower Detailed in section Refitting, cable
arm.
harness, axes 1-4 on page 205.
Resecure any cable attachments.
244
4 Repair
Step
Action
Note/Illustration
DANGER!
it is vital that:
245
4 Repair
4.4.5. Replacement of lower arm shaft

Prerequisites
This section details how to remove and refit the lower arm shaft as a step in the procedure of
removing/refitting the complete lower arm. To perform the procedure described in this
section, it is required that the preceding instructions in section Replacement of complete lower
arm on page 238 are followed! These include:
removing the upper arm
removing the cabling in the lower arm
unloading the balancing device and removing the front eye shaft
draining the oil in gearbox axis 2
unloading the lower arm with specific lifting equipment.
Components, lower arm shaft

The figure below shows the components fitted to the lower arm shaft.
xx0300000487
246
Protection plug
Lower arm shaft (axis 2 shaft)
Thrust washer
Bearing
Protection washer
Retaining ring
4 Repair
Required equipment
Equipment
Art. no.
Note
Bearing
3HAC 12441-2

reassembling!
Puller device, axis 2 shaft
3HAC 021563-001
Press device, axis 2 shaft
3HAC 021600-001
3HAC 13086-1

(Glycerin)
3HAC 021563-012
Press tool, axis 2 bearing
3HAC 13527-1
Retaining ring plier
Isopropanol
1177 1012-208
For cleaning the shaft.
Grease
3HAB 3537-1
For lubrication of the bearing.
Glycerin
For lubrication of the shaft.
Puller device for removal of axis 2 shaft

The illustration below shows the puller tool used to remove the lower arm shaft (axis 2 shaft).
A
B
xx0400001029
Nipple for the hydraulic pump
Nipple for the glycerin pump
247
4 Repair
Press device for refitting of axis 2 shaft

The illustration below shows the press tool used to refit the lower arm shaft (axis 2 shaft).
A
B
xx0300000485
Nipple for the hydraulic pump
Nipple for the glycerin pump
Indicator
Removal, lower arm shaft

The procedure below details how to remove the lower arm shaft.
If encountering any problems when removing the shaft, contact ABB Robotics!
Step
Action
Note/Illustration
1.
Warning!
This procedure is a step in the complete

procedure of removing the lower arm! Make sure
all the preceding steps specified in Prerequisites
on page 246 are made before removing the
lower arm shaft!
2.
248
Remove the protection plug.
Shown in the figure Components,

4 Repair
Step
Action
Note/Illustration
3.
Remove the protection washer and the retaining Shown in the figure Components,
ring.
Use a plier for the retaining ring.
4.
Fit the puller device to the shaft as shown in the Art. no. is specified in Required
figure to the right.
xx0300000010
5.
Fit both the hydraulic pump and the glycerin

pump to the puller device.
6.
Increase the pressure of the glycerin pump and, Note! Do not exceed the limit of
at the same time, pull out the shaft with the puller maximum pressure classified for
tool by increasing the pressure of the hydraulic the pumps!
pump.
7.
Remove the bearing and thrust washer from the

shaft hole in the lower arm, recommendable
after removing the complete lower arm as
detailed in section Removal, lower arm on page
241.

The attachments on the tool are
shown in figure Puller device for
removal of axis 2 shaft on page
247.
249
4 Repair
Refitting, lower arm shaft

The procedure below details how to refit the lower arm shaft.
Step
Action
Note/Illustration
1.
Clean the shaft with isopropanol and lubricate it Art. no. is specified in Required
with glycerin.
2.
Push the shaft in by hand.
3.
Refit the thrust washer to the shaft.
4.
Apply the press device, axis 2 shaft against the Art. no. is specified in Required
shaft.
5.
Tighten the M16 nut.
6.
Fit both the hydraulic pump and the glycerin

pump to the press device.

The attachments on the tool are
shown in the figure Press device
for refitting of axis 2 shaft on page
248.
7.
Set the indicator on the press device to zero.
Shown in the figure Press device

for refitting of axis 2 shaft on page
248.
8.
Press in the shaft with the hydraulic cylinder by

setting the pressure of the hydraulic pump to
approximately 35-55 MPa and the pressure of
the glycerin pump to 55 MPa.
9.
Increase the pressure of the both pumps

Correct value: 2.45 mm 0.15
alternately until the correct value is reached with mm.
the indicator on the press tool.
Note! Do not exceed the limit of
maximum pressure classified for
the pumps!
Also shown in the figure

Components, lower arm shaft on
page 246!
10. When a correct value is reached, release the

pressure from the glycerin pump first, then from
the hydraulic pump (approximately 1/2 minute
after), in order to avoid movement of the shaft.
11. Remove the press device, axis 2 shaft.
12. Apply grease to the location of the shaft where Art. no. is specified in Required
the bearing is to be mounted.
13. Press in the new bearing with the press tool,
axis 2 bearing.

reassembling!
14. Refit the protection washer and the retaining

ring.

15. Refit the protection plug.

16. Proceed with the refitting procedure of the lower

arm, detailed in section Refitting, lower arm on
page 243.
250
4 Repair
4.4.6. Securing the lower arm

General
This section details how to secure the lower arm with a specific fixture prior to performing
certain service activities to the manipulator.
Attachment points, manipulator
The special equipment used to secure the lower arm is fitted to the attachment points shown
in the figure below.
xx0400000708
Attachment hole, securing screw
Holes for M12 bolts
Holes for M16 bolts
251
4 Repair
Required equipment
Equipment, etc
Art. no.
Note
Fixture lower arm
3HAC 020584-001
Includes the locking screw for securing the

lower arm.
Standard toolkit
3HAC 15571-1

Fixture, lower arm

The attachment bolts, locking screw, adjusters and ring nuts are attached to the fixture tool as
shown in the figure below. Move them to the attachment points shown in the instruction.
B
D
xx0400000709
252
Locking screw
Adjusters, 2 pcs
M16 bolts, 4 pcs
Ring nuts, 2 pcs
M12 bolts and washers, 2 pcs
4 Repair
Securing the lower arm

The procedure below details how to secure the lower arm by fitting the fixture to the
manipulator.
Step
Action
Note/Illustration
1.
Danger!
2.
Remove any load or equipment fitted to the

upper arm or turning disk.
3.
Move 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.
xx0200000260
4.
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.
5.
Remove the locking screw from the fixture,

where it is attached.
Shown in the figure Fixture, lower

arm on page 252.
Art. no. of the fixture is specified in
6.
Secure the lower arm to the frame by inserting

the locking screw into a specific attachment
hole through the frame, into the lower arm.
Shown in the figure Attachment

points, manipulator on page 251.
253
4 Repair
Step
7.
Action
Note/Illustration
Fit the fixture, lower arm to the frame and the

lower arm, according to following instruction:
1. Fit the both adjusters in the correct holes
and make sure that they are screwed
back (C).
2. Align the fixture with the frame and lower
arm.
3. Make sure the fixture is pressed tightly
against the lower arm before securing
with screws!
4. Fit and tighten the four M16 bolts in the
attachment holes on the inside of the
frame with tightening torque: 220 Nm
(A). Note!The attachment holes are
elliptic, making the fixture adjustable for
different manipulator models. Tighten
the bolts properly!
5. Screw in the two adjusters until they rest
against the flats on the lower arm.
Tighten by hand.
6. Lock, using the two ring nuts.
7. Fit and tighten the two M12 bolts in the
attachment holes on the lower arm with
tightening torque: 91 Nm (C).

Attachment holes on the frame
and on the lower arm are shown in
the figure Attachment points,
manipulator on page 251!
The adjusters, bolts and ring nuts
are shown in the figure Fixture,
lower arm on page 252.
A
xx0400000710
A: Holes for M16 bolts.

C: Holes for M12 bolts (2
pcs), adjusters, ring nuts
and washers.
8.
Warning!
The lower arm is now secured and it is safe to

remove the gearbox of axis 2, according to
section Removal, gearbox on page 318,
provided that the balancing device is unloaded.
254
4 Repair
4.5.1. Replacement of SMB unit
4.5 Frame and base

Location of SMB unit
The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame
as shown in the figure below.
xx0200000203
SMB cover
SMB unit
Pins
Battery cable
Required equipment
Equipment, etc.
SMB unit
3HAC 16014-1
Standard toolkit
Circuit Diagram
3HAC 15571-1
Note
information!
See chapter Circuit diagram in
information.
255
4 Repair
Removal, SMB unit

The procedure below details how to remove the SMB unit.
Step
Action
Note
1.
Danger!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
256
3.
Remove the SMB cover by unscrewing its

attachment screws.

SMB unit on page 255!
4.
Remove the connectors X8, X9 and X10 from the

brake release board, if need of more space.
5.
Remove the nuts and washers from the pins

securing the board.
6.
Gently disconnect the connectors from the SMB Connectors R1.SMB1-3,

unit when pulling the board out.
R1.SMB4-6 and R2.SMB
7.
Disconnect the battery cable from the SMB unit. Shown in the figure Location of
SMB unit on page 255.

4 Repair
Refitting, SMB unit

The procedure below details how to refit the SMB unit.
Step
Action
Note
1.
Danger!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
3.
Connect the battery cable to the SMB unit.

SMB unit on page 255.
4.
Connect all connectors to the SMB board and fit Art. no. is specified in Required
the SMB unit onto the pins .
R1.SMB1-3, R1.SMB4-6 and
R2.SMB
5.
Secure the SMB unit to the pins with the nuts and
washers.
6.
If disconnected, reconnect the connectors X8, X9

and X10 to the brake release board.
7.
Secure the SMB cover with its attachment

screws.

8.
Update the revolution counter!
Detailed in chapter Calibration section Updating revolution

counters on page 342!
DANGER!
it is vital that:
257
4 Repair
4.5.2. Replacement 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 next to the gearbox, axis 2, as shown in figure below.
Some early designs are equipped with a separate box on the frame, with the brake release unit
inside, not shown in the figure.
xx0200000226
Brake release unit
Attachment screws, brake release unit (4 pcs)
Buttons
SMB cover
Push button guard
Required equipment
258
Equipment, etc.
Art. no.
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.
4 Repair
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1



Removal, brake release unit

The procedure below details how to remove the brake release unit.
Step
Action
Note/Illustration
1.
Danger!
2.
Warning!
WARNING!
handling the unit please observe the
safety information in section WARNING The unit is sensitive to ESD! on page 40
3.
Remove the push button guard from the

SMB cover.
4.
Open the SMB cover by unscrewing the Shown in the figure Location of brake
attachment screws.
release unit on page 258!
Let the battery stay connected, to avoid
the need of synchronization of the robot!
5.
Remove the complete brake release unit

(including brake release unit and bracket)
from the SMB recess, by removing its two
attachment screws.
Shown in the figure Location of brake

release unit on page 258.
The guard must be removed to ensure a
correct refitting of the brake release unit.
259
4 Repair
Step
6.
Action
Note/Illustration
Disconnect the connectors X8, X9 and

X10 from the brake release unit.
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons
Location of brake release unit is shown
in the figure Location of brake release
unit on page 258!
7.
Remove the brake release unit from the

bracket by removing the four attachment
screws.
Refitting, brake release unit

The procedure below details how to refit the brake release unit.
Step
Action
Note/Illustration
1.
Danger!
2.
Warning!
WARNING!
handling the unit please observe the safety
260
4 Repair
Step
Action
3.
Fasten the brake release unit on the

bracket with the attachment screws.
Make sure the unit is positioned as straight
as possible on the bracket! The push
buttons can otherwise get jammed when
the SMB cover is refitted.
4.
Connect the connectors X8, X9 and X10 to

the brake release unit.
Note/Illustration
xx0200000129
5.
Refit the complete brake release unit

(including brake release unit and bracket)
to the SMB recess with the two attachment
screws.
6.
Refit the SMB cover with its attachment

screws.
The push button guard must not be
mounted on the cover before the check
described below is made!
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons

7.
Warning!
Before continuing any service work,
please observe the safety information in
section WARNING - The brake release
buttons may be jammed after service work
on page 39!
8.
Refit the push button guard to the SMB

cover.

release unit on page 258.
9.
If the battery has been disconnected the

revolution counter must be updated.
Detailed in the Calibration chapter section Updating revolution counters on

page 342.
261
4 Repair
DANGER!
it is vital that:
262
4 Repair
4.5.3. Replacement of balancing device

Location of balancing device
The balancing device is located on rear top of the frame as shown in the figure below.
xx0200000223
Balancing device
Rear cover
Support shaft inside
Attachment screws, rear cover
Balancing device shaft, including securing screw
Bearing attachment
Parallel pin (inside bearing attachment)
Attachment screws, bearing attachments
263
4 Repair
Attachment points, balancing device

The attachment points for the lifting tools etc. are located as shown in the figure below.
The attachment for the balancing device lifting tool is either a threaded hole or a lifting eye,
depending on the version of the balancing device.
xx0300000482
264
Lifting eye or threaded hole for the lifting equipment
Securing screw attachment hole, secures the bearing attachment to the balancing
device (remove the protection plug)
Hole in the frame to access the balancing device shaft with the puller/press tool
Locking screw attachment hole, secures the lower arm to the frame
4 Repair
Required equipment
Equipment
Spare part no.
Art. no.
Note
Balancing device
(IRB 6600)
3HAC 020691-001
IRB 6600
Includes balancing device
3HAC 17117-2!
Includes end cover gasket
3HAC 17188-1.
Balancing device
(IRB 6650)
3HAC 020692-001
IRB 6650
Includes balancing device
3HAC 17117-3!
Includes end cover gasket
3HAC 17188-1.
Gasket, end cover
3HAC 17188-1
Locking screw
3HAA 1001-266
M16 x 60
For securing the lower arm.
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.
Locking liquid
Loctite 243
To apply to the securing
screw in the shaft.
Grease pump
To lubricate spherical roller

bearing.
3HAC 13120-5
Always use guide pins in

pairs!
Lifting eye M12
3HAC 14457-3
Used if the balancing

device is equipped with a
threaded hole.
Shackle, balancing
device
3HAC 020997-1
Used if the balancing

device is equipped with a
lifting eye.
3HAC 15556-1
Press tool, balancing

device
3HAC 020902-001
Puller tool, balancing

device shaft
3HAC 12475-1

device shaft
3HAC 17129-1
Hydraulic cylinder
3HAC 11731-1
To be used with the press

and puller tools.
265
4 Repair
Equipment
Spare part no.
Art. no.
Note
Hydraulic pump, 80
MPa
3HAC 13086-1
To be used with the

hydraulic cylinder.
Standard toolkit
3HAC 15571-1

the Product manual,
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.

required.
Removal, balancing device

The procedure below details how to remove the balancing device.
Step
Action
Note/Illustration
1.
Danger!
2.
Run the lower arm to a position close to the

calibration position.
3.
Secure the lower arm to the frame by inserting Attachment hole for the locking
the locking screw into the attachment hole in screw is shown in the figure
the frame.
Attachment points, balancing
device on page 264.
4.
Caution!
The balancing device weighs 210 kg! All lifting
accordingly!
5.
266
Apply the lifting eye or the shackle to the

balancing device, and raise to unload the
device.

Attachments are shown in the figure
Attachment points, balancing
device on page 264.
4 Repair
Step
Action
Note/Illustration
6.
Unload the balancing device with the press

tool in order to make the piston rod and front equipment on page 265!
ear adjustable when pulling the shaft out.
Detailed in section Unloading the
7.
Remove the securing screw from the

balancing device shaft.
8.
Apply the puller tool, balancing device shaft

to the shaft through the hole in the frame.
The shaft has a M20 thread diameter, as
Pull the shaft out using the puller tool and the
hydraulic pump.

balancing device on page 263!
xx0300000056
Note! The dimension of the shaft

puller 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 Attachment points,
9.
Restore the balancing device.
10. Secure the two bearing attachments to the

balancing device by replacing the protection
plug on the outside of each attachment, with
securing screws.
The protection plugs must be refitted after
refitting the balancing device, do not loose
them!
Detailed in section Restoring the

points, balancing device on page
264!
Dimensions for the securing screws
are specified in Required equipment
on page 265.
11. Remove the two bearing attachments from

the frame by unscrewing their four attachment balancing device on page 263!
screws.
Make sure the parallel pins inside
are not lost!
12. Fit two guide pins, through the upper holes of Art. no. is specified in Required
the bearing attachments, to the frame.
13. Lift the balancing device gently backwards to
a secure area, allowing the bearing
attachments to slide on the guide pins.
Note! Make sure not to burden the

guide pins with the weight of the
balancing device!
267
4 Repair
Refitting, balancing device

The procedure below details how to refit the balancing device.
Step
Action
Note/Illustration
1.
Danger!
2.
Secure the lower arm to the frame by

inserting the locking screw into the
attachment hole in the frame.

Attachment hole is shown in the
figure Attachment points, balancing
device on page 264.
3.
Secure the bearing attachments to the

balancing device with securing screws.

points, balancing device on page
264!
Dimension of the securing screws is
specified in Required equipment on
page 265.
4.
Refit the two parallel pins in the frame.

5.
Fit two guide pins to the upper holes in the

frame, where the bearing attachments are to
be attached.
6.
Fit the lifting eye to the balancing device.

Attachments are shown in the
figureAttachment points, balancing
device on page 264.
7.
Caution!
The balancing device weighs 210 kg! All
lifting equipment used must be dimensioned
accordingly!
268
8.
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
guide pins.
balancing device!
9.
Remove the guide pins.
4 Repair
Step
Action
Note/Illustration
10. Secure the rear of the balancing device by

fastening the two bearing attachments to the balancing device on page 263!
frame with their four attachment screws.
4 pcs, M16x70, 12.9 quality
UNBRAKO, tightening torque: 300
Nm.
11. Remove the screws from outside of the
bearing attachments and refit the protection
plugs.
12. Raise the balancing device to a position
where the balancing device shaft may be
inserted through the piston shaft front eye.
13. Unload the balancing device with the press
tool.
Detailed in section Unloading the

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.
14. Lubricate the shaft with grease.

15. Apply the shaft press tool to the lubricated

shaft .
Fit the shaft to the piston shaft front eye
through the hole in the frame, using the shaft
press tool and the hydraulic pump .
The hole in the frame is shown in the

figure Attachment points, balancing
device on page 264!
Note! Make sure the shaft is pressed
all the way to the bottom.
16. Refit the securing screw into the shaft using

locking liquid.
M16 x 180, tightening torque: 50 Nm.

Locking liquid is specified in
17. 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 are specified in

Lubrication is further detailed in
section Lubrication, balancing
device bearing on page 179.
18. Restore the balancing device.
Detailed in section Restoring the

269
4 Repair
Step
Action
Note/Illustration
19.
Danger!
The rear cover of the balancing device is a
safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the robot!
20. Remove the locking screw that secures the
lower arm to the frame.
xx0300000483
A: Attachment hole for the securing

screw.
DANGER!
it is vital that:
270
4 Repair
4.5.4. Unloading the balancing device

Prerequisite
This section details how to unload the balancing device with the press tool.
The lower arm must be secured before unloading the balancing device! How to secure the
lower arm is detailed in the current repair activity, e.g removal of the balancing device.
Press tool and hydraulic cylinder
The figure below shows the hydraulic cylinder mounted on the press tool.
The press tool includes two press devices that are used to different models of the balancing
device.
xx0200000174
Press block
Hydraulic cylinder
Press device
Bolt, press device
Moving pin with marking
Bolt (4 pcs)
Pin, attached to the fix plate
271
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Press tool, balancing device
3HAC 020902-001 Includes

press device 3HAC 15767-2
press device 3HAC 18100-1
Choose the correct device, depending
on model of balancing device.
Hydraulic cylinder
3HAC 11731-1
To be used with the press tool.
3HAC 13086-1
To be used with the hydraulic cylinder.
Standard toolkit
3HAC 15571-1

Using the correct press device

The different designs of the balancing device require different versions of the press device,
included in the complete press tool. The table below specifies which press device to use to
which balancing device.
The article number of the balancing device may be found on a label at the rear of the balancing
device.
Balancing device
Press device
Art. no: 3HAC 14678-1 (IRB 6600), 3HAC 16189-1 Art. no: 3HAC 15767-2
(IRB 6650)
Description: balancing device with threaded hole for
lifting lug.
xx0300000600
xx0300000601
Art. no: 3HAC 17117-2 (IRB 6600), 3HAC 17117-3

(IRB 6650)
Description: balancing device with lifting eye.
Art. no: 3HAC 18100-1
xx0300000599
xx0300000602
272
4 Repair
Unloading the balancing device

The procedure below details how to use the press tool in order to unload the balancing device.
How to remove the press tool, is detailed in section Restoring the balancing device on page
275.
Step
Action
Note/Illustration
1.
Fit the moving pin to the current press device. Choose the correct press device,
according to the table Using the
correct press device on page 272.
The moving pin is shown in the
figure Press tool and hydraulic
cylinder on page 271.
2.
Fit the correct press device and moving pin to Shown in the figure Press tool and
the press tool. Secure with the bolt, press
hydraulic cylinder on page 271.
device.
Note! Make sure the bolt is secured properly!
3.
Remove the rear cover of the balancing

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

screws, 4 pcs
4.
Valid for balancing device 3HAC 14678-1 and The article number of the balancing
3HAC 16189-1:
device may be found on a label at
the rear of the balancing device.
Remove the support shaft from the
balancing device.
Remove the o-ring from the balancing
device end.
5.
Valid for balancing device 3HAC 17117-2 and The article number of the balancing
3HAC 17117-3:
device may be found on a label at
Remove the gasket from the balancing the rear of the balancing device.
device end.
6.
Fit the press tool to the rear of the balancing

device with enclosed bolts. Tighten them
properly!

See the figure Press tool and
hydraulic cylinder on page 271!
7.
Fit the hydraulic cylinder to the press tool.

8.
Connect the hydraulic pump to the cylinder.

273
4 Repair
Step
9.
Action
Note/Illustration
Increase the pressure and press until the

marking on the moving pin indicates the
correct position (in level with the pressure
block).

Do not apply more pressure than
necessary, it could damage
bearings and sealings at the shaft.
10. Turn the fix plate to position "Closed" in order See the figure Press tool and
to lock the tool in loaded condition.
11. Unload the hydraulic cylinder.
12. The hydraulic cylinder may now be removed
from the tool, when necessary.
274
4 Repair
4.5.5. Restoring the balancing device

Overview
This section details how to restore the balancing device and how to remove the press tool
from the device.
Press tool and hydraulic cylinder
The figure below shows the hydraulic cylinder mounted on the press tool.
The press tool includes two press devices that are used to different models of the balancing
device.
xx0200000174
Press block
Hydraulic cylinder
Press device
Bolt, press device
Moving pin with marking
Bolt (4 pcs)
Pin, attached to the fix plate
275
4 Repair
Required equipment
The different designs of the balancing device are sealed in different ways beneath the rear
Equipment, etc.
Art. no.
Note
Hydraulic cylinder
3HAC 11731-1
To be used with press tool.
3HAC 13086-1
To be used with hydraulic cylinder.
Locking liquid
Loctite 577
Used to secure the attachment screws
of the rear cover at the end of the
balancing device.
Gasket, end cover
3HAC 17188-1
To balancing device:
3HAC 17117-2 (IRB 6600)
3HAC 17117-3 (IRB 6650)
O-rings
3HAB 3772-44
2 pcs
To balancing device:
3HAC 14678-1 (IRB 6600)
3HAC 16189-1 (IRB 6650)
Standard toolkit
3HAC 15571-1

Restoring the balancing device

The procedure below details how to restore the balancing device, i.e. removing the press tool.
Step
276
Action
Note/Illustration
1.
Refit the hydraulic cylinder to the press tool, Shown in the figure Press tool and
in case it has been removed.
2.
Press with the cylinder and the hydraulic

pump until the fix plate is movable again.
Turn the pin on the fix plate to position
"Open".
Shown in the figure Press tool and

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

bolts.

6.
Valid for balancing device 3HAC 14678-1

and 3HAC 16189-1:
Lubricate and refit the o-ring at the
end of the balancing device.
Refit the support shaft and the
lubricated o-ring.
Make sure the o-rings are seated

properly! Replace them if damaged.
7.
Valid for balancing device 3HAC 17117-2

and 3HAC 17117-3:
Refit the gasket to the rear of the
balancing device.
Replace the gasket if damaged!
4 Repair
Step
8.
Action
Note/Illustration
Refit the rear cover to the balancing device

with its attachment screws, using locking
liquid.
xx0200000175
4 pcs: M10x30, tightening

torque: 50 Nm.
Locking liquid is specified in Required
9.
Danger!
The rear cover of the balancing device is a
safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the robot!
277
4 Repair
4.6.1. Replacement of motor, axis 1
4.6 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
278
Equipment, etc.
Note
Motor axis 1
3HAC 15879-2
Includes
motor
pinion
o-ring 2152 2012430.
O-ring
2152 2012-430
Must be replaced when

reassembling motor!
Grease
3HAB 3537-1
Used to lubricate the o-ring.
4 Repair
Equipment, etc.
Note
Removal tool, motor M12x
3HAC 14631-1
Always use the removal

tools in pairs!
Lifting tool, motor ax 1, 4, 5
3HAC 14459-1
Power supply
24 VDC, max. 1,5 A

Standard toolkit
3HAC 15571-1

the Product manual,

references to these

required.
Circuit Diagram
See chapter Circuit

diagram in the Product
manual, reference
information.
Removal, motor
The procedure below details how to remove motor, axis 1.
Step
Action
Note/Illustration
1.
Danger!
2.
Remove the cover for connector access on top of the

motor by unscrewing its four attachment screws.
3.
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!
4.
Disconnect all connectors beneath the motor cover.
5.
Apply lifting tool, motor axis 1, 4, 5 to the motor.

page 278!
279
4 Repair
Step
Action
Note/Illustration
6.
In order to release the brakes, connect the 24 VDC

power supply.
Connect to connector
R2.MP1
+: pin 2
-: pin 5
7.
Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers.
of motor on page 278!
8.
If required, press the motor out of position by fitting

removal tool, motor to the motor attachment screw
holes.

page 278!
tools in pairs!
9.
Caution!
The motor weighs 25 kg! All lifting equipment used
10. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
11. Remove the motor by gently lifting it straight up.
Refitting, motor
The procedure below details how to refit motor, axis 1.
Step
Action
Note/Illustration
1.
Danger!
2.
Make sure the o-ring on the circumference of the

motor is seated properly. Lightly lubricate the o-ring
with grease.
Art no. is specified in

page 278!
3.
Caution!
The motor weighs 25 kg! All lifting equipment used
4.
280
Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in
page 278!
4 Repair
Step
Action
Note/Illustration
5.
In order to release the brake, connect the 24 VDC

power supply.
R2.MP1
+: pin 2
-: pin 5
6.
Fit the motor, making sure the motor pinion is properly Make sure the motor is
mated to gearbox of axis 1.
turned the right way, i.e.
connections forwards.
Make sure the motor pinion
does not get damaged!
7.
Secure the motor with its four attachment screws and M10 x 40, tightening torque:
plain washers.
50 Nm.
8.
Perform a leak-down test of the axis 1 gearbox.
9.
Disconnect the brake release voltage.
Detailed in section
Performing a leak-down test
on page 196.
10. Reconnect all connectors beneath the motor cover.

11. Refit the cable gland cover at the cable exit with its
two attachment screws.
Make sure the cover is

tightly sealed!
12. Refit the motor cover with its four attachment screws. Make sure the cover is
tightly sealed!
Calibration is detailed in
separate calibration
manuals.
specified in section
Document references in the
information.
DANGER!
it is vital that:
281
4 Repair
4.6.2. Replacement 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.
xx0200000169
282
Motor axis 2
Hole for lock screw
Cable gland cover (located on the lower side of the motor)
Motor attachment holes (4 pcs)
4 Repair
Required equipment
Equipment, etc.
Spare part no.
Art. no.
Note
Motor axis 2 (175/

2.55)
3HAC 15882-2
Includes
motor
pinion
o-ring 2152 2012-430
Motor axis 2
(125/3.2, 175/2.8,
200/2.75, 225/2.55
3HAC 15885-2
Includes
motor
pinion
o-ring 2152 2012-430
O-ring
2152 2012-430

reassembling motor!
Grease
3HAB 3537-1
For lubricating the o-ring.
Locking screw
3HAA 1001-266 M16 x 60

For securing the lower arm.
Removal tool, motor

M12x
3HAC 14631-1
Always use the removal tools

in pairs!
Guide pins M10 x

150
3HAC 15521-2
For guiding the motor.

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

2, 3, 4
3HAC 15534-1
Power supply
24 VDC, 1.5 A
Rotation tool
3HAC 17105-1
Used to rotate the motor

pinion when mating it to the
gear, when brakes are
released with 24VDC power
supply.
Standard toolkit
3HAC 15571-1

information!
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.

required.
Circuit diagram

the Product manual,
283
4 Repair
Removal, motor
The procedure below details how to remove the motor, axis 2.
Step
Action
Note
1.
Danger!
284
2.
Run the manipulator to a position close

enough to its calibration position, to allow the motor on page 282!
lock screw to be inserted into the hole for lock
screw.
3.
Lock the lower arm by inserting the lock screw Art. no. is specified in Required
into the hole.
4.
Drain the oil from gearbox, axis 2.
5.
Remove the cover on top of the motor by

unscrewing its four attachment screws.
6.
Remove the cable gland cover at the cable

exit by unscrewing its two attachment screws. motor on page 282!
damaged!
7.
Disconnect all connectors beneath the motor

cover.
8.
In order to release the brake, connect the 24

VDC power supply.
9.
Remove the motor by unscrewing its four

attachment screws and plain washers.


+: pin 2
-: pin 5
10. Fit the two guide pins in two of the motor

attachment holes.

motor on page 282!
11. If required, press the motor out of position by

fitting the removal tool, motor to the remaining
motor attachment holes.

motor on page 282!
Always use the removal tools in
pairs!
12. Remove the removal tools and fit the lifting

tool, motor axis 2, 3, 4 to the motor.

4 Repair
Step
Action
Note
13.
Caution!
The motor weighs 27 kg! All lifting equipment
14. Lift the motor to get the pinion away from the
gear.
Make sure the motor pinion does

not get damaged!
15. Remove the motor by gently lifting it straight

out and place it on a secure surface.
Refitting, motor
The procedure below details how to refit the motor axis 2.
Step
Action
Note/Illustration
1.
Danger!
2.
Make sure the o-ring on the

circumference of the motor is seated
properly. Lightly lubricate the o-ring with
grease.

3.
In order to release the brake, remove the Connect to connector R2.MP2

cover on top of the motor and connect the
+: pin 2
24 VDC power supply.
-: pin5
4.
Fit the lifting tool, motor axis 2, 3, 4 to the Art. no. is specified in Required
motor.
5.
Fit the two guide pins in the two lower


Shown in the figure Location of motor on
page 282!
6.
Caution!
The motor weighs 27 kg! All lifting
accordingly!
285
4 Repair
Step
Action
Note/Illustration
7.
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.
8.
Remove the lifting tool and allow the motor

to rest on the guide pins.
9.
Use the rotation tool in order to rotate the Art. no. is specified in Required
motor pinion when mating it to the gear
(see figure beside). Fit the motor, making
sure the motor pinion is properly mated to
the gear of gearbox axis 2 and that it
doesnt get damaged.
xx0200000165

A: Rotation tool
10. Remove the guide pins.
11. Secure the motor with four attachment
M10 x 40, tightening torque: 50 Nm.

12. Disconnect the brake release voltage.

13. Reconnect all connectors beneath the
motor cover.
Connect in accordance with markings

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

exit with its two attachment screws.
Shown in the figure Location of motor on

page 282!
15. Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
16. Remove the lock screw from the hole for Shown in the figure Location of motor on
lock screw.
page 282!
286
17. Perform a leak down test.
Detailed in Performing a leak-down test

on page 196.

axis 2 on page 160.

4 Repair
DANGER!
it is vital that:
287
4 Repair

Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure below.
xx0200000186
Motor axis 3
Cable gland cover, motor axis 3
Required equipment
Equipment, etc.
288
Note
Motor axis 3 (175/2.55) 3HAC 15882-2
Includes
motor
pinion
o-ring 2152 2012-430
Motor axis 3
(125/3.2, 175/2.8, 225/
2.55, 200/2.75)
Includes
motor
pinion
o-ring 2152 2012-430
3HAC 15885-2
O-ring
2152 2012-430

reassembling motor!
Grease
3HAB 3537-1
Removal tool, motor

M12x
3HAC 14631-1

in pairs!
4 Repair
Equipment, etc.
Note
Mech stop ax 3
3HAC 12708-1
May be used to fix axis 3.

Use attachment screws 3HAB
3409-86 (M16 x 60).
Washers for mech stop

axis 3
3HAA 1001-186
3HAC 15521-1
3HAC 15521-2
Rotation tool
3HAC 17105-1

released with 24 VDC power
supply.
Power supply
24 VDC, max. 1.5 A

Standard toolkit
3HAC 15571-1

information!
Other tools and

procedures may be
required. See
references to these
procedures in the stepby-step instructions
below.

required.
Circuit Diagram

the Product manual,
289
4 Repair
Removal, motor
Step
Action
Note/Illustration
1.
Danger!
2.
Unload the upper arm of the robot 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.
The upper arm must be positioned as horizontal
as possible!
xx0300000051
Fit the mechanical stop to the third

and final attachment hole (A),
below the fixed stop (B) in the
upper arm. See the figure above!
3.
4.
Remove any equipment hindering access to

motor axis 3.
5.

6.
Remove the cable gland cover at the cable exit Shown in the figure Location of
by unscrewing its two securing screws.
motor on page 288!
damaged!
7.

cover.
8.
Release the brake by connecting the 24 VDC

power supply.
+: pin 2
Make sure the weight of the complete upper arm
-: pin 5
rests safely on the mechanical stops, the fork lift
or the lifting slings before removing the motor.
9.
Unscrew the motors four attachment screws

and plain washers .

attachment screw holes.
290


motor on page 288!
4 Repair
Step
Action
Note/Illustration
11. Press the motor out of position by fitting

removal tool, motor to the remaining motor

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

motor.

13.
Caution!
14. Lift the motor to get the pinion away from the
gear.
15. Remove the motor by gently lifting it straight out Make sure the motor pinion is not
and disconnect the brake release voltage.
damaged!
Refitting, motor
Step
Action
Note/Illustration
1.
Danger!
2.
Make sure the o-ring on the circumference

of the motor is seated properly. Lightly
lubricate it with grease .
Art no. is specified in Required

3.
Fit the lifting tool, motor axis 2, 3, 4 to the

motor.

4.
Fit the two guide pins in the two lower


Shown in the figure Location of motor
on page 288!
5.
Caution!
291
4 Repair
Step
Action
Note/Illustration
6.
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.
7.
Remove the lifting tool and allow the motor

stay on the guide pins.
8.
In order to release the brake, connect the 24 Connect to connector R2.MP3

VDC power supply.
+: pin 2
-: pin 5
9.
Use the rotation tool in order to rotate the

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.

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

motor cover, directly on the motor
shaft as shown in figure above.
A: Rotation tool.
10. Remove the guide pins.
11. Secure the motor with four attachment
4 pcs: M10 x 40, tightening torque: 50

Nm.

13. Reconnect all connectors beneath the motor Connect in accordance with markings
cover.
on connectors.
14. Refit the cable gland cover at the cable exit Make sure the cover is tightly sealed!
on page 288!
15. Refit the cover on top of the motor with its
Make sure the cover is tightly sealed!
16. Remove the equipment used to unload the

upper arm.
292

4 Repair
Step
Action
Note/Illustration
Art. no. for the manuals are specified
in section Document references in the
information.
DANGER!
it is vital that:
293
4 Repair

Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0200000202
Motor, axis 4
Cable gland cover, motor axis 4
Required equipment
Equipment, etc.
294
Note
Motor axis 4 (175/2.55) 3HAC 15887-2
Includes
motor
pinion
o-ring 2152 2012-430.
Motor axis 4
(125/3.2, 175/2.8, 225/
2.55, 200/2.75)
Includes
motor
pinion
o-ring 2152 2012-430.
3HAC 15889-2
O-ring
2152 2012-430

reassembling motor!
Grease
3HAC 3537-1
Used to lubricate the o-ring.
Removal tool, motor

M10x
3HAC 14972-1

in pairs!
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
4 Repair
Equipment, etc.
Note
Rotation tool
3HAC 17105-1

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

Standard toolkit
3HAC 15571-1

information!
Other tools and

procedures may be
required. See
references to these
below.

required.
Circuit Diagram

Removal, motor
Step
Action
Note/Illustration
1.
Danger!
2.
Run the robot to a position where the upper arm is

Draining of oil is described in
pointed straight up.
section Draining, oil on page
168.
This position enables the motor to be replaced
without draining the gear oil, which in turn saves time.
Any other position of the upper arm requires a
draining of oil from the gearbox for axis 4.
3.
Remove the cable gland cover at the cable exit of the Shown in the figure Location
motor by unscrewing its two attachment screws.
damaged!
4.
Remove the cover on top of the motor by unscrewing

its four attachment screws.
5.
Disconnect all connectors beneath the motor cover.
295
4 Repair
Step
Action
Note/Illustration
6.
In order to release the brake, connect the 24 VDC

power supply.
R2.MP4
+: pin 2
-: pin 5
7.
Unscrew the motors four attachment screws and

plain washers.

8.
Fit the two guide pins, M8 in two of the motor

9.

removal tool, motor M10 to the motor attachment
screw holes.

page 294!
tools in pairs!
10. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
11. Remove the motor by gently lifting it straight out.
Make sure the motor pinion

is not damaged!
Refitting, motor
Step
Action
Note/Illustration
1.
Danger!
296
2.
Make sure the o-ring on the

circumference of the motor is seated
properly. Lightly lubricate the o-ring with
grease.

3.
In order to release the brakes, connect the Connect to connector R2.MP4:

24 VDC power supply.
+: pin 2
-: pin 5
4.
Fit the two guide pins, M8 in two of the


on page 294!
5.
Fit the motor, with guidance of the pins,

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

get damaged!
4 Repair
Step
6.
Action
Note/Illustration
Use the rotation tool in order to rotate the

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.
7.
8.
Secure the motor with four attachment

9.

Nm.
10. Reconnect all connectors beneath the

motor cover.
11. Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
12. Refit the cable gland cover at the cable
exit with its two attachment screws.

on page 294!
13. Perform a leak-down test if gearbox has

been drained.
14. Refill the gearbox with oil if drained.
Detailed in section Filling, oil on page

169.

297
4 Repair
DANGER!
it is vital that:
298
4 Repair

Reused pinion
The pinion in the motor, axis 5, is matched with the beveral gear for axis 5. When the motor
is replaced the pinion must therefor be removed from the dismounted motor and fitted onto
the new motor shaft as detailed in this section.
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.
Spare part
no.
Art. no.
Note
Motor axis 5 (175/2.55) 3HAC 17484-7
Does not include pinion. Use

the pinion from the motor to be
replaced.
Includes o-ring 2152 2012-430.
Motor axis 5
(125/3.2, 200/2.75,
175/2.8, 225/2.55)
Does not include pinion. Use

the pinion from the motor to be
replaced.
Includes o-ring 2152 2012-430.
3HAC 17484-10
299
4 Repair
Equipment, etc.
300
Spare part
no.
Art. no.
Note
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 2012-430

reassembling motor!
Grease
3HAC 3537-1
Isopropanol
1177 1012-208
For cleaning motor pinion and

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

and pinion hole.
Removal tool, motor

M10x
3HAC 14972-1

pairs!
Oil injector / max 500

MPa
3HAC 021590001
For pressing out the pinion,

motor 5.
Motor press pinion
3HAC 021883001
For pressing the pinion on to

the new motor.
Measuring tool
6896 134-GN
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Power supply
24 VDC, 1.5 A
Standard toolkit
3HAC 15571-1

information!
Other tools and

procedures may be
required. See
references to these
below.

Circuit Diagram

information.
4 Repair
Removal, motor
Step
Action
Note/Illustration
1.
Danger!
2.

3.
Remove the wrist unit.
Detailed in section Removal, wrist

unit on page 226.
4.
Place the wrist unit safely on a workbench, in

a fixture or similar.
5.

6.
Remove the cable gland cover at the cable

exit by unscrewing its two attachment screws.
7.

cover and remove the separate cable of the
axis 5 motor.
8.
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
9.



11. If required, press the motor out of position by Art. no. is specified in Required
fitting removal tool, motor, M10 to the motor equipment on page 299!
Always use the removal tools in pairs
and diagonally!
12. Lift the motor to get the pinion away from the Make sure the motor pinion is not
gear and disconnect the brake release
damaged!
voltage.
13. Remove the motor by gently lifting it straight
out.
Keep track of the shims between the

motor flange and the wrist housing.
14. Measure the distance between the motor

flange, included eventual shims, and the
outer surface of the pinion, with measuring
tool.

Make a note of the distance.
301
4 Repair
Step
Action
15. Press out the pinion from the dismounted

motor, with the equipment included in the oil
injector kit.
Note! If the pinion is damaged the complete
wrist unit must be replaced!
Note/Illustration
Replacing the complete wrist unit is
detailed in section Replacement of
complete wrist unit on page 225. Art.
no. is specified in Required
Refitting, motor
Step
Action
Note/Illustration
1.
Danger!
302
2.
Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 299!
the o-ring with grease.
3.
Clean the motor pinion and the motor pinion

hole in the motor, with isopropanol.
Note!If the pinion is damaged the complete
wrist unit must be replaced!
4.
Apply a thin film of mineral oil to the pinion Art. no. is specified in Required
shaft and the pinion hole in order to make the equipment on page 299!
pinion run smoothly and to achieve an even
friction torque when assembling the pinion.
5.
Place the motor and pinion in the press

fixture.

6.
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!
7.
Measure the distance between the motor

flange and the outer surface of the pinion with equipment on page 299.
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).

Replacing the complete wrist unit is
detailed in section Replacement of
complete wrist unit on page 225.
4 Repair
Step
Action
Note/Illustration
8.

VDC power supply.
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
- : pin D
9.
Fit the two guide pins in two of the motor

attachment holes.

10. Fit the motor, with guidance from the pins,

mated to the gear of axis 5.

get damaged!
11. Secure the motor with four attachment screws 4 pcs: M8 x 25; tightening torque: 24
and plain washers.
Nm.
13. Refit the separate cable of the axis 5 motor
and reconnect all connectors beneath the
motor cover.
14. Refit the cable gland cover at the cable exit
15. Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!

17. Refit the wrist unit.
Detailed in section Refitting, wrist

unit on page 228.
18. Refill the gear with oil.


DANGER!
it is vital that:
303
4 Repair

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0200000222
304
Wrist unit
Motor, axis 6
4 Repair
Required equipment
Equipment, etc.
Note
Motor axis 6 (175/2.55) 3HAC 15990-4
Includes
motor
pinion
o-ring 2152 2012-430
Motor axis 6
(125/3.2, 200/2.75,
175/2.8, 225/2.55)
Includes
motor
pinion
o-ring 2152 2012-430
3HAC 15991-4
O-ring
2152 2012-430

reassembling motor!
Removal tool, motor

M10x
3HAC 14972-1

in pairs!
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Power supply
24 VDC, 1.5 A
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1

information!
Other tools and

procedures may be
required. See
references to these
below.

required.
Circuit Diagram

information.
305
4 Repair
Removal, motor
Step
Action
Note/Illustration
1.
Danger!
2.
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.
3.
Remove the rear motor cover by unscrewing the

six attachment screws.
4.
Disconnect all connectors beneath the cover.
5.
In order to release the brake, connect the 24 VDC Connect to connector R3.MP6
power supply.
+: pin 2
-: pin 5
6.

7.

removal tool, motor to the motor attachment
screw holes.
8.
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!
9.
Remove the motor by gently lifting it straight out.

pairs!
Refitting, motor
Step
Action
Note/Illustration
1.
Danger!
2.
306
Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 305!
the o-ring with grease.
4 Repair
Step
Action
Note/Illustration
3.

VDC power supply.

+: pin 2
-: pin 5
4.
Fit the two guide pins in two of the motor

attachment holes.

5.
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!
6.
7.
Secure the motor with its four attachment

8.
9.
Reconnect all connectors beneath the motor

cover.

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


DANGER!
it is vital that:
307
4 Repair
4.7.1. Replacement of gearbox, axis 1
4.7 Gearboxes
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
xx0300000015
308
Gearbox, axis 1
Frame
Base
Attachment screws, gearbox axis 1 (not shown in figure)
4 Repair
Required equipment
Equipment, etc.
Note
Gearbox axis 1
3HAC 10828-8
Includes:
gearbox
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
3HAC 15535-1
Lifting device, base
3HAC 15560-1
3HAC 15556-1
Standard toolkit
3HAC 15571-1
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.

information!
309
4 Repair
Removal, gearbox axis 1

The procedure below details how to remove gearbox, axis 1.
Step
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
2.
Move the robot to its most stable

position, shown in the figure to the
right.
xx0300000022
3.
Drain the oil from gearbox 1.
4.
Disconnect all cabling in the rear of

the manipulator base and remove the
cable support plate inside of the base.
5.
Pull the disconnected cabling up

through the center of gearbox 1.
6.
Remove the complete arm system.
7.
Remove the manipulators attachment

screws to unfasten the base from the
foundation.
8.
Attach the lifting device, base and

gear 1 and the lifting tool (chain) , to
the gearbox.
Detailed in section Removal, arm system on

page 217.

on page 309!
9.
Caution!
The base (without gearbox 1) weighs
263 kg! All lifting equipment used must
be dimensioned accordingly!
310
4 Repair
Step
Action
10. Lift the manipulator base to allow

fitting the support, base and gear 1
on each sides of the base.
Note/Illustration
on page 309!
11. Fit the support, base.

Make sure the base remains in a
stable position before performing any
work underneath the base!
12. Remove the bottom plate from
underneath the base in order to get
access to the attachment screws. It
may be necessary to also remove the
rear connector plate.
xx0300000612
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
13. Unscrew the 18 attachment screws

and remove the 3 washers, shown in
the figure to the right.
xx0200000227
A view from below:

A: Oil drain hose
B: Attachment screws, gearbox axis
1, 18 pcs
C: Washers, 3 pcs
311
4 Repair
Step
Action
Note/Illustration
14. Remove the cable guide in the center

of gearbox 1 by unscrewing its
attachment screws.
xx0200000256
A: Location for attachment screws,

cable guide (cable guide removed in
the figure)
15.
Caution!
The gearbox weighs 160 kg! All lifting
accordingly!
16. Lift the gearbox away with the already
mounted lifting tools.
Refitting, gearbox axis 1

The procedure below details how to refit gearbox, axis 1.
Step
Action
Note/Illustration
1.
Danger!
2.
312
If the base is not supported with support, Mounting of the support, base and gear
base and gear 1, this should be done first. 1 is detailed in section Removal,
4 Repair
Step
3.
Action
Note/Illustration
Make sure the two o-rings (C, D) on the

circumference of the gearbox are seated
properly in their grooves respectively.
Lubricate them with grease .
Make sure the small o-ring around the oil
hole is fitted properly!

xx0200000055
4.
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
5.
A: Location for attachment

screws, cable guide (cable guide
removed in figure)
Fit the lifting device, base and the lifting Art no. is specified in Required
tool (chain) to the gearbox.
6.
Caution!
The gearbox weighs 160 kg! All lifting
accordingly!
7.
Lift the gearbox to its mounting position in

the center of the base.
313
4 Repair
Step
Action
Note/Illustration
8.
Make sure the guide pin in the bottom face Shown in the figure xx0200000055
of the gearbox is properly aligned with the above!
base.
9.
Secure the gearbox and the three washers 18 pcs, M16 x 70, 12.9 quality
with the 18 attachment screws, gearbox UNBRAKO, tightening torque: 300 Nm.
axis 1 .
xx0200000227
A view from below:

A: Oil drain hose
B: Attachment screws, gearbox
axis 1, 18 pcs
C: Washers, 3 pcs
10. Refit the bottom plate underneath the
manipulator base by pushing it into the
groove and fitting the attachment screw.
Note!Direct the bends on the plate
downwards!
If removed, also refit the rear connector
plate.
1 screw: M6 x 8.
xx0300000612
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
11.
Caution!
The base (without gearbox 1) weighs 263
kg! All lifting equipment used must be
314
4 Repair
Step
Action
Note/Illustration
12. Lift the manipulator base and gearbox 1 to

allow removing the support, base and
gear.
13. Secure the base to the mounting site.
Detailed in section Orienting and

securing the robot on page 74.
14. Refit the complete arm system.
Detailed in section Refitting, arm

system on page 218.
This is a complex task to be performed
with utmost care in order to avoid injury
or damage!
15. Refit the cable support plate inside of the

base and reconnect the cabling in the rear
of the manipulator base.

axis 1 on page 156.

DANGER!
it is vital that:
315
4 Repair
4.7.2. Replacement of gearbox axis 2

Different designs, cover axis 2
Between the axis 2 motor and gearbox there is a cover, that includes the motor attachment.
This cover exists in following designs:
Design 1: attached directly to the gearbox, with the front attachment screws of the
gearbox.
Design 2: attached directly to the frame. This design also includes an additional cover
that overlaps the motor attachment and is equipped with oil plugs.
Design 3: attached directly to the frame.
The service work differ some between the designs. Be aware of the differences made in the
instruction.
Location of gearbox
The gearbox for axis 2 is located in the lower arm rotational center, underneath the cover.
The figure below shows design 2 of the cover.
xx0200000171
316
Gearbox axis 2 (behind cover, not shown in figure )
Attachment hole for locking screw, lower arm
Attachment holes inside of frame for fixture, lower arm
4 Repair
Attachment holes for fixture, lower arm
Balancing device
Motor axis 2
Rear attachment screws, gearbox
Attachment screws, cover
Additional cover
Cover, axis 2
Required equipment
Equipment
Spare part no.
Gearbox axis 2
3HAC 021127-001
Art. no.
Note
Includes
gearbox
o-ring.
Does not include "Sealing,
axis 2/3"!
O-ring
3HAB 3772-68
O-ring in gearbox, 1pc.
O-ring
3HAB 3772-68
3HAB 3772-70
O-rings in the additional

cover (design 2). Should
be replaced if damaged!
O-ring
3HAB 3772-69
O-ring in the cover, axis 2,

1 pc. Should be replaced if
damaged!
Sealing, axis 2/3
3HAC 17212-1
A new sealing must be

used on each assembly!
Grease
3HAB 3537-1
For lubricating o-rings.
Fixture lower arm
3HAC 020584-001
Lifting tool, gearbox

axis 2
3HAC 13698-1
Guide pins M12 x

150
3HAC 13056-2
For guiding the gearbox.
Guide pins M12 x

200
3HAC 13056-3

device
3HAC 020902-001
Hydraulic cylinder
3HAC 11731-1

tool and the hydraulic
pump, when unloading the
balancing device.
Hydraulic pump, 80
MPa
3HAC 13086-1

tool and the hydraulic
cylinder, when unloading
the balancing device.
Guide pins, sealing

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

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

correct position.
317
4 Repair
Equipment
Spare part no.
Standard toolkit
Art. no.
Note
3HAC 15571-1

the Product manual,
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.

required.
Removal, gearbox
The procedure below details how to remove the gearbox, axis 2.
Step
Action
Note/Illustration
1.
Danger!
318
2.
Secure the lower arm with the special fixture

equipment according to section Securing the lower
arm on page 251.
3.
Unload the balancing device shaft by using the press Art. no. is specified in
tool, balancing device, according to section
Unloading the balancing device on page 271!
page 317!
4.
Drain the gearbox, axis 2.
Notice! Time-consuming
activity!
Detailed in section Oil
change, gearbox axis 2 on
page 160.
5.
Detailed in section Removal,

motor on page 284.
6.
Remove the rear attachment screws, gearbox from

inside of the lower arm.

of gearbox on page 316!
7.
Remove the cover, axis 2 by unscrewing the

design 1: 24 front attachment screws,
gearbox, shown in the figure below.
design 2: 15 attachment screws, cover.
design 3: 14 attachment screws, cover.
Read more about the

variations in design in
section Different designs,
cover axis 2 on page 316.
4 Repair
Step
8.
Action
Note/Illustration
If the robot is equipped with the design 2 or 3 of the

cover; now remove the 24 front gearbox attachment
screws, shown in the figure to the right.
xx0200000172
9.
A: Front attachment
screws, gearbox (24
pcs)
B: M12 holes for
pressing the gearbox
out
Fit two guide pins in 180 relation to each other in the Art. no. is specified in
empty holes of the front gearbox attachment screws. Required equipment on
page 317!
10. If required, apply two M12 screws to the holes, shown

in the figure above, to press it free.
11. Fit the lifting tool, gearbox axis 2 to the gearbox.

page 317!
12.
Caution!
The gearbox weighs 53 kg! All lifting equipment used
13. Remove the gearbox axis 2 using an overhead crane
or similar, with guidance from the mounted guide
pins.
14. Remove the friction washer and clean it.
15. Remove the sealing from the lower arm.
319
4 Repair
Refitting, gearbox
The procedure below details how to refit the gearbox axis 2.
Step
Action
Note/Illustration
1.
Danger!
2.
Make sure the both o-rings are fitted to the gearbox

as shown in the figure to the right. Lightly lubricate
them with grease.

page 317!
xx0200000173
3.
320
Fit the lifting tool, gearbox axis 2 to the gearbox.
A: O-ring, gearbox
axis 2

page 317!
4 Repair
Step
4.
Action
Note/Illustration
Fit the guide pins, sealing axis 2/3 to the rear of the
gearbox, axis 2.
Use the attachment holes shown in the figure to the
right!
xx0300000553
A: Rear attachment
screws, gearbox (33
pcs)
B: Holes for the guide
pins, sealing axis 2/3
on the gearbox
5.
Fit the new sealing, axis 2/3 on to the guide pins on Art. no. is specified in
the gearbox.
page 317!
Note! Do not remove the guide pins for the sealing
until the rear attachment screws are secured.
6.
Fit two guide pins, M12 in 180 relation to each other Art. no. is specified in
in the frame, in the screw holes for the gearboxes
front attachment screws.
page 317!
7.
Fit the cleaned friction washer onto the guide pins,

M12.
8.
Caution!
9.
Lift the gearbox to its mounting position and slide it

onto the guiding pins attached in the frame, through
the front attachment screw holes.
10. Align the gearbox attachment screw holes to the hole Art. no. is specified in
patterns in the lower arm, with help from the guide
pins, sealing axis 2/3.
page 317!
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!
321
4 Repair
Step
Action
Note/Illustration
11. 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.
12. Remove the lifting tool from the gearbox.
13. Design 1 of the cover, axis 2:
Lift the cover and slide it on to the guide pins.
If necessary, use a plastic mallet to knock the
cover into place.
Insert and secure 22 of the 24 front
attachment screws, gearbox.
Remove the guide pins, M12 and refit the two
remaining screws.
Choose correct instruction

depending on which cover
the robot is equipped with.
Read more about the
variations in Different
designs, cover axis 2 on
page 316.
Shown in the figure
xx0200000166 above!
14. Design 2 and 3 of the cover, axis 2:

Insert and secure 22 of the 24 front
attachment screws, gearbox.
Remove the guide pins, M12 and refit the two
remaining screws.
Lubricate the o-ring at the sealing surface of
the cover. Replace it if damaged.
Refit the cover by pressing it against the frame
and refitting the attachment screws, cover.
Front attachment screws,

gearbox: 24 pcs: M12 x 60,
page 317!
Attachment screws, cover:
15 pcs: M8 x 25, tightening
torque: 24 Nm.
of gearbox on page 316.
15. Insert and secure 31 of the 33 rear attachment

screws, gearbox on the inside of the lower arm.

33 pcs: M12 x 50, 12.9
quality UNBRAKO,
Reused screws may be
used, providing they are
lubricated as detailed in
section Screw joints in the
16. Remove the guide pins, sealing axis 2/3, and tighten
the two remaining screws as detailed above.
17. Refit the motor.

motor on page 285.
Detailed in section
Performing a leak-down test
on page 196.
Detailed in section Oil

change, gearbox axis 2 on
page 160.
20. Restore the balancing device.
Detailed in section Restoring

the balancing device on
page 275!
21. Remove the fixture, lower arm.
322
4 Repair
Step
Action
Note/Illustration
22. Remove the locking screw, lower arm, and re-attach

it to the fixture tool.
23. Refit any mechanical stops if such were removed
during disassembly.
24. Refit any equipment to the turning disk if such was
removed during disassambly.
manuals.
information.
DANGER!
it is vital that:
323
4 Repair

Location of gearbox
xx0200000194
324
Gearbox, axis 3
Motor, axis 3
Upper arm
Attachment screws, gearbox (24 pcs)
4 Repair
Required equipment
Equipment, etc.
Spare part no.
Gearbox axis 3
3HAC 021127-001
Art. no.
Note
Includes
gearbox
o-ring.
Does not include the sealing,
axis 2/3!
O-ring
3HAB 3772-68
1 pc on the gearbox.
Grease
3HAB 3537-1
For lubricating the o-rings.
Sealing, axis 2/3
3HAC 17212-1
A new sealing must be used

on each assembly!
Mech stop ax 3
3HAC 12708-1
Used to secure the upper

arm. Use attachment screws
3HAB 3409-86 (M16 x 60).
Washers for mech

stop axis 3
3HAA 1001-186
Lifting eye M12
3HAC 14457-3
3HAC 13056-3

Use guides in pairs!
3HAC 13056-4

Guide pins, sealing

ax 2/3, 80mm
3HAC 14628-1
For guiding the sealing, axis

2/3.
Guide pins, sealing

ax 2/3, 100mm
3HAC 14628-2
For guiding the sealing, axis

2/3.
Standard toolkit
3HAC 15571-1

information!
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.

required.
325
4 Repair
Removal, gearbox
Step
Action
Note/Illustration
1.
Danger!
2.
Secure the upper arm in a horizontal position Art. no. is specified in Required
using a mechanical stop.
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.
xx0300000051
326
3.
Detailed in section Removal, motor

on page 290.
Note! When removing the motor
axis 3, the brake on axis 3 is
released. Make sure the upper arm
is secured and disabled to move!
4.
Remove the upper arm.
Detailed in sectionRemoval, upper

arm on page 233.
5.
Remove the sealing, axis 2/3 between

gearbox and lower arm.
On reassembly a new sealing must

be used!
6.
Place the upper arm safely on a workbench, in

a fixture or similar.
7.
Remove the attachment screws, gearbox.
8.
Fit the two guide pins, M12 in 180 relation to Art. no. is specified in Required
each other in the gearbox attachment screw
holes.

4 Repair
Step
9.
Action
Note/Illustration
Fit the lifting eye, M12 to the gearbox, in one Art. no. is specified in Required
of the attachment screw holes that attaches the equipment on page 325!
gearbox to the lower arm (position C in the
figure to the right).
xx0200000201
A: M12 holes for pressing

the gearbox out
B: Attachment screw holes,
gearbox - upper arm
C: Attachment screw holes,
gearbox - lower arm
10. If required, apply M12 screws to the holes (A)

shown in the figure above to press the gearbox
free.
11.
Caution!
The gearbox weighs 60 kg! All lifting equipment
12. Remove the gearbox, with guidance from the
guide pins, using an overhead crane or similar.
327
4 Repair
Refitting, gearbox
Step
Action
Note/Illustration
1.
Danger!
2.
Turn the upper arm in such a position that the gear

mating surface faces upwards.
3.
Fit two guide pins in 180 relation to each other in the Art. no. is specified in
holes in the upper arm, used for the gearbox
attachment screws.
page 325!
4.
Caution!
5.
Fit the lifting eye, M12 to the gearbox.

page 325!
6.
Make sure the o-rings are fitted to the gearbox.

Apply grease to the o-rings to make sure they stick Required equipment on
in their grooves during assembly.
page 325!
Replace them if damaged!
xx0200000173
328
A: O-rings, gearbox
axis 3
4 Repair
Step
Action
7.
Lift the gearbox to its mounting position.
8.
Turn the gearbox to align the attachment screw holes

with those in the upper arm.
9.
Fit the gearbox onto the guide pins and slide it into
position.
Note/Illustration
Make sure the o-rings are

seated properly and the
gearbox correctly oriented!
10. Remove the lifting tool.

11. 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.

Reused screws may be
used, providing they are
lubricated as detailed in
section Screw joints in the
12. Refit the upper arm with a new sealing, axis 2/3 .

page 325!
13. Refit the motor.

motor on page 291.
14. Remove the mechanical stop used to secure the

upper arm.
manuals.
information.
DANGER!
it is vital that:
329
4 Repair

Location of gearbox
The different robot versions result in two different designs of the gearbox.
xx0300000555
330
Gearbox, axis 6
Attachment screws and washers, gearbox for robot version IRB 6600 - 175/2.55
(8 pcs)
4 Repair
xx0200000219
Gearbox, axis 6
Attachment screws and washers, gearbox for robot version IRB 6600 225/2.55
and 175/2.8, IRB 6650 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.
Spare part no.
Art. no.
Note
Gearbox axis 6
(175/2.55)
3HAC 10828-10
Includes o-ring 3HAB 3772-58.
Gearbox axis 6
(125/3.2, 200/2.75,
175/2.8, 225/2.55)
3HAC 10828-13
Includes o-ring 3HAB 3772-57.
Washers
3HAA 1001-172 Not included in gearbox!

O-ring
3HAB 3772-58
/3HAB 3772-57

reassembling gearbox!
Grease
3HAB 3537-1
For lubricating o-ring.
331
4 Repair
Equipment, etc.
Spare part no.
Standard toolkit
Art. no.
Note
3HAC 15571-1

information!
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.

Removal, gearbox
Step
Action
Note/Illustration
1.
Danger!
332
2.
Drain the oil from gearbox, axis 6.

axis 6 on page 173.
3.
Remove the turning disk.
Detailed in section Removal, turning

disk on page 222.
4.
Remove the gearbox by unscrewing its 8

or 18 attachment screws (amount
depends on robot version).
Shown in the figure Location of gearbox

on page 330!
4 Repair
Step
5.
Action
Note/Illustration
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)
xx0200000220
6.
A: M8 holes for pressing the

gearbox out
Remove the gearbox axis 6 by lifting it out Be careful not to damage the motor
carefully.
pinion!
Refitting, gearbox
Step
Action
Note/Illustration
1.
Danger!
333
4 Repair
Step
2.
Action
Note/Illustration
Make sure the o-ring is fitted to the rear of Art. no. is specified in Required
the gearbox. Lubricate the o-ring with
grease.
xx0100000132
334
A: O-ring, gearbox axis 6
3.
Insert the gearbox, axis 6 into the wrist

unit.

Make sure the gears of the gearbox
mate with those of the motor!
4.
Secure the gearbox with the attachment

screws and washers.
Shown in figure above!

8 pcs or 18 pcs (depending on robot
version): M8 x 40, 12.9 quality
they are lubricated as detailed in
section Screw joints in the Product
manual, reference information before
fitting.
5.
Refit the turning disk.
Detailed in section Refitting, turning

disk on page 223.
6.
Perform a leak-down test.
7.
Refill the gearbox with oil.

axis 6 on page 173.
8.
Recalibrate the robot.

4 Repair
DANGER!
it is vital that:
335
4 Repair
336
5.1. Introduction
5.1. Introduction
General
This chapter includes general information about different calibration methods and details also
procedures that does not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 338, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.
Contents of the revolution counter memory are lost
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 342. This will occur when:
the battery is discharged
a resolver error occurs
the signal between a resolver and measurement board is interrupted
a robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are connected at
the first installation.
The robot is rebuilt
If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
References
The article numbers for the Calibration manuals are listed in section Document references in
the Product manual (part 2 of 2), reference information. Article numbers for the calibration
tools are also listed in part 2 of the Product manual.
337
5.2. Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
Types of calibration
Type of
calibration
Description
Calibration method
Standard
calibration
The calibrated robot is positioned at home

position, i.e. the axes positions (angles) are
set to 0.
Standard calibration data is found in the file
calib.cfg, supplied with the robot at delivery.
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Calibration Pendulum
(standard method)
or
Levelmeter calibration
(alternative method)
Absolute Accuracy
calibration
(optional)
Based on standard calibration, but besides

CalibWare
positioning the robot at home position, the
Absolute Accuracy calibration also
compensates for:
mechanical tolerances in the robot
structure
deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
motor positions as well as absacccompensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy
performance, the robot must be recalibrated
for Absolute Accuracy!
xx0400001197
338
Calibration methods
Each calibration method is detailed in separate manuals. Below is a brief description of the
methods available.
Calibration Pendulum - standard method
Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the manual Calibration Pendulum Instruction.
Levelmeter Calibration - alternative method
Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots,
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but has not as good mechanical tolerances to the toolkit
parts as the standard method with Calibration Pendulum.
This method may, after calibration, require modifications in the robot program, and is
therefore not recommended.
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter
2000.
CalibWare - Absolute Accuracy calibration
In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the manual xx.
If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.
339
5.3. Calibration scales and correct axis position
5.3. Calibration scales and correct axis position

Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
Calibration scales/marks, IRB 6600, IRB 6650, IRB 6650S,IRB 7600
The illustration below shows the location of the calibration scales on specific plates and the
calibration marks directly in the casting at axes 2 and 3.
xx0200000176
A1
Calibration scale, axis 1 (early design)
A2
Calibration scale, axis 1 (later design)
B1
B2
Calibration mark, axis 2 (later design)
C1
C2
Calibration mark, axis 3 (later design)
Calibration scale, axis 4
Calibration marks at axes 2 and 3

The calibration marks at axes 2 and 3, shown in the figure above, consist of two single marks
that should be positioned opposite to one another when the robot is standing in its calibration
position. One of the marks is more narrow than the other and should be positioned within the
limits of the wider mark.
340
5.4. Calibration movement directions for all axes
5.4. Calibration movement directions for all axes

Calibration movement directions
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
Note! The figure shows an IRB 7600, but the positive direction is the same for all robots,
except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!
xx0200000089
341
5.5. Updating revolution counters

General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using either the TPU or the FlexPendant.
Manually running the robot to the calibration position
This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.
Step
Action
Note
1.
Select axis-by-axis motion mode.
2.
Jog the robot so that the calibration marks lie Shown in section Calibration scales
within the tolerance zone.
and correct axis position on page 340
in either of the manuals: Instructions
for Levelmeter Calibration or
Calibration Pendulum Instruction,
depending on which calibration
method to be used.
3.
When all axes are positioned, store the

revolution counter settings.
Detailed in sections:
Storing the revolution counter setting
with the TPU on page 343
(RobotWare 4.0).
Storing the revolution counter setting
with the FlexPendant on page 344
(RobotWare 5.0).
Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have
any mechanical stops and can therefore be calibrated at the wrong turn.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the exact calibration position will be lost due to
uneven gear ratio. This affects the following robots:
342
Robot variant
Axis 4
Axis 6
IRB6600 / 175kg_2,55 m
Yes
No
IRB6600 / others
Yes
Yes
Storing the revolution counter setting with the TPU

This section details the second step when updating the revolution counter; storing the
revolution counter setting with the TPU (RobotWare 4.0).
Step
1.
Action
Note
Press the button "Miscellaneous" then ENTER to select the

service window.
xx0100000194
2.
Select Calibration from the View menu.

The Calibration window appears.
If there is more than one unit connected to the robot, they will
be listed in the window.
xx0100000201
3.
Select the desired unit and choose Rev Counter Update

from the Calib menu.
The Revolution Counter Update window appears.
xx0100000202
4.
Select the desired axis and press Incl to include it (it will
be marked with an x) or press All to select all axes.
5.
Press OK when all axes that are to be updated are marked

with an x.
CANCEL returns to the Calibration window.
343
Step
Action
Note
6.
Press OK again to confirm and start the update.

CANCEL returns to the Revolution Counter Update window.
7.
At this point, it is recommended that the revolution counter

values are saved to a diskette.
Not required.
8.
Caution!
If a revolution counter is incorrectly updated, it will cause
incorrect robot positioning, which in turn may cause damage or
injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the
calibration position on page 346.
Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).
Step
Action
1.
On the ABB menu, tap Calibration.

All mechanical units connected to the system are shown along with their calibration
status.
2.
Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.
en0400000771
344
Step
Action
3.
Tap Update revolution counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
Tap Yes to update the revolution counters.
Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4.
Select the axis to have its revolution counter updated by:

Ticking in the box to the left
Tapping Select all to update all axes.
Then tap Update.
5.
A dialog box is displayed, warning that the updating operation cannot be undone:
Tap Update to proceed with updating the revolution counters.
Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from
the list of axes.
6.
Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 346.
345
5.6. Checking the calibration position

General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
Using a MoveAbsJ instruction with argument zero on all axes
Using the Jogging window on the teach pendant
Using a MoveAbsJ instruction on the TPU, S4Cplus

This section describes how to create a program, which runs all the robot axes to their zero
position
Step
Action
1.
Crate a new program
2.
Use MoveAbsJ
3.
Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs
, v1000, z50, Tool0
4.
Run the program in manual mode
5.
Check that the calibration marks for the axes align

correctly. If they do not, update the revolution
counters!
Note
The calibration marks are

shown in section Calibration
scales and correct axis
position on page 340.
How to update the revolution
counters is detailed in section
Updating revolution counters
on page 342
Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero
position.
Step
346
Action
1.
On ABB menu tap Program Editor.
2.
Create a new program.
3.
Use MoveAbsJ in the Motion&Proc menu.
4.
Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff
s, v1000, z50, Tool0
5.
Run the program in manual mode.
6.

counters!
Note

How to update the revolution
counters is detailed in section
on page 342.
Using the Jogging window on the TPU, S4Cplus

This section describes how to jog the robot to all axes zero position.
Step
Action
Illustration/information
1.
Open the Jogging window.
2.
Choose running axes-by-axes.
3.
Manually run the robot axes to a position where the

axis position value read on the TPU, is equal to
zero.
4.
Check that the calibration marks for the axes align The calibration marks are
counters!
Detailed in section Updating
revolution counters on page
342.
xx0100000195
xx0100000196
Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.
Step
Action
1.
Tap Jogging in the ABB menu.
2.
Tap Motion mode to choose group of axes to jog.
3.
Tap axes 1-3 to jog axes 1, 2 or 3.
4.
Manually run the robots axes to a position where the

axis position value read on the FlexPendant, is equal
to zero.
5.

counters!
Note

How to update the counters
is detailed in section
on page 342.
347
348
6 Decommissioning
6 Decommissioning
349
6 Decommissioning
6.1. Environmental information
6.1. Environmental information

Hazardous material
The table specifies some of the materials in the manipulator and their respective use
throughout the product.
Dispose the components properly to prevent health or environmental hazards.
Material
Example application
Batteries, NiCad or Lithium
Serial measurement board
Copper
Cables, motors
Cast iron / nodular iron
Base, lower arm, upper arm
Steel
Gears, screws, base-frame etc.
Neodymium
Brakes, motors
Plastic / rubber (PVC)
Cables, connectors, drive belts etc.
Oil, grease
Gearboxes
Aluminium
Covers, sync. brackets
Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorized
person/contractor in accordance with local regulations. Do no dispose of oil and grease near
lakes, ponds, ditches, down drains, or on to soil. Incineration must be carried out under
controlled conditions in accordance with local regulations.
Also note that:
350
Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
Spillage may penetrate the soil causing ground water contamination.
6 Decommissioning
6.2. Decommissioning of balancing device

General
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Cutting torch
For opening housing and cutting coils


DANGER!
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!
Procedure
The instruction below details how to cut open the balancing device housing and removing the
tension in the coil springs before opening the device.
Contact ABB Robotics for further consultation.
Step
Action
Info/Illustration
1.
Remove the balancing device from

the manipulator.
Detailed in section Removal, balancing

device on page 266.
2.
Place it on a workbench or similar.

Make sure it is clamped in position
with a vice or similar.
351
6 Decommissioning
Step
3.
Action
Info/Illustration
Open a hole in the side of the

housing as shown in the figure.
Use a cutting torch.
xx0400000700
352
4.
Cut the coils of the three springs

Use a cutting torch.
inside the housing as specified
below:
Outer spring: cut at least five
(5) coils!
Middle spring: cut at least
four (4) coils!
Inner spring: cut at least four
(4) coils!
5.
After double-checking the number of

coils cut and making sure all the
tension in the springs is removed,
remove the end cover of the
balancing device.
6.
Dismantle the balancing device and

sort its parts for the recycling plant.
Index
C
cabling, position switch 105
cabling, robot 104
cabling, robot axes 1-4 201
cabling, robot axes 5-6 210
calibration position 342
calibration position, checking 346
calibration position, jog to 347
Connection of external safety devices 17
D
direction of axes 341
G
gearbox oil 152
L
Limitation of Liability 18
N
negative directions, axes 341
O
oil, amount 152
oil, types 152
P
positive directions, axes 341
R
Revolution counters 342
S
Safety, service 17
securing, base plate 70
securing, lower arm 251
securing, robot 74
securing, upper arm 290
U
Updating revolution counters 342
V
Validity and responsibility 17
353

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Product manual (part 1 of 2), procedures

Product manual (part 1 of 2), procedures

Copyright 2004 ABB All right reserved.

1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.3.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2.5.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Replacement/changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

3.5.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

3HAC 020938-001 Revision: C

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4.4.1 Replacement of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.5.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

6.1 Environmental information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

3HAC 020938-001 Revision: C

3HAC 020938-001 Revision: C

mechanical and electrical installation of the manipulator

maintenance of the manipulator

mechanical and electrical repair of the manipulator.

Who should read this manual?

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/

3HAC 020938-001 Revision: C

Information about installation of the manipulator.

Information about maintenance work, including maintenance

Information about repair work.

Procedures that does not require specific calibration

Environmental information about the manipulator.

Model M2004 implemented.

3HAC 020938-001 Revision: C

3HAC 020938-001 Revision: C

Changes made in chapter Calibration:

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views

In addition, spare part information is supplied for the entire option.

3HAC 020938-001 Revision: C

Product documentation, M2004

Product documentation, M2004