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
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2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Inspection, oil level gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Inspection, oil level gearbox axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.4 Inspection, oil level gearbox axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.6 Inspection, oil level gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.5 Oil change, gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.6 Oil change, gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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

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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
4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.6.5 Replacement of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.6.6 Replacement of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

4.7.2 Replacement of gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4.7.3 Replacement of gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
4.7.4 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
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

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Table of Contents

3HAC 020938-001 Revision: C

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.

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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.

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Overview

Revision Description
B

3HAC 020938-001 Revision: C

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

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Product documentation, M2004

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)

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

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.

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11

Product documentation, M2004

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)

3HAC 020938-001 Revision: C

How to read the product manual

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.

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13

How to read the product manual

14

3HAC 020938-001 Revision: C

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.

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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)

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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.

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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

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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

3HAC 020938-001 Revision: C

Installation and commissioning

19

1 Safety
1.2.3.1. Safety risks during service work on robot

1.2.3. Safety risks

1.2.3.1. Safety risks during service work on robot
Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.

20

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1 Safety
1.2.3.1. Safety risks during service work on robot

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!

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21

1 Safety
1.2.3.1. Safety risks during service work on robot

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

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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.

3HAC 020938-001 Revision: C

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

3HAC 020938-001 Revision: C

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

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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

3HAC 020938-001 Revision: C

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.

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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

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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.

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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

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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!

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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.

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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.

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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.

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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.

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1 Safety
1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general
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

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1 Safety
1.3.1. Safety signals, general

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

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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.

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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!

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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.

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1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

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!

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1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

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.

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1 Safety
1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!

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.

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Note

43

1 Safety
1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!

44

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2 Installation and commissioning

2.1. Introduction

2 Installation and commissioning

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.

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2 Installation and commissioning

2.2.1. Pre-installation procedure

2.2 Unpacking
2.2.1. Pre-installation procedure
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

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2 Installation and commissioning

2.2.1. Pre-installation procedure

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

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2 Installation and commissioning

2.2.1. Pre-installation procedure

Protection classes, robot

The table below shows the protection class of the robot:

48

Equipment

Protection class

robot

IP 67

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2 Installation and commissioning

2.2.2. Working range

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

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2 Installation and commissioning

2.2.2. Working range

IRB 6600 - 175/2.8

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

xx0200000026

50

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2 Installation and commissioning

2.2.2. Working range

IRB 6650 - 125/3.2

The illustration below shows the unrestricted working range of IRB 6650 - 125/3.2:

xx0200000338

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2 Installation and commissioning

2.2.2. Working range

IRB 6650 - 200/2.75

The illustration below shows the unrestricted working range of IRB 6650 - 200/2.75:

xx0200000339

52

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2 Installation and commissioning

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!

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2 Installation and commissioning

2.3.1. Lifting robot with fork lift

2.3 On-site installation

2.3.1. Lifting robot with fork lift
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

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2 Installation and commissioning

2.3.1. Lifting robot with fork lift

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!

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3HAC 1557-1

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2 Installation and commissioning

2.3.1. Lifting robot with fork lift

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)

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2 Installation and commissioning

2.3.1. Lifting robot with fork lift

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)

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2 Installation and commissioning

2.3.1. Lifting robot with fork lift

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

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2 Installation and commissioning

2.3.1. Lifting robot with fork lift

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)!
Attachment points on the robot are
shown in the figure Attachment points
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

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A: securing screw

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2 Installation and commissioning

2.3.1. Lifting robot with fork lift

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.
Make sure the original screws are
always used (or replacements of
equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment points
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.
Make sure the original screws are
always used (or replacements of
equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment points
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

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2.3.1. Lifting robot with fork lift

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!

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2.3.2. Lifting robot with roundslings

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!

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2 Installation and commissioning

2.3.2. Lifting robot with roundslings

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!

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2.3.3. Lifting robot with lifting slings

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

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2 Installation and commissioning

2.3.3. Lifting robot with lifting slings

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
equipment used must be dimensioned
accordingly!

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2.3.3. Lifting robot with lifting slings

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.

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2 Installation and commissioning

2.3.4. Manually releasing the brakes

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!

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2.3.4. Manually releasing the brakes

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

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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.

3HAC 020938-001 Revision: C

Shown in the figure Hole

configuration on page 69!

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2.3.6. Securing the base plate

2.3.6. Securing the base plate

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

xx0100000105

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2.3.6. Securing the base plate

xx0400000715

Note1
3HAC 020938-001 Revision: C

Four holes for alternative clamping

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2.3.6. Securing the base plate

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

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

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.

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2.3.6. Securing the base plate

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.
grooves and holes on page 72.

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.

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2.3.7. Orienting and securing the robot

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

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2.3.7. Orienting and securing the robot

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,

grooves and holes on page 72.
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

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2.3.7. Orienting and securing the robot

Cross section, guide sleeve hole

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

xx0100000109

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2.3.8. Fitting equipment on robot

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

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2.3.8. Fitting equipment on robot

xx0300000571

xx0300000572

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2.3.8. Fitting equipment on robot

Illustration, fitting of extra equipment on upper arm

The illustration below shows the mounting holes available for fitting extra equipment on the
upper arm.

xx0300000573

xx0200000196

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2.3.8. Fitting equipment on robot

Illustration, fitting of extra equipment on frame

The illustration below shows the mounting holes available for fitting extra equipment on the
frame.

xx0200000198

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2.3.8. Fitting equipment on robot

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

3HAC 020938-001 Revision: C

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.

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2.3.8. Fitting equipment on robot

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.

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2.3.9. Installation of chip and dust protection (option)

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

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2.3.9. Installation of chip and dust protection (option)

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

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2.3.9. Installation of chip and dust protection (option)

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.

Tightening torque: 24 Nm.
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

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2.3.9. Installation of chip and dust protection (option)

Step
5.

Action

Illustration

Fit the stop to the robot. Use the

enclosed attachment screws.

xx0400001080

6.

C: Attachment screws: 2 pcs, M6x25.

Remove the rear bracket from the

upper shield.

xx0400001099

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2.3.9. Installation of chip and dust protection (option)

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

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2.3.9. Installation of chip and dust protection (option)

Step
9.

Action

Illustration

Secure the cover, balancing

device to the robot with the
original attachment screws,
earlier removed from the rear
cover of the balancing device.
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

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2.3.9. Installation of chip and dust protection (option)

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
enclosed attachment screws.

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

3HAC 020938-001 Revision: C

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.
Tightening torque: 50 Nm.

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2.3.9. Installation of chip and dust protection (option)

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.

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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.

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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)

Axis 2, hardware (mechanical stop) and software (signal from adjustable position
switch)

Axis 3, hardware (mechanical stop) and software (signal from adjustable position
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.

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2.4.2. Mechanically restricting the working range of axis 1

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

The contents are defined in section

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.

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2.4.2. Mechanically restricting the working range of axis 1

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.

Tightening torque: 120 Nm.

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!

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2.4.3. Mechanically restricting the working range of axis 2

2.4.3. Mechanically restricting the working range of axis 2

General
The working range of axis 2 is limited by fixed mechanical stops and can be reduced by
adding up to six additional mechanical stops with 15 graduation in respective direction.
Mechanical stops, axis 2
The illustration below shows the mounting position of the mechanical stops on axis 2.

xx0300000047

Additional mechanical stops

Fixed mechanical stop

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

Standard toolkit in the Product manual,
reference information!

Users Guide (RobotWare 4.0) Operator's manual

(RobotWare 5.0)

3HAC 020938-001 Revision: C

Note

Art. no. is specified in section Document

references in the Product manual,
reference information.

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2.4.3. Mechanically restricting the working range of axis 2

Installation, mechanical stops axis 2

The procedure below details how to fit the mechanical stops for axis 2, on to the robot. An
assembly drawing is also enclosed with the product.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
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!

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2.4.4. Mechanically restricting the working range of axis 3

2.4.4. Mechanically restricting the working range of axis 3

General
The working range of axis 3 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops with 20 graduation in respective direction.
Mechanical stops, axis 3
The illustration below shows the mounting position of the mechanical stops on axis 3.

xx0300000048

Additional mechanical stops

Fixed mechanical stop

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

3HAC 15571-1 The contents are defined in section

Standard toolkit in the Product
manual, reference information!

Users Guide (RobotWare 4.0)

Operator's manual (RobotWare 5.0)

3HAC 020938-001 Revision: C

Art. no. is specified in section

Document references in the Product
manual, reference information.

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2.4.4. Mechanically restricting the working range of axis 3

Installation, mechanical stops axis 3

The procedure below details how to fit the mechanical stops for axis 3 on to the robot. An
assembly drawing is also enclosed with the product.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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
Tightening torque: 115 Nm.

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!

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2.4.5. Position switches

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

Position switch, axis 2 complete

3HAC 15710-1

Position switch, axis 3 complete

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)

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2.4.5. Position switches

Protection sheet

Rail

Rail attachment

Axis 2
The illustration below shows the position switch for axis 2:

xx0100000159

100

Position switch, axis 2

Cam

Set screw, cam (cam stop)

Rail

Rail Attachment

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2.4.5. Position switches

Axis 3
The illustration below shows the position switch for axis 3:

xx0100000160

Position switch, axis 3

Cam

Set screw, cam (cam stop)

Rail

Rail attachment

Specifications
Maximum voltage/current for the position switches:

Parameter

Value

Voltage

Max. 50 VDC

Current

Max. 1 A

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2.4.5. Position switches

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.

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2.4.5. Position switches

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

3HAC 020938-001 Revision: C

Remove the gray section

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2.5.1. Robot cabling and connection points

2.5 Electrical connections

2.5.1. Robot cabling and connection points
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
Product manual, reference information.

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

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2 Installation and commissioning

2.5.1. Robot cabling and connection points

Robot cable, power

Cable

Art. no.

Robot cable, power, 7 m

3HAC 11818-1

Robot cable, power, 15 m

3HAC 11818-2

Robot cable, power, 30 m

3HAC 11818-4

Cable

Art. no.

Robot cable, signal, shielded, 7 m

3HAC 7998-1

Robot cable, signal, shielded, 15 m

3HAC 7998-2

Robot cable, signal, shielded, 22 m

3HAC 7998-3

Robot cable, signal, shielded, 30 m

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

Position switch cable, axis 1, 15 m

3HAC 13175-2

XS8

R1.SW

Position switch cable, axis 1, 30 m

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

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2 Installation and commissioning

2.5.1. Robot cabling and connection points

106

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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.

3HAC 020938-001 Revision: C

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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

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3 Maintenance
3.2.2. Maintenance schedule

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

Axis 2 gear, oil level

12 mths

1)

Inspection, oil level

gearbox axis 2 on page
116

Inspection

Axis 3 gear, oil level

12 mths

1)

Inspection, oil level

gearbox axis 3 on page
119

Inspection

Axis 4 gear, oil level

12 mths

Inspection, oil level

gearbox axis 4 on page
121

Inspection

Axis 5 gear, oil level

12 mths

Inspection, oil level,

gearbox axis 5 on page
123

Inspection

Axis 6 gear, oil level

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

3HAC 020938-001 Revision: C

- 7)

1)

1)

Inspection, oil level

gearbox axis 6 on page
125

Oil change, gearbox axis

1 on page 156
-

109

3 Maintenance
3.2.2. Maintenance schedule

Maintenance
Equipment
activity

110

Interval

Detailed in section
1)

Changing

Axis 2 gear, oil: Optimol 12 000 h

Optigear RMO 150

Changing

Axis 2 gear oil: Shell

Tivela S 150

Changing

Axis 3 gear, oil: Optimol 12 000 h

Optigear RMO 150

Changing

Axis 3 gear oil: Shell

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)

Oil change, gearbox, axis

5 on page 170

Changing

Axis 6 gear, oil: Optimol 12 000 h

Optigear RMO 150 7)

1)

Oil change, gearbox axis

6 on page 173

Changing

Axis 6 gear oil: Shell

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

or typically 96 mths
axis 2 on page 316

Replacement

Axis 3 gearbox

As specified by the SIS, Replacement of gearbox,

or typically 96 mths
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

As specified by the SIS, Replacement of gearbox,

or typically 96 mths
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)

Oil change, gearbox axis

2 on page 160
-

1)

Oil change, gearbox, axis

3 on page 164
-

4)

Lubrication, balancing
device bearing on page
179

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3 Maintenance
3.2.2. Maintenance schedule

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

3HAC 020938-001 Revision: C

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

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3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1

3.3 Inspection activities

3.3.1. Inspection, oil level gearbox axis 1
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

3HAC 020938-001 Revision: C

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3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1

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

The contents are defined in

section Special tools in the
Product manual, reference
information.

Other tools and procedures may

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

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

114

3.

Open the oil plug, inspection.

4.

Required oil level: max. 10 mm below the oil

plug hole!

5.

Add oil if required.

Shown in the figure Location of

gearbox on page 113!

Art. no. is specified in Required

equipment on page 114!
Further information about how to
fill the oil may be found in section
Filling, oil on page 158.

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3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1

Step
6.

Action
Refit the oil plug, inspection.

Note/Illustration
Tightening torque: 24 Nm.

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!

3HAC 020938-001 Revision: C

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3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2

3.3.2. Inspection, oil level gearbox axis 2

Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two
different designs.

The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.

The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.

The 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

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3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2

Required equipment
Equipment etc.

Art. no.

Note

Lubricating oil

3HAC 16483-1 /
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

Other tools and procedures may be

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

These procedures include

references to the tools required.

Inspection, oil level gearbox 2

The procedure below details how to inspect the oil level in gearbox axis 2.
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

Open the oil plug, filling.

Shown in the figure Location of

gearbox on page 116!

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.

Shown in the figure Location of

gearbox on page 116!
Read more about the variations in
design in Different designs on page
116.

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117

3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2

Step

Action

Note/Illustration

5.

Add oil if required.

Art. no. is specified in Required

equipment on page 117!
Filling of oil is detailed further in
section Filling, oil on page 162.

6.

Refit the oil plug, filling.

Tightening torque: 24 Nm.

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!

118

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3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3

3.3.3. Inspection, oil level gearbox axis 3

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

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

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

3HAC 020938-001 Revision: C

119

3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3

Equipment, etc.

Art. no.

Other tools and procedures may

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

Note
These procedures include
references to the tools required.

Inspection, oil level gearbox 3

The procedure below details how to inspect the oil level in the gearbox axis 3.
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.

Move the robot to the calibration position.

Detailed in section Calibration scales

and correct axis position on page 340.

3.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4.

Open the oil plug, filling.

Shown in the figure Location of

gearbox on page 119!

5.

Required oil level: max 10 mm below the oil

plug hole.

6.

Add oil if required.

Art. no. is specified in Required

equipment on page 119!
Further information about how to fill
the oil may be found in section Filling,
oil on page 166.

7.

Refit the oil plug, filling.

Tightening torque: 24 Nm.

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

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3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4

3.3.4. Inspection, oil level gearbox axis 4

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

The contents are defined in section

Standard toolkit in the Product
manual, reference information!

Other tools and procedures may

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

3HAC 020938-001 Revision: C

These procedures include

references to the tools required.

121

3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4

Inspection, oil level gearbox 4

The procedure below details how to inspect the oil level in gearbox axis 4.
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.

Run the manipulator to the calibration position.

Shown in section Calibration

scales and correct axis position
on page 340.

3.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4.

Open the oil plug, filling.

Shown in the figure Location of

gearbox on page 121!

5.

Required oil level: max 10 mm below the oil plug

hole.

6.

Add oil if required.

Art. no. is specified in Required

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.

Tightening torque: 24 Nm.

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!

122

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3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5

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

The contents are defined in section

Standard toolkit in the Product
manual, reference information!

Other tools and procedures may

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

3HAC 020938-001 Revision: C

These procedures include

references to the tools required.

123

3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5

Inspection, oil level gearbox 5

The procedure below details how to inspect the oil level in gearbox axis 5.
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

Turn the wrist unit so that the both oil plugs face
upwards.

4.

Open the oil plug, filling.

5.

Measure the oil level.

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

6.

Add oil if required.

Art. no. is specified in Required

equipment on page 123.
Further information about how
to fill the oil may be found in
section Filling, oil on page 172.

7.

Refit the oil plug.

Tightening torque: 24 Nm.

Shown in the figure Location of

gearbox on page 123!

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

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3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6

3.3.6. Inspection, oil level gearbox axis 6

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

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

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and procedures may be

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

3HAC 020938-001 Revision: C

These procedures include

references to the tools required.

125

3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6

Inspection, oil level gearbox 6

The procedure below details how to inspect the oil level in gearbox axis 6.
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

Make sure the oil plug, filling is facing

upwards and open it.

Shown in the figure Location of

gearbox on page 125!

4.

Measure the oil level.

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

5.

Add oil if required.

Art. no. is specified in Required

equipment on page 125!
Further information about how to fill
the oil may be found in section Filling,
oil on page 175.

6.

Refit the oil plug, filling.

Tightening torque: 24 Nm.

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

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3 Maintenance
3.3.7. Inspection, balancing device

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

3HAC 020938-001 Revision: C

127

3 Maintenance
3.3.7. Inspection, balancing device

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

3HAC 020938-001 Revision: C

3 Maintenance
3.3.7. Inspection, balancing device

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

For maintenance of balancing

device 3HAC 17117-2 and 3HAC
17117-3.
Includes:
complete kit including the
kit with bearings and seals
instructions for
maintenance.

Maintenance kit,
bearings and seals

3HAC 16194-1

For maintenance of balancing

device 3HAC 14678-1 and 3HAC
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

For maintenance of balancing

device 3HAC 17117-2 and 3HAC
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

3HAC 020938-001 Revision: C

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
3.3.7. Inspection, balancing device

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

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

These procedures include

references to the tools required.

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

according to given instructions in
Maintenance kit, complete / 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.

3HAC 020938-001 Revision: C

3 Maintenance
3.3.7. Inspection, balancing device

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.

3HAC 020938-001 Revision: C

If damage is detected...

the piston rod (part of the piston rod ... perform maintenance or upgrade
that is visible at the front of the
according to given instructions in
balancing device).
Maintenance kit, complete / 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.

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
3.3.7. Inspection, balancing device

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

3HAC 020938-001 Revision: C

3 Maintenance
3.3.7. Inspection, balancing device

Step

Action

Note

3.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

3HAC 020938-001 Revision: C

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

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

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

Other tools and procedures may

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

These procedures include references to

the tools required.

Circuit diagram

See chapter Circuit diagram in the

Product manual, reference information.

3HAC 020938-001 Revision: C

3 Maintenance
3.3.8. Inspection, cable harness

Inspection, cable harness 1-4

The procedure below details how to inspect the cable harness of axes 1-4.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

Shown in the figure Location of

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.
cable harness, axes 1-4 on page
200!

3HAC 020938-001 Revision: C

135

3 Maintenance
3.3.8. Inspection, cable harness

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

136

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3 Maintenance
3.3.8. Inspection, cable harness

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.
cable harness, axes 5-6 on page
209!

3HAC 020938-001 Revision: C

Shown in the figure Location of

cabling axes 5-6 on page 136!

137

3 Maintenance
3.3.9. Inspection, information labels

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

3HAC 020938-001 Revision: C

3 Maintenance
3.3.9. Inspection, information labels

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Check the labels, located as shown in the

figures Location of labels on page 138.

3.

Replace any missing or damaged labels.

3HAC 020938-001 Revision: C

Art. no. is specified in Required

equipment on page 139!
139

3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

140

3HAC 020938-001 Revision: C

3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1

Step

Action

Note/Illustration

2.

Inspect the mechanical stop, axis 1.

Shown in the figure Location of

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!
equipment on page 140!

3HAC 020938-001 Revision: C

141

3 Maintenance
3.3.11. Inspection, additional mechanical stops

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.

Mechanical stop axis 1

3HAC 11076-2

Limits the robot working range by 15.

Mechanical stop axis 2

3HAC 13787-1

Mechanical stop axis 3

3HAC 13128-2

Standard toolkit

3HAC 15571-1

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

3HAC 020938-001 Revision: C

3 Maintenance
3.3.11. Inspection, additional mechanical stops

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

3HAC 020938-001 Revision: C

Shown in the figure Location

of mechanical stops on page
142!

143

3 Maintenance
3.3.12. Inspection, damper axes 2-5

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 3 (2 pcs)

Damper, axis 4 (1 pc)

Damper, axis 5 (2 pcs)

Required equipment

144

Equipment

Art. no.

Note

Damper axis 2

3HAC 12991-1

To be replaced if damaged!

Damper axis 3

3HAC 12320-1

To be replaced if damaged!

Damper axis 4

3HAC 13564-1

To be replaced if damaged!

3HAC 020938-001 Revision: C

3 Maintenance
3.3.12. Inspection, damper axes 2-5

Equipment

Art. no.

Note

Damper axis 5

3HAB 4337-2

To be replaced if damaged!

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!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2.

Check all dampers for damage, and for cracks or

Shown in the figure Location
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!

3HAC 020938-001 Revision: C

Art. no. is specified in

Required equipment on
page 144!

145

3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3

3.3.13. Inspection, position switch axes 1, 2 and 3

Position switch, axis 1
The illustration below shows the position switch for axis 1.

xx0100000158

146

Position switch, axis 1

Cam

Set screw, cam

Protection sheet

Rail

Rail attachment

3HAC 020938-001 Revision: C

3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3

Position switch, axis 2

The illustration below shows the position switch for axis 2.

xx0100000159

Position switch, axis 2

Cam

Set screw, cam

Rail

Rail attachment

3HAC 020938-001 Revision: C

147

3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3

Position switch, axis 3

The illustration below shows the position switch for axis 3.

xx0100000160

Position switch, axis 3

Cam

Set screw, cam

Rail

Rail attachment

Required equipment

148

Equipment, etc.

Art. no.

Position switch, axis 1

3HAC 15715-1

Position switch, axis 2

3HAC 16418-1

Position switch, axis 3

3HAC 16417-1

Note

3HAC 020938-001 Revision: C

3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3

Equipment, etc.

Art. no.

Note

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and procedures

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

These procedures include

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!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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!

3HAC 020938-001 Revision: C

Art. no. is specified in

Required equipment on
page 148!

149

3 Maintenance
3.3.14. Inspection, signal lamp

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.)

3HAC 020938-001 Revision: C

3 Maintenance
3.3.14. Inspection, signal lamp

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

The contents are defined in section

Standard toolkit in the Product
manual, reference information!

Other tools and procedures may

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

These procedures include

references to the tools required.

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!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3.

3HAC 020938-001 Revision: C

If the lamp is not lit, trace the fault by:

Art. no. is specified in
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

3.4.1. Oil in gearboxes
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

3HAC 020938-001 Revision: C

3 Maintenance
3.4.1. Oil in gearboxes

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

Optimol Optigear RMO 150 /

3HAC 16843-1 /
Shell Tivela S 150 (001A9646) 3HAC 021469-001

7,300 ml

Axis 2

Optimol Optigear RMO 150 /

3HAC 16483-1 /
Shell Tivela S 150 (001A9646) 3HAC 021469-001

4,600 ml (later
design of motor
attachment)
1,800 ml (early
design of motor
attachment)

Axis 3

Optimol Optigear RMO 150 /

3HAC 16843-1 /
Shell Tivela S 150 (001A9646) 3HAC 021469-001

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

Optimol Optigear RMO 150 /

3HAC 16843-1 /
Shell Tivela S 150 (001A9646) 3HAC 021469-001

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!

3HAC 020938-001 Revision: C

153

3 Maintenance
3.4.1. Oil in gearboxes

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

3HAC 020938-001 Revision: C

3 Maintenance
3.4.1. Oil in gearboxes

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!

3HAC 020938-001 Revision: C

155

3 Maintenance
3.4.2. Oil change, gearbox axis 1

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
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!

3HAC 020938-001 Revision: C

3 Maintenance
3.4.2. Oil change, gearbox axis 1

Equipment, etc.

Art. no.

Amount

Oil collecting vessel

Note
Capacity: 8,000 ml.

Oil exchange
equipment

3HAC 021745-001

The contents are defined in

section Special tools in the
Product manual, reference
information.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

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.
3.

3HAC 020938-001 Revision: C

Remove the rear cover on the base by

unscrewing its attachment screws.

157

3 Maintenance
3.4.2. Oil change, gearbox axis 1

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

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.

158

3HAC 020938-001 Revision: C

3 Maintenance
3.4.2. Oil change, gearbox axis 1

Step

Action

Note

3.

Open the oil plug, filling.

Shown in the figure Location of

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!
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!
6.

3HAC 020938-001 Revision: C

Refit the oil plug, filling.

Tightening torque: 24 Nm.

159

3 Maintenance
3.4.3. Oil change, gearbox axis 2

3.4.3. Oil change, gearbox axis 2

Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two
different designs.

The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.

The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.

The 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

3HAC 020938-001 Revision: C

3 Maintenance
3.4.3. Oil change, gearbox axis 2

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)

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!

Oil collecting vessel -

Capacity: 5,000 ml.

Oil exchange
equipment

3HAC 021745-001

The contents are defined in

section Special tools in the
Product manual, reference
information.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
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 161.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

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.
3.

3HAC 020938-001 Revision: C

Remove the plug of the vent hole .

Shown in the figure Location of oil

plugs on page 160!

161

3 Maintenance
3.4.3. Oil change, gearbox axis 2

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.
Vessel capacity is specified in
Required equipment on page 161!
Draining is time-consuming.
Elapsed time varies depending on
the temperature of the oil.

5.

Refit the oil plug.

Tightening torque: 24 Nm.

Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
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 161.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

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.
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.

Refill the gearbox with lubricating oil.

Art. no. and total amount are
specified in Required equipment
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil on page 161!
level is detailed in section Inspection, oil level
gearbox axis 2 on page 116.

5.

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!

162

3HAC 020938-001 Revision: C

3 Maintenance
3.4.3. Oil change, gearbox axis 2

Step
6.

3HAC 020938-001 Revision: C

Action

Note

Refit the oil plug and the plug in the vent hole.

Tightening torque: 24 Nm.

163

3 Maintenance
3.4.4. Oil change, gearbox, axis 3

3.4.4. Oil change, gearbox, axis 3

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

164

Equipment, etc.

Art. no.

Amount

Lubricating oil

3HAC 16843-1 /
2,500 ml
3HAC 021469-001

Note
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!

3HAC 020938-001 Revision: C

3 Maintenance
3.4.4. Oil change, gearbox, axis 3

Equipment, etc.

Art. no.

Amount

Note

Oil exchange
equipment

3HAC 021745-001

The contents are defined in

section Special tools in the
Product manual, reference
information.

Oil collecting vessel

Capacity: 3,000 ml.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
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 164.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

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.
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!

Shown in the figure Location of

gearbox on page 164!
Vessel capacity is specified in
Required equipment on page 164!
Draining is time-consuming. Elapsed
time varies depending on the
temperature of the oil.

4.

Refit the oil plug.

Tightening torque: 24 Nm.

3HAC 020938-001 Revision: C

165

3 Maintenance
3.4.4. Oil change, gearbox, axis 3

Filling, oil
The procedure below details how to fill oil to the gearbox, axis 3.
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 164.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

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.
3.

Remove the oil plug, filling.

Shown in the figure Location of

gearbox on page 164!

4.

Refill the gearbox with lubricating oil.

Art. no. and total amount are
specified in Required equipment
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil on page 164!
level is detailed in section Inspection, oil level
gearbox axis 3 on page 119.

5.

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!
6.

166

Refit the oil plug.

Tightening torque: 24 Nm.

3HAC 020938-001 Revision: C

3 Maintenance
3.4.5. Oil change, gearbox, axis 4

3.4.5. Oil change, gearbox, axis 4

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

The contents are defined in

section Special tools in the
Product manual, reference
information.

Oil collecting vessel

Capacity: 9,000 ml.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

3HAC 020938-001 Revision: C

167

3 Maintenance
3.4.5. Oil change, gearbox, axis 4

Draining, oil
The procedure below details how to drain the oil in the gearbox, axis 4.
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 167.
Step
1.

Action

Note

Run the upper arm -45 from the calibration

position.

2.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

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.

168

4.

Drain the oil from the gearbox into an vessel

by opening theoil plug, draining.
Remove the oil plug, filling in order to drain
the oil quicker!

Shown in the figure Location of

gearbox on page 167!
Vessel capacity is specified in
Required equipment on page 167!

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.

Tightening torque: 24 Nm.

3HAC 020938-001 Revision: C

3 Maintenance
3.4.5. Oil change, gearbox, axis 4

Filling, oil
The procedure below details how to fill the oil in the gearbox, axis 4.
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 167.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2.

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.
3.

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 4 on page 121.

Shown in the figure Location of

gearbox on page 167!
Art. no. and total amount are
specified in Required
equipment on page 167.

4.

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!
5.

3HAC 020938-001 Revision: C

Refit the oil plug, filling.

Tightening torque: 24 Nm.

169

3 Maintenance
3.4.6. Oil change, gearbox, axis 5

3.4.6. Oil change, 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

170

Equipment, etc.

Art. no.

Amount Note

Lubricating oil

1171 2016-604

6,700 ml

Oil exchange equipment

3HAC 021745-001

The contents are defined in

section Special tools in the
Product manual, reference
information.

Oil collecting vessel

Capacity: 7,000 ml.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Mobil Gearlube X320

This is a common oil that can
be replaced with an equivalent
oil from another manufacturer!

3HAC 020938-001 Revision: C

3 Maintenance
3.4.6. Oil change, gearbox, axis 5

Draining, oil
The procedure below details how to change the oil in gearbox, axis 5.
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 170.
Step
1.

Action

Note

Run axis 4 to a position where the oil plug,

draining, is facing downwards.

2.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

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.
4.

Drain the oil from the gearbox by opening the

oil plug, draining.
Remove the oil plug, filling in order to drain
the oil quicker!

Shown in the figure Location of

gearbox on page 170!
Vessel capacity is specified in
Required equipment on page 170!

5.

Refit the oil plug, draining.

Tightening torque: 24 Nm.

3HAC 020938-001 Revision: C

171

3 Maintenance
3.4.6. Oil change, gearbox, axis 5

Filling, oil
The procedure below details how to change the oil in gearbox, axis 5.
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 170.
Step

Action

Note

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.

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

Shown in the figure Location of

gearbox on page 170!
Art. no. and total amount are
specified in Required equipment on
page 170.

5.

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!
6.

172

Refit the oil plug, filling.

Tightening torque: 24 Nm.

3HAC 020938-001 Revision: C

3 Maintenance
3.4.7. Oil change, gearbox axis 6

3.4.7. Oil change, gearbox axis 6

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions 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
Optimol Optigear RMO 150 /
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

The contents are defined in

section Special tools in the
Product manual, reference
information.

Oil collecting vessel

Vessel capacity: 500 ml.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

3HAC 020938-001 Revision: C

Amount

Note

173

3 Maintenance
3.4.7. Oil change, gearbox axis 6

Draining, oil
The procedure below details how to drain oil from the gearbox, axis 6.
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 173.
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.

Shown in the figure Location of

gearbox on page 173!

2.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

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.

174

4.

Drain the oil from gearbox into a vessel by

removing the oil plug.

Vessel capacity is specified in

Required equipment on page
173!

5.

Refit the oil plug, draining.

Tightening torque: 24 Nm.

3HAC 020938-001 Revision: C

3 Maintenance
3.4.7. Oil change, gearbox axis 6

Filling, oil
The procedure below details how to fil oil in the gearbox, axis 6.
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 173.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

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.
3.

Remove the oil plug, filling.

Shown in the figure Location of

gearbox on page 173!

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 6 on page 125.

Art. no. and the total amount are

specified in Required equipment
on page 173!

5.

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!
6.

3HAC 020938-001 Revision: C

Refit the oil plug.

Tightening torque: 24 Nm.

175

3 Maintenance
3.4.8. Replacement of SMB battery

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

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!
See chapter Circuit diagram in the
Product manual, reference
information.

3HAC 020938-001 Revision: C

3 Maintenance
3.4.8. Replacement of SMB battery

Removal, battery
The procedure below details how to remove the SMB battery.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 .

Shown in the figure Location of SMB

battery on page 176!

5.

Remove the SMB battery.

Shown in the figure Location of SMB
Battery includes protection circuits. Replace battery on page 176!
it only with the specified spare part or with
an ABB approved eqvivalent.

3HAC 020938-001 Revision: C

177

3 Maintenance
3.4.8. Replacement of SMB battery

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

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

Reconnect the battery cable to the SMB

battery pack and fit it to the frame.

Art. no. is specified in Required

equipment on page 176!
Shown in the figure Location of SMB
battery on page 176!

4.

Secure the SMB battery cover with its

attachment screws.

Shown in the figure Location of SMB

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.

3HAC 020938-001 Revision: C

3 Maintenance
3.5.1. Lubrication, balancing device bearing

3.5 Lubrication activities

3.5.1. Lubrication, balancing device bearing
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

3HAC 020938-001 Revision: C

179

3 Maintenance
3.5.1. Lubrication, balancing device bearing

Lubrication, balancing device bearing

The procedure below details how to lubricate the spherical roller bearing.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

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.

Art. no. is specified in Required

equipment on page 179!
Shown in the figure Location of
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.

3HAC 020938-001 Revision: C

3 Maintenance
3.6.1. Cleaning, robot

3.6 Cleaning activities

3.6.1. Cleaning, robot
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

3HAC 020938-001 Revision: C

181

3 Maintenance
3.6.1. Cleaning, robot

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!

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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.

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3 Maintenance
3.7.2. Description of Service Information System (SIS)

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

Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox service
interval

Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox service
interval

Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox service
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

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3 Maintenance
3.7.2. Description of Service Information System (SIS)

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
the SIS parameters on page 189.

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
(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 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
the SIS parameters on page 189.

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
(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 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.

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3 Maintenance
3.7.2. Description of Service Information System (SIS)

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

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3 Maintenance
3.7.3. SIS system parameters

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.

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3 Maintenance
3.7.3. SIS system parameters

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

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3 Maintenance
3.7.4. Setting the SIS parameters

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

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3 Maintenance
3.7.4. Setting the SIS parameters

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.

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3 Maintenance
3.7.4. Setting the SIS parameters

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.

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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.
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.

Operation time

Service Message
X production hours
to next service.

X number of operation hours remain until the

manually set operation 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.

Gearbox time

Service Message
Gearbox x requires
service!

The automatically calculated gearbox time limit has

expired.
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.

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.
How to set the value determining when the
message is to be shown, is detailed in section
Setting the SIS parameters on page 189.

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3 Maintenance
3.7.6. Exporting the SIS data

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

Estimated life of gearbox axis 2

sisL10h_Time_2

hrs*

Gearbox time

Operation time of gearbox axis 2

sisL10h_3

hrs

Gearbox time

Estimated life of gearbox axis 3

sisL10h_Time_3

hrs*

Gearbox time

Operation time of gearbox axis 3

sisL10h_6

hrs

Gearbox time

Estimated life of gearbox axis 6

sisL10h_Time_6

hrs

Gearbox time

Operation time of gearbox axis 6

* For RobotWare releases earlier than 5.05, the unit is seconds.

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3 Maintenance
3.7.6. Exporting the SIS data

194

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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.

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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.

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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.

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4 Repair
4.2.3. Mounting instructions for seals

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
Art. no. is specified in
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.

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4 Repair
4.2.3. Mounting instructions for seals

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.

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

4.3 Complete manipulator

4.3.1. Replacement of cable harness, axes 1-4
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

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Connectors at motor 2: R2.FB2 and R2.MP2

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)

Connectors at motor 4: R2.FB4 and R2.MP4

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

The contents are defined in

section Standard toolkit in
the Product manual,
reference information!

Other tools and

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

These procedures include

references to the tools
required.

Circuit Diagram

See chapter Circuit diagram

in the Product manual,
reference information.

Removal, cable harness, axes 1-4

The procedure below details how to remove the cable harness, axes 1-4.
Step
1.

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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

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Step

Action

Note/Illustration

2.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

Remove the rear cover plate on the manipulator

by removing its attachment screws.

Shown in the figure Location of

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

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

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.

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

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.
cable harness on page 200.
14. Disconnect connector R2.M5/6 at the cable
division point.

Shown in the figure Location of

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

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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
Axis 6: no significance

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!
Attachment point is shown in the
figure Location of cable harness on
page 200.

5.

Reconnect the earth cable.

Attachment point is shown in the

figure Location of cable harness on
page 200!

6.

Refit the rear cover plate on the manipulator

with its attachment screws.

Shown in the figure Location of

cable harness on page 200.

7.

Reconnect all connectors at motor 1 and

motor 2.

Specified and shown in the figure

Location of cable harness on page
200!

3HAC 020938-001 Revision: C

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
4.3.1. Replacement of cable harness, axes 1-4

Step
8.

Action

Note/Illustration

Secure the cable gland (A) with four

Locking liquid is specified in
attachment screws (B) from inside the SMB
Required equipment on page 201.
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

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

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
inside the lower arm.

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!

Shown in the figure Location of

cable harness on page 200!
M6, 2 pcs.

17. Secure the cable harness to the upper arm

Shown in the figure Location of
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!

3HAC 020938-001 Revision: C

Detailed in the Calibration chapter section Updating revolution

counters on page 342.

207

4 Repair
4.3.1. Replacement of cable harness, axes 1-4

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

208

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.

3HAC 020938-001 Revision: C

4 Repair
4.3.2. Replacement of cable harness, axes 5-6

4.3.2. Replacement of cable harness, axes 5-6

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

3HAC 020938-001 Revision: C

209

4 Repair
4.3.2. Replacement of cable harness, axes 5-6

Required equipment
Equipment, etc.

Spare part no. Art. no.

Cable harness axes 5-6

3HAC 14140-1

Cable harness axis 5

3HAC 14139-1

Standard toolkit

Note

3HAC 15571-1

The contents are defined in

section Standard toolkit in
the Product manual,
reference information!

Other tools and

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

These procedures include

references to the tools
required.

Circuit Diagram

See chapter Circuit diagram

in the Product manual,
reference information.

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!
Turn off all electric power, hydraulic and
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

3HAC 020938-001 Revision: C

4 Repair
4.3.2. Replacement of cable harness, axes 5-6

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
harness ax 5-6 on page 209!
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

harness ax 5-6 on page 209!

10. Remove the cable attachment, rear.

Shown in the figure Location of cable

harness ax 5-6 on page 209!

11. Disconnect connector R2.M5/6 at the

cable harness division point.

Shown in the figure Location of cable

harness ax 5-6 on page 209!

12. Gently pull the cable harness out.

3HAC 020938-001 Revision: C

211

4 Repair
4.3.2. Replacement of cable harness, axes 5-6

Removal, cable harness, axis 5

The procedure below details how to remove the cable, axis 5.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

212

2.

The manipulator is required to be positioned

in the following position:
Axis 4: 0 degrees
Axis 5: +90 degrees
Axis 6: no significance

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.

Shown in the figure Location of cable

harness ax 5-6 on page 209!

3HAC 020938-001 Revision: C

4 Repair
4.3.2. Replacement of cable harness, axes 5-6

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.

Shown in the figure Location of cable

harness ax 5-6 on page 209!

11. Reconnect connector R2.M5/6 gently at the Shown in the figure Location of cable
rear cable division point with two screws,
harness ax 5-6 on page 209!
M6.
Be careful not to bend the attachment plate
when fastening the screws!

3HAC 020938-001 Revision: C

213

4 Repair
4.3.2. Replacement of cable harness, axes 5-6

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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
references in the Product manual,
reference information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

214

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.

3HAC 020938-001 Revision: C

4 Repair
4.3.3. Replacement of complete arm system

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

3HAC 020938-001 Revision: C

215

4 Repair
4.3.3. Replacement of complete arm system

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

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

Other tools and procedures

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

216

These procedures include references to

the tools required.

3HAC 020938-001 Revision: C

4 Repair
4.3.3. Replacement of complete arm system

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

3HAC 020938-001 Revision: C

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
4.3.3. Replacement of complete arm system

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
must be dimensioned accordingly!
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

218

Fit the lifting device as detailed in enclosed Art. no. is specified in Required
instruction.
equipment on page 216!
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!

3HAC 020938-001 Revision: C

4 Repair
4.3.3. Replacement of complete arm system

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.

3HAC 020938-001 Revision: C

219

4 Repair
4.3.3. Replacement of complete arm system

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
Product manual, reference
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,
gearbox axis 1 on page 156.
14. Recalibrate the robot.

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified
in section Document references in the
Product manual, reference
information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

220

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.

3HAC 020938-001 Revision: C

4 Repair
4.4.1. Replacement of turning disk

4.4 Upper and lower arm

4.4.1. Replacement of turning disk
Location of turning disk
The turning disk is located in the front of the wrist housing, as shown in the figure below.
The 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

3HAC 020938-001 Revision: C

221

4 Repair
4.4.1. Replacement of turning disk

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)

For all IRB 6600 and IRB 6650 robot

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

3HAC 15571-1 The contents are defined in section

Standard toolkit in the Product
manual, reference information!

Other tools and

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

These procedures include

references to the tools required.

Removal, turning disk

The procedure below details how to remove the turning disk.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

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.

Shown in the figure Location of

turning disk on page 221!

4.

Drain the oil from gearbox 6.

Detailed in section Oil change,

gearbox axis 6 on page 173.

5.

Remove the turning disk by unscrewing its

attachment screws .

Shown in the figure Location of

turning disk on page 221!

3HAC 020938-001 Revision: C

4 Repair
4.4.1. Replacement of turning disk

Refitting, turning disk

The procedure below details how to refit the turning disk.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Lubricate the turning disk o-ring with

Art. no. is specified in Required
grease.
equipment on page 222!
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.
For all IRB 6600 and IRB 6650 robot
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.

3HAC 020938-001 Revision: C

Detailed in section Performing a leakdown test on page 196.

223

4 Repair
4.4.1. Replacement of turning disk

Step

Action

5.

Refill the gearbox 6 with oil.

6.

Refit any equipment removed during

disassembly, to the turning disk.

Note/Illustration
Detailed in section Oil change, gearbox
axis 6 on page 173.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

224

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.

3HAC 020938-001 Revision: C

4 Repair
4.4.2. Replacement of complete wrist unit

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.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

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

3HAC 020938-001 Revision: C

225

4 Repair
4.4.2. Replacement of complete wrist unit

Required equipment
Equipment etc.

Spare part no. Art. no.

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

Guide pins M12 x 200

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
in the Product manual,
reference information!

Other tools and

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

These procedures include

references to the tools
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!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!

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.

Shown in the figure Location

of wrist unit on page 225!

5.

Remove the cover, upper arm tube.

Shown in the figure Location

of wrist unit on page 225!

6.

Remove the cover of motor, axis 6 and disconnect

all connectors beneath.

3HAC 020938-001 Revision: C

4 Repair
4.4.2. Replacement of complete wrist unit

Step
7.

Action

Note/Illustration

Loosen the cable bracket on top of the wrist by

Shown in the figure Location
undoing the three attachment screws.
of wrist unit on page 225!
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

Shown in the figure Location

of wrist unit on page 225!

10. Disconnect the motor axis 5 by disconnecting the

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

Shown in the figure Location

of wrist unit on page 225!

11. Fit the lifting tool to the wrist unit.

Art. no. is specified in

Required equipment on page
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 .

Shown in the figure Location

of wrist unit on page 225!

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

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4 Repair
4.4.2. Replacement of complete wrist unit

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Fit two guide pins, M12 in the upper arm

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

Art. no. is specified in Required

equipment on page 226!
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
dimensioned accordingly!

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.

Shown in the figure Location of wrist

unit on page 225!
12 pcs: M12 x 50, 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
Product manual, reference information
before fitting.

Shown in the figure Location of wrist

unit on page 225!

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4 Repair
4.4.2. Replacement of complete wrist unit

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.

Shown in the figure Location of wrist

unit on page 225!

15. Refit the cover, wrist unit.

Shown in the figure Location of wrist

unit on page 225!

16. Recalibrate the robot!

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference
information.

17. Refit any equipment previously removed

from the turning disk.

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4 Repair
4.4.2. Replacement of complete wrist unit

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

230

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.

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4 Repair
4.4.3. Replacement of upper arm

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.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

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4 Repair
4.4.3. Replacement of upper arm

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)

3HAC 020938-001 Revision: C

4 Repair
4.4.3. Replacement of upper arm

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

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and procedures may be

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

These procedures include

references to the tools required.

Removal, upper arm

The procedure below details how to remove the upper arm.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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
equipment on page 233!
lifting eye on the upper arm tube.
Shown in the figure Location of
upper arm on page 231!

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4 Repair
4.4.3. Replacement of upper arm

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 .

Art. no. is specified in Required

equipment on page 233!
Attachment point is 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!

6.

Fasten the lifting tool (chain) onto the lifting

eye, the lifting device and an overhead crane.

Art. no. is specified in Required

equipment on page 233!

7.

Drain the oil from gearbox axis 3.

Detailed in section Oil change,

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.

Shown in the figure Location of

upper arm on page 231!

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.

Shown in the figure Location of

upper arm on page 231!

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

Shown in the figure Location of

upper arm on page 231!

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4 Repair
4.4.3. Replacement of upper arm

Refitting, upper arm

The procedure below details how to refit the upper arm.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
Art. no. is specified in Required
Guide the new sealing, axis 2/3 into
equipment on page 233!
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.

Art. no. is specified in Required

equipment on page 233!
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.

Art. no. is specified in Required

equipment on page 233!
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!

3HAC 020938-001 Revision: C

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4 Repair
4.4.3. Replacement of upper arm

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.

Art. no. is specified in Required

equipment on page 233!

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

Art. no. is specified in Required
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.

Shown in the figure Location of upper

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.

Shown in the figure Location of upper

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.

3HAC 020938-001 Revision: C

4 Repair
4.4.3. Replacement of upper arm

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
UNBRAKO, tightening torque: 120 Nm.
Reused screws may be used, providing
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.
Be careful not to bend the attachment plate
when fastening the screws!
19. Perform a leakdown test.

Detailed in section Performing a leakdown test on page 196.

20. Refill the gearbox with oil.

Detailed in section Oil change,

gearbox, axis 3 on page 164.

21. Recalibrate the robot.

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

3HAC 020938-001 Revision: C

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4 Repair
4.4.4. Replacement of complete lower arm

4.4.4. Replacement of complete lower arm

Location of lower arm
The lower arm is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

xx0200000255

238

Lower arm

Pivot point, axis 2

Front shaft, balancing device, including securing screw

Attachment for lifting equipment, balancing device

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4 Repair
4.4.4. Replacement of complete lower arm

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

3HAC 020938-001 Revision: C

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4 Repair
4.4.4. Replacement of complete lower arm

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

Hydraulic pump, 150 MPa

(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

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

Other tools and procedures

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

240

The use of the tool is detailed in section

Replacement of lower arm shaft on page
246.

These procedures include references to

the tools required.

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4 Repair
4.4.4. Replacement of complete lower arm

Removal, lower arm

The procedure below details how to remove the complete lower arm.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Remove the upper arm.

Detailed in section Removal, upper

arm on page 233.

3.

Disconnect and remove the cables from

inside the lower arm.
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.

Art. no. is specified in Required

equipment on page 240.
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
shown in the figure to the right.
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.
Art. no. is specified in Required
equipment on page 240.
8.

3HAC 020938-001 Revision: C

Lower the balancing device until it rests

safely against the bottom of the frame.

241

4 Repair
4.4.4. Replacement of complete lower arm

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.

Art. no. is specified in Required

equipment on page 240!

11. Drain the oil from gearbox 2.

Detailed in section Oil change,

gearbox axis 2 on page 160.

12.

Caution!
The lower arm weighs 160 kg! All lifting
equipment used must be dimensioned
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.
components, lower arm on page 239!
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.
components, lower arm on page 239!
On reassembly new sealings must
be used!

242

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4 Repair
4.4.4. Replacement of complete lower arm

Refitting, lower arm

The procedure below details how to refit the lower arm.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Fit a new VK-cover on a new lower arm or

replace the existing if damaged.

Part no. is specified in Required

equipment on page 240!

3.

Fit two guidings in the attachment holes of

the lower arm.

Art. no. is specified in Required

equipment on page 240!

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!
Art. no. is specified in Required
equipment on page 240!

5.

Apply the lifting tool to the lower arm.

Art. no. is specified in Required

equipment on page 240!

6.

Caution!
The lower arm weighs 160 kg! All lifting
equipment used must be dimensioned
accordingly!
7.

3HAC 020938-001 Revision: C

Lift the lower arm and move it to its mounting

position.

243

4 Repair
4.4.4. Replacement of complete lower arm

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.
Art. no. is specified in Required
equipment on page 240!
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.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints in
the Product manual, reference
information before fitting.
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,
lower arm shaft on page 250!
13. Remove the lifting tool from the lower arm.
14. Refit and restore the balancing device.

Detailed in section Refitting,

balancing device on page 268.

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.

17. Refill the gearbox with oil.

Detailed in section Oil change,

gearbox axis 2 on page 160.

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

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4 Repair
4.4.4. Replacement of complete lower arm

Step

Action

19. Recalibrate the robot!

Note/Illustration
Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are
specified in section Document
references in the Product manual,
reference information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

3HAC 020938-001 Revision: C

245

4 Repair
4.4.5. Replacement of lower arm shaft

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

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4 Repair
4.4.5. Replacement of lower arm shaft

Required equipment
Equipment

Art. no.

Note

Bearing

3HAC 12441-2

Always use a new bearing when

reassembling!

Puller device, axis 2 shaft

3HAC 021563-001

Press device, axis 2 shaft

3HAC 021600-001

Hydraulic pump, 80 MPa

3HAC 13086-1

Hydraulic pump, 150 MPa

(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

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4 Repair
4.4.5. Replacement of lower arm shaft

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,

lower arm shaft on page 246!

3HAC 020938-001 Revision: C

4 Repair
4.4.5. Replacement of lower arm shaft

Step

Action

Note/Illustration

3.

Remove the protection washer and the retaining Shown in the figure Components,
ring.
lower arm shaft on page 246!
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.
equipment on page 247!

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.

3HAC 020938-001 Revision: C

Art. no. is specified in Required

equipment on page 247.
The attachments on the tool are
shown in figure Puller device for
removal of axis 2 shaft on page
247.

249

4 Repair
4.4.5. Replacement of lower arm shaft

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.
equipment on page 247!

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.
equipment on page 247!

5.

Tighten the M16 nut.

Tightening torque: 20 Nm.

6.

Fit both the hydraulic pump and the glycerin

pump to the press device.

Art. no. is specified in Required

equipment on page 247.
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.
equipment on page 247!
13. Press in the new bearing with the press tool,
axis 2 bearing.

Always use a new bearing when

reassembling!
Art. no. is specified in Required
equipment on page 247!

14. Refit the protection washer and the retaining

ring.

Shown in the figure Components,

lower arm shaft on page 246!

15. Refit the protection plug.

Shown in the figure Components,

lower arm shaft on page 246!

16. Proceed with the refitting procedure of the lower

arm, detailed in section Refitting, lower arm on
page 243.

250

3HAC 020938-001 Revision: C

4 Repair
4.4.6. Securing the lower arm

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

3HAC 020938-001 Revision: C

251

4 Repair
4.4.6. Securing the lower arm

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

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

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

3HAC 020938-001 Revision: C

4 Repair
4.4.6. Securing the lower arm

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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
Required equipment on page 252.

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.

3HAC 020938-001 Revision: C

253

4 Repair
4.4.6. Securing the lower arm

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).

Art. no. is specified in Required

equipment on page 252.
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

3HAC 020938-001 Revision: C

4 Repair
4.5.1. Replacement of SMB unit

4.5 Frame and base

4.5.1. Replacement of SMB unit
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.

Spare part no. Art. no.

SMB unit

3HAC 16014-1

Standard toolkit

Circuit Diagram

3HAC 020938-001 Revision: C

3HAC 15571-1

Note
The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
See chapter Circuit diagram in
the Product manual, reference
information.

255

4 Repair
4.5.1. Replacement of SMB unit

Removal, SMB unit

The procedure below details how to remove the SMB unit.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

Shown in the figure Location of

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.

Shown in the figure Location of

SMB unit on page 255!

3HAC 020938-001 Revision: C

4 Repair
4.5.1. Replacement of SMB unit

Refitting, SMB unit

The procedure below details how to refit the SMB unit.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

Shown in the figure Location of

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 .
equipment on page 255!
Shown in the figure Location of
SMB unit on page 255!
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.

Shown in the figure Location of

SMB unit on page 255!

8.

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:

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.

3HAC 020938-001 Revision: C

257

4 Repair
4.5.2. Replacement of brake release unit

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.

3HAC 020938-001 Revision: C

4 Repair
4.5.2. Replacement of brake release unit

Equipment, etc.

Art. no.

Note

Standard toolkit

3HAC 15571-1

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

Other tools and procedures may

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

These procedures include references

to the tools required.

Removal, brake release unit

The procedure below details how to remove the brake release unit.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 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.

3HAC 020938-001 Revision: C

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
4.5.2. Replacement of brake release unit

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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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

260

3HAC 020938-001 Revision: C

4 Repair
4.5.2. Replacement of brake release unit

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
Shown in the figure Location of brake
release unit on page 258!
Art. no. is specified in Required
equipment on page 258!

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

Shown in the figure Location of brake

release unit on page 258!

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.

Shown in the figure Location of brake

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.

3HAC 020938-001 Revision: C

261

4 Repair
4.5.2. Replacement of brake release unit

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

262

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.

3HAC 020938-001 Revision: C

4 Repair
4.5.3. Replacement of balancing device

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

3HAC 020938-001 Revision: C

263

4 Repair
4.5.3. Replacement of balancing device

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

3HAC 020938-001 Revision: C

4 Repair
4.5.3. Replacement of balancing device

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

To be replaced if damaged!

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.

Guide pins M16 x 300

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.

Lifting tool (chain)

3HAC 15556-1

Press tool, balancing

device

3HAC 020902-001

Puller tool, balancing

device shaft

3HAC 12475-1

Press tool, balancing

device shaft

3HAC 17129-1

Hydraulic cylinder

3HAC 11731-1

3HAC 020938-001 Revision: C

To be used with the press

and puller tools.

265

4 Repair
4.5.3. Replacement of balancing device

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 contents are defined in

section Standard toolkit in
the Product manual,
reference information!

Other tools and

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

These procedures include

references to the tools
required.

Removal, balancing device

The procedure below details how to remove the balancing device.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
Art. no. is specified in Required
equipment on page 265!

4.

Caution!
The balancing device weighs 210 kg! All lifting
equipment used must be dimensioned
accordingly!
5.

266

Apply the lifting eye or the shackle to the

balancing device, and raise to unload the
device.

Art. no. is specified in Required

equipment on page 265!
Attachments are shown in the figure
Attachment points, balancing
device on page 264.

3HAC 020938-001 Revision: C

4 Repair
4.5.3. Replacement of balancing device

Step

Action

Note/Illustration

6.

Unload the balancing device with the press

Art. no. is specified in Required
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
balancing device on page 271.

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
shown in the figure to the right.
Pull the shaft out using the puller tool and the
hydraulic pump.

Shown in the figure Location of

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.
Art. no. is specified in Required
equipment on page 265!
The hole in the frame is shown in
the figure Attachment points,
balancing device on page 264!
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

balancing device on page 275.
Shown in the figure Attachment
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

Shown in the figure Location of
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.
equipment on page 265!
13. Lift the balancing device gently backwards to
a secure area, allowing the bearing
attachments to slide on the guide pins.

3HAC 020938-001 Revision: C

Note! Make sure not to burden the

guide pins with the weight of the
balancing device!

267

4 Repair
4.5.3. Replacement of balancing device

Refitting, balancing device

The procedure below details how to refit the balancing device.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Secure the lower arm to the frame by

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

Art. no. is specified in Required

equipment on page 265!
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.

Shown in the figure Attachment

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.

Shown in the figure Location of

balancing device on page 263!

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.

Art. no. is specified in Required

equipment on page 265!
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.

3HAC 020938-001 Revision: C

4 Repair
4.5.3. Replacement of balancing device

Step

Action

Note/Illustration

10. Secure the rear of the balancing device by

Shown in the figure Location of
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.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints in the
Product manual, reference
information before fitting.
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

balancing device on page 271.
Art. no. is specified in Required
equipment on page 265!
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.

Art. no. is specified in Required

equipment on page 265!

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!
Art. no. is specified in Required
equipment on page 265!
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
Required equipment on page 265!

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

Required equipment on page 265!
Lubrication is further detailed in
section Lubrication, balancing
device bearing on page 179.

18. Restore the balancing device.

Detailed in section Restoring the

balancing device on page 275.

3HAC 020938-001 Revision: C

269

4 Repair
4.5.3. Replacement of balancing device

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!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

270

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.

3HAC 020938-001 Revision: C

4 Repair
4.5.4. Unloading the balancing device

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

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4 Repair
4.5.4. Unloading the balancing device

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.

Hydraulic pump, 80 MPa

3HAC 13086-1

To be used with the hydraulic cylinder.

Standard toolkit

3HAC 15571-1

The contents are defined in section

Standard toolkit in the Product
manual, reference information!

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

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4 Repair
4.5.4. Unloading the balancing device

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!

Art. no. is specified in Required

equipment on page 272!
See the figure Press tool and
hydraulic cylinder on page 271!

7.

Fit the hydraulic cylinder to the press tool.

Art. no. is specified in Required

equipment on page 272!
See the figure Press tool and
hydraulic cylinder on page 271!

8.

Connect the hydraulic pump to the cylinder.

Art. no. is specified in Required

equipment on page 272!

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4 Repair
4.5.4. Unloading the balancing device

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).

See the figure Press tool and

hydraulic cylinder on page 271!
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.
hydraulic cylinder on page 271!
11. Unload the hydraulic cylinder.
12. The hydraulic cylinder may now be removed
from the tool, when necessary.

274

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4 Repair
4.5.5. Restoring the balancing device

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

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4 Repair
4.5.5. Restoring the balancing device

Required equipment
The different designs of the balancing device are sealed in different ways beneath the rear
cover of the balancing device.

Equipment, etc.

Art. no.

Note

Hydraulic cylinder

3HAC 11731-1

To be used with press tool.

Hydraulic pump, 80 MPa

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

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

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.
hydraulic cylinder on page 275!

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

hydraulic cylinder on page 275!
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.

Shown in the figure Press tool and

hydraulic cylinder on page 275!

4.

Remove the hydraulic cylinder.

5.

Remove the press tool by unscrewing the

bolts.

Shown in the figure Press tool and

hydraulic cylinder on page 275!

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!

3HAC 020938-001 Revision: C

4 Repair
4.5.5. Restoring the balancing device

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
equipment on page 276.
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!

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4 Repair
4.6.1. Replacement of motor, axis 1

4.6 Motors
4.6.1. Replacement of motor, axis 1
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.

Spare part no. Art. no.

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.

3HAC 020938-001 Revision: C

4 Repair
4.6.1. Replacement of motor, axis 1

Equipment, etc.

Spare part no. Art. no.

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

For releasing the brakes.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in
the Product manual,
reference information!

Other tools and procedures

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

These procedures include

references to the tools
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!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.

3HAC 020938-001 Revision: C

Art. no. is specified in

Required equipment on
page 278!

279

4 Repair
4.6.1. Replacement of motor, axis 1

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.

Art. no. is specified in

Required equipment on
page 278!
Always use the removal
tools in pairs!

9.

Caution!
The motor weighs 25 kg! All lifting equipment used
must be dimensioned accordingly!
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!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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

Required equipment on
page 278!

3.

Caution!
The motor weighs 25 kg! All lifting equipment used
must be dimensioned accordingly!
4.

280

Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in
Required equipment on
page 278!

3HAC 020938-001 Revision: C

4 Repair
4.6.1. Replacement of motor, axis 1

Step

Action

Note/Illustration

5.

In order to release the brake, connect the 24 VDC

power supply.

Connect to connector
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!
13. Recalibrate the robot!

Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

3HAC 020938-001 Revision: C

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4 Repair
4.6.2. Replacement of motor axis 2

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)

3HAC 020938-001 Revision: C

4 Repair
4.6.2. Replacement of motor axis 2

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

Must be replaced when

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
For releasing the brakes.

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

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

These procedures include

references to the tools
required.

Circuit diagram

See chapter Circuit diagram in

the Product manual,
reference information.

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4 Repair
4.6.2. Replacement of motor axis 2

Removal, motor
The procedure below details how to remove the motor, axis 2.
Step

Action

Note

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

284

2.

Run the manipulator to a position close

Shown in the figure Location of
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.
equipment on page 283!

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

Shown in the figure Location of
exit by unscrewing its two attachment screws. motor on page 282!
Make sure the gasket is not
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.

Detailed in section Oil change,

gearbox axis 2 on page 160.

Connect to connector R2.MP2

+: pin 2
-: pin 5

10. Fit the two guide pins in two of the motor

attachment holes.

Art. no. is specified in Required

equipment on page 283!
Shown in the figure Location of
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.

Art. no. is specified in Required

equipment on page 283!
Shown in the figure Location of
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.

Art. no. is specified in Required

equipment on page 283!

3HAC 020938-001 Revision: C

4 Repair
4.6.2. Replacement of motor axis 2

Step

Action

Note

13.

Caution!
The motor weighs 27 kg! All lifting equipment
used must be dimensioned accordingly!
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.
Disconnect the brake release voltage.

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

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 Required

equipment on page 283!

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.
equipment on page 283!

5.

Fit the two guide pins in the two lower

motor attachment holes.

Art. no. is specified in Required

equipment on page 283!
Shown in the figure Location of motor on
page 282!

6.

Caution!
The motor weighs 27 kg! All lifting
equipment used must be dimensioned
accordingly!

3HAC 020938-001 Revision: C

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4 Repair
4.6.2. Replacement of motor axis 2

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
equipment on page 283!
(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

The rotation tool is used beneath the

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
screws and plain washers.

M10 x 40, tightening torque: 50 Nm.

Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints in the Product manual,
reference information before fitting.

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.

18. Refill the gearbox with oil.

Detailed in section Oil change, gearbox

axis 2 on page 160.

19. Recalibrate the robot.

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

3HAC 020938-001 Revision: C

4 Repair
4.6.2. Replacement of motor axis 2

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

3HAC 020938-001 Revision: C

287

4 Repair
4.6.3. Replacement of motor, axis 3

4.6.3. Replacement of motor, axis 3

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

Motor attachment holes (4 pcs)

Required equipment
Equipment, etc.

288

Spare part no. Art. no.

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

Must be replaced when

reassembling motor!

Grease

3HAB 3537-1

For lubricating the o-ring.

Removal tool, motor

M12x

3HAC 14631-1

Always use the removal tools

in pairs!

3HAC 020938-001 Revision: C

4 Repair
4.6.3. Replacement of motor, axis 3

Equipment, etc.

Spare part no. Art. no.

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

Guide pins M10 x 100

3HAC 15521-1

For guiding the motor.

Guide pins M10 x 150

3HAC 15521-2

For guiding the motor.

Rotation tool

3HAC 17105-1

Used to rotate the motor

pinion when mating it to the
gear, when brakes are
released with 24 VDC power
supply.

Power supply

24 VDC, max. 1.5 A

For releasing the brakes.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

These procedures include

references to the tools
required.

Circuit Diagram

See chapter Circuit diagram in

the Product manual,
reference information.

3HAC 020938-001 Revision: C

289

4 Repair
4.6.3. Replacement of motor, axis 3

Removal, motor
The procedure below details how to remove motor, axis 3.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

Drain the oil from gearbox axis 3.

4.

Remove any equipment hindering access to

motor axis 3.

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 Shown in the figure Location of
by unscrewing its two securing screws.
motor on page 288!
Make sure the gasket is not
damaged!

7.

Disconnect all connectors beneath the motor

cover.

8.

Release the brake by connecting the 24 VDC

Connect to connector R2.MP3
power supply.
+: pin 2
Make sure the weight of the complete upper 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 .

10. Fit the two guide pins in two of the motor

attachment screw holes.

290

Detailed in section Oil change,

gearbox, axis 3 on page 164.

Shown in the figure Location of

motor on page 288!
Art. no. is specified in Required
equipment on page 288!

3HAC 020938-001 Revision: C

4 Repair
4.6.3. Replacement of motor, axis 3

Step

Action

Note/Illustration

11. Press the motor out of position by fitting

removal tool, motor to the remaining motor
attachment screw holes.

Art. no. is specified in Required

equipment on page 288!
Always use the removal tools in
pairs!

12. Apply the lifting tool, motor axis 2 ,3, 4 to the

motor.

Art. no. is specified in Required

equipment on page 288!

13.

Caution!
The motor weighs 27 kg! All lifting equipment
used must be dimensioned accordingly!
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
The procedure below details how to refit motor, axis 3.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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

equipment on page 288!

3.

Fit the lifting tool, motor axis 2, 3, 4 to the

motor.

Art no. is specified in Required

equipment on page 288!

4.

Fit the two guide pins in the two lower

motor attachment holes.

Art no. is specified in Required

equipment on page 288!
Shown in the figure Location of motor
on page 288!

5.

Caution!
The motor weighs 27 kg! All lifting equipment
used must be dimensioned accordingly!

3HAC 020938-001 Revision: C

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4 Repair
4.6.3. Replacement of motor, axis 3

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.

Art no. is specified in Required

equipment on page 288!
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

The rotation tool is used beneath the

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
screws and plain washers.

4 pcs: M10 x 40, tightening torque: 50

Nm.

12. Disconnect the brake release voltage.

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!
with its two attachment screws.
Shown in the figure Location of motor
on page 288!
15. Refit the cover on top of the motor with its
four attachment screws.

Make sure the cover is tightly sealed!

16. Remove the equipment used to unload the

upper arm.

292

17. Perform a leak-down test.

Detailed in section Performing a leakdown test on page 196.

18. Refill the gearbox with oil.

Detailed in section Oil change,

gearbox, axis 3 on page 164.

3HAC 020938-001 Revision: C

4 Repair
4.6.3. Replacement of motor, axis 3

Step

Action

19. Recalibrate the robot!

Note/Illustration
Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are specified
in section Document references in the
Product manual, reference
information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

3HAC 020938-001 Revision: C

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4 Repair
4.6.4. Replacement of motor, axis 4

4.6.4. Replacement of motor, axis 4

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

Motor attachment holes (4 pcs)

Required equipment
Equipment, etc.

294

Spare part no. Art. no.

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

Must be replaced when

reassembling motor!

Grease

3HAC 3537-1

Used to lubricate the o-ring.

Removal tool, motor

M10x

3HAC 14972-1

Always use the removal tools

in pairs!

Guide pins M8 x 100

3HAC 15520-1

For guiding the motor.

Guide pins M8 x 150

3HAC 15520-2

For guiding the motor.

3HAC 020938-001 Revision: C

4 Repair
4.6.4. Replacement of motor, axis 4

Equipment, etc.

Spare part no. Art. no.

Note

Rotation tool

3HAC 17105-1

Used to rotate the motor

pinion when mating it to the
gear, when brakes are
released with 24 VDC power
supply.

Power supply

24 VDC, max. 1,5 A

For releasing the brakes.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

These procedures include

references to the tools
required.

Circuit Diagram

See chapter Circuit diagram

in the Product manual,
reference information.

Removal, motor
The procedure below details how to remove the motor, axis 4.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
of motor on page 294!
Make sure the gasket is not
damaged!

4.

Remove the cover on top of the motor by unscrewing

its four attachment screws.

5.

Disconnect all connectors beneath the motor cover.

3HAC 020938-001 Revision: C

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4 Repair
4.6.4. Replacement of motor, axis 4

Step

Action

Note/Illustration

6.

In order to release the brake, connect the 24 VDC

power supply.

Connect to connector
R2.MP4
+: pin 2
-: pin 5

7.

Unscrew the motors four attachment screws and

plain washers.

Shown in the figure Location

of motor on page 294!

8.

Fit the two guide pins, M8 in two of the motor

attachment screw holes.

9.

If required, press the motor out of position by fitting

removal tool, motor M10 to the motor attachment
screw holes.

Art. no. is specified in

Required equipment on
page 294!
Always use the removal
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
The procedure below details how to refit motor, axis 4.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

296

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 Required

equipment on page 294!

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

motor attachment holes.

Art. no. is specified in Required

equipment on page 294!
Shown in the figure Location of motor
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.

Make sure the motor pinion does not

get damaged!

3HAC 020938-001 Revision: C

4 Repair
4.6.4. Replacement of motor, axis 4

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.

Art. no. is specified in Required

equipment on page 294!
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

The rotation tool is used beneath the

motor cover, directly on the motor shaft
as shown in figure above.
A: Rotation tool.
7.

Remove the guide pins.

8.

Secure the motor with four attachment

screws and plain washers.

9.

Disconnect the brake release voltage.

4 pcs: M8 x 25, tightening torque: 24

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!
four attachment screws.
12. Refit the cable gland cover at the cable
exit with its two attachment screws.

Shown in the figure Location of motor

on page 294!

13. Perform a leak-down test if gearbox has

been drained.

Detailed in section Performing a leakdown test on page 196.

14. Refill the gearbox with oil if drained.

Detailed in section Filling, oil on page

169.

15. Recalibrate the robot!

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

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4 Repair
4.6.4. Replacement of motor, axis 4

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

298

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.

3HAC 020938-001 Revision: C

4 Repair
4.6.5. Replacement of motor, axis 5

4.6.5. Replacement of motor, axis 5

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.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

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 020938-001 Revision: C

3HAC 17484-10

299

4 Repair
4.6.5. Replacement of motor, axis 5

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

Must be replaced when

reassembling motor!

Grease

3HAC 3537-1

For lubricating the o-ring.

Isopropanol

1177 1012-208

For cleaning motor pinion and

motor pinion hole.

Mineral oil

CS 320

For lubrication of pinion shaft

and pinion hole.

Removal tool, motor

M10x

3HAC 14972-1

Always use the removal tools in

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

For guiding the motor.

Guide pins M8 x 150

3HAC 15520-2

For guiding the motor.

Power supply

24 VDC, 1.5 A
For releasing the brakes.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

These procedures include

references to the tools required.

Circuit Diagram

See chapter Circuit diagram in

the Product manual, reference
information.

3HAC 020938-001 Revision: C

4 Repair
4.6.5. Replacement of motor, axis 5

Removal, motor
The procedure below details how to remove motor, axis 5.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Drain the oil from gearbox axis 5.

Detailed in section Oil change,

gearbox, axis 5 on page 170.

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.

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.

7.

Disconnect all connectors beneath the motor

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.

Remove the motor by unscrewing its four

attachment screws and plain washers.

10. Fit the two guide pins in two of the motor

attachment screw holes.

Art. no. is specified in Required

equipment on page 299!

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!
attachment screw holes.
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.

Art. no. is specified in Required

equipment on page 299!
Make a note of the distance.

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4 Repair
4.6.5. Replacement of motor, axis 5

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
equipment on page 299.

Refitting, motor
The procedure below details how to refit motor, axis 5.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

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.

Art. no. is specified in Required

equipment on page 299!

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

Art. no. is specified in Required
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).

Art. no. is specified in Required

equipment on page 299!
Replacing the complete wrist unit is
detailed in section Replacement of
complete wrist unit on page 225.

3HAC 020938-001 Revision: C

4 Repair
4.6.5. Replacement of motor, axis 5

Step

Action

Note/Illustration

8.

In order to release the brake, connect the 24

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.

Art. no. is specified in Required

equipment on page 299!

10. Fit the motor, with guidance from the pins,

making sure the motor pinion is properly
mated to the gear of axis 5.

Make sure the motor pinion does not

get damaged!

11. Secure the motor with four attachment screws 4 pcs: M8 x 25; tightening torque: 24
and plain washers.
Nm.
12. Disconnect the brake release voltage.
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
with its two attachment screws.
15. Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
16. Perform a leak-down test.

Detailed in section Performing a

leak-down test on page 196.

17. Refit the wrist unit.

Detailed in section Refitting, wrist

unit on page 228.

18. Refill the gear with oil.

Detailed in section Oil change,

gearbox, axis 5 on page 170.

19. Recalibrate the robot.

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are
specified in section Document
references in the Product manual,
reference information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

3HAC 020938-001 Revision: C

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4 Repair
4.6.6. Replacement of motor, axis 6

4.6.6. Replacement of motor, axis 6

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

xx0200000222

304

Wrist unit

Motor, axis 6

3HAC 020938-001 Revision: C

4 Repair
4.6.6. Replacement of motor, axis 6

Required equipment
Equipment, etc.

Spare part no. Art. no.

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

Must be replaced when

reassembling motor!

Removal tool, motor

M10x

3HAC 14972-1

Always use the removal tools

in pairs!

Guide pins M8 x 100

3HAC 15520-1

For guiding the motor.

Guide pins M8 x 150

3HAC 15520-2

For guiding the motor.

Power supply

24 VDC, 1.5 A
For releasing the brakes.

Grease

3HAB 3537-1

For lubricating the o-ring.

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

These procedures include

references to the tools
required.

Circuit Diagram

See chapter Circuit diagram in

the Product manual, reference
information.

3HAC 020938-001 Revision: C

305

4 Repair
4.6.6. Replacement of motor, axis 6

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

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

Remove the motor by unscrewing its four

attachment screws and plain washers.

7.

If required, press the motor out of position by fitting

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.

Art. no. is specified in Required

equipment on page 305!
Always use the removal tools in
pairs!

Refitting, motor
The procedure below details how to refit motor, axis 6.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.

3HAC 020938-001 Revision: C

4 Repair
4.6.6. Replacement of motor, axis 6

Step

Action

Note/Illustration

3.

In order to release the brake, connect the 24

VDC power supply.

Connect to connector R3.MP6

+: pin 2
-: pin 5

4.

Fit the two guide pins in two of the motor

attachment holes.

Art. no. is specified in Required

equipment on page 305!

5.

Fit the motor, with guidance from the pins,

making sure the motor pinion is properly
mated to the gear of gearbox, axis 6.

Make sure the pinion on the motor

shaft is not damaged!

6.

Remove the guide pins.

7.

Secure the motor with its four attachment

screws and plain washers.

8.

Disconnect the brake release voltage.

9.

Reconnect all connectors beneath the motor

cover.

4 pcs: M8 x 25, tightening torque: 24

Nm.

10. Refit the cover on top of the motor with its six Make sure the cover is tightly
attachment screws.
sealed!
11. Perform a leak-down test.

Detailed in section Performing a

leak-down test on page 196.

12. Recalibrate the robot.

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are
specified in section Document
references in the Product manual,
reference information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

3HAC 020938-001 Revision: C

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4 Repair
4.7.1. Replacement of gearbox, axis 1

4.7 Gearboxes
4.7.1. Replacement of gearbox, axis 1
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

xx0300000015

308

Gearbox, axis 1

Frame

Base

Attachment screws, gearbox axis 1 (not shown in figure)

3HAC 020938-001 Revision: C

4 Repair
4.7.1. Replacement of gearbox, axis 1

Required equipment
Equipment, etc.

Spare part no. Art. no.

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

Replace only when damaged!

Sealing ring

3HAC 11581-4

Replace only when damaged!

Grease

3HAC 3537-1

For lubricating the o-rings.

Support, base

3HAC 15535-1

Lifting device, base

3HAC 15560-1

Lifting tool (chain)

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.

3HAC 020938-001 Revision: C

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!
These procedures include
references to the tools required.

309

4 Repair
4.7.1. Replacement of gearbox, axis 1

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.

Art. no. is specified in Required equipment

on page 309!

9.

Caution!
The base (without gearbox 1) weighs
263 kg! All lifting equipment used must
be dimensioned accordingly!

310

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4 Repair
4.7.1. Replacement of gearbox, axis 1

Step

Action

10. Lift the manipulator base to allow

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

Note/Illustration
Art. no. is specified in Required equipment
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

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4 Repair
4.7.1. Replacement of gearbox, axis 1

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
equipment used must be dimensioned
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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,
gearbox axis 1 on page 310.

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4 Repair
4.7.1. Replacement of gearbox, axis 1

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!

Art no. is specified in Required

equipment on page 309!

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.
equipment on page 309!

6.

Caution!
The gearbox weighs 160 kg! All lifting
equipment used must be dimensioned
accordingly!
7.

3HAC 020938-001 Revision: C

Lift the gearbox to its mounting position in

the center of the base.

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4 Repair
4.7.1. Replacement of gearbox, axis 1

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 .
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints in the Product manual,
reference information before fitting.

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
dimensioned accordingly!

314

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4 Repair
4.7.1. Replacement of gearbox, axis 1

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.
16. Perform a leak-down test.

Detailed in section Performing a leakdown test on page 196.

17. Refill the gearbox with oil.

Detailed in section Oil change, gearbox

axis 1 on page 156.

18. Recalibrate the robot.

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

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4 Repair
4.7.2. Replacement of gearbox axis 2

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.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

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

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4 Repair
4.7.2. Replacement of gearbox axis 2

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

For guiding the gearbox.

Press tool, balancing

device

3HAC 020902-001

Hydraulic cylinder

3HAC 11731-1

To be used with the press

tool and the hydraulic
pump, when unloading the
balancing device.

Hydraulic pump, 80
MPa

3HAC 13086-1

To be used with the press

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.

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4 Repair
4.7.2. Replacement of gearbox axis 2

Equipment

Spare part no.

Standard toolkit

Art. no.

Note

3HAC 15571-1

The contents are defined in

section Standard toolkit in
the Product manual,
reference information!

Other tools and

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

These procedures include

references to the tools
required.

Removal, gearbox
The procedure below details how to remove the gearbox, axis 2.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!

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
Required equipment on
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.

Remove the motor, axis 2.

Detailed in section Removal,

motor on page 284.

6.

Remove the rear attachment screws, gearbox from

inside of the lower arm.

Shown in the figure Location

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.
Shown in the figure Location
of gearbox on page 316!

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4 Repair
4.7.2. Replacement of gearbox axis 2

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.

Art. no. is specified in

Required equipment on
page 317!

12.

Caution!
The gearbox weighs 53 kg! All lifting equipment used
must be dimensioned accordingly!
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.

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4 Repair
4.7.2. Replacement of gearbox axis 2

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

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.

Art. no. is specified in

Required equipment on
page 317!

xx0200000173

3.

320

Fit the lifting tool, gearbox axis 2 to the gearbox.

A: O-ring, gearbox
axis 2

Art. no. is specified in

Required equipment on
page 317!

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4 Repair
4.7.2. Replacement of gearbox axis 2

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.
Required equipment on
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
Required equipment on
front attachment screws.
page 317!

7.

Fit the cleaned friction washer onto the guide pins,

M12.

8.

Caution!
The gearbox weighs 53 kg! All lifting equipment used
must be dimensioned accordingly!
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
Required equipment on
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!

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4 Repair
4.7.2. Replacement of gearbox axis 2

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.
Tightening torque: 115 Nm.
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,
tightening torque: 115 Nm.
Art. no. is specified in
Required equipment on
page 317!
Attachment screws, cover:
15 pcs: M8 x 25, tightening
torque: 24 Nm.
Shown in the figure Location
of gearbox on page 316.

15. Insert and secure 31 of the 33 rear attachment

screws, gearbox on the inside of the lower arm.

Shown in the figure Location

of gearbox on page 316!
33 pcs: M12 x 50, 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
Product manual, reference
information before fitting.

16. Remove the guide pins, sealing axis 2/3, and tighten
the two remaining screws as detailed above.
17. Refit the motor.

Detailed in section Refitting,

motor on page 285.

18. Perform a leak-down test.

Detailed in section
Performing a leak-down test
on page 196.

19. Refill the gearbox with oil.

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

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4 Repair
4.7.2. Replacement of gearbox axis 2

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.
25. Recalibrate the robot.

Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

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4 Repair
4.7.3. Replacement of gearbox, axis 3

4.7.3. Replacement of gearbox, axis 3

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

xx0200000194

324

Gearbox, axis 3

Motor, axis 3

Upper arm

Attachment screws, gearbox (24 pcs)

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4 Repair
4.7.3. Replacement of gearbox, axis 3

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

Guide pins M12 x 200

3HAC 13056-3

For guiding the gearbox.

Use guides in pairs!

Guide pins M12 x 250

3HAC 13056-4

For guiding the gearbox.

Use guides in pairs!

Guide pins, sealing

ax 2/3, 80mm

3HAC 14628-1

For guiding the sealing, axis

2/3.
Use guides in pairs!

Guide pins, sealing

ax 2/3, 100mm

3HAC 14628-2

For guiding the sealing, axis

2/3.
Use guides in pairs!

Standard toolkit

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

3HAC 020938-001 Revision: C

These procedures include

references to the tools
required.

325

4 Repair
4.7.3. Replacement of gearbox, axis 3

Removal, gearbox
The procedure below details how to remove gearbox, axis 3.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Secure the upper arm in a horizontal position Art. no. is specified in Required
using a mechanical stop.
equipment on page 325.
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.

Remove the motor, axis 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
equipment on page 325!
holes.

Shown in the figure Location of

gearbox on page 324!

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4 Repair
4.7.3. Replacement of gearbox, axis 3

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
used must be dimensioned accordingly!
12. Remove the gearbox, with guidance from the
guide pins, using an overhead crane or similar.

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4 Repair
4.7.3. Replacement of gearbox, axis 3

Refitting, gearbox
The procedure below details how to refit gearbox, axis 3.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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
Required equipment on
attachment screws.
page 325!

4.

Caution!
The gearbox weighs 60 kg! All lifting equipment used
must be dimensioned accordingly!
5.

Fit the lifting eye, M12 to the gearbox.

Art. no. is specified in

Required equipment on
page 325!

6.

Make sure the o-rings are fitted to the gearbox.

Art. no. is specified in
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

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4 Repair
4.7.3. Replacement of gearbox, axis 3

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.

Tightening torque: 115 Nm.
Reused screws may be
used, providing they are
lubricated as detailed in
section Screw joints in the
Product manual, reference
information before fitting.

12. Refit the upper arm with a new sealing, axis 2/3 .

Art. no. is specified in

Required equipment on
page 325!
Detailed in section Refitting,
upper arm on page 235!

13. Refit the motor.

Detailed in section Refitting,

motor on page 291.

14. Remove the mechanical stop used to secure the

upper arm.
15. Recalibrate the robot!

Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

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4 Repair
4.7.4. Replacement of gearbox, axis 6

4.7.4. Replacement of gearbox, axis 6

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions result in two different designs of the gearbox.

xx0300000555

330

Gearbox, axis 6

Attachment screws and washers, gearbox for robot version IRB 6600 - 175/2.55
(8 pcs)

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4 Repair
4.7.4. Replacement of gearbox, axis 6

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!

Replace only when damaged!

O-ring

3HAB 3772-58
/3HAB 3772-57

Must be replaced when

reassembling gearbox!

Grease

3HAB 3537-1

For lubricating o-ring.

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4 Repair
4.7.4. Replacement of gearbox, axis 6

Equipment, etc.

Spare part no.

Standard toolkit

Art. no.

Note

3HAC 15571-1

The contents are defined in

section Standard toolkit in the
Product manual, reference
information!

Other tools and

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

These procedures include

references to the tools required.

Removal, gearbox
The procedure below details how to remove gearbox, axis 6.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

332

2.

Drain the oil from gearbox, axis 6.

Detailed in section Oil change, gearbox

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!

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4 Repair
4.7.4. Replacement of gearbox, axis 6

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
The procedure below details how to refit gearbox, axis 6.
Step

Action

Note/Illustration

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

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4 Repair
4.7.4. Replacement of gearbox, axis 6

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
equipment on page 331!
grease.

xx0100000132

334

A: O-ring, gearbox axis 6

3.

Insert the gearbox, axis 6 into the wrist

unit.

Art. no. is specified in Required

equipment on page 331!
Shown in the figure Location of
gearbox on page 330!
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
UNBRAKO, tightening torque: 30 Nm.
Reused screws may be used, providing
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.

Detailed in section Performing a leakdown test on page 196.

7.

Refill the gearbox with oil.

Detailed in section Oil change, gearbox

axis 6 on page 173.

8.

Recalibrate the robot.

Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

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4 Repair
4.7.4. Replacement of gearbox, axis 6

DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:

all the service tools and other foreign objects are removed from the manipulator!

all normal safety equipment is installed properly, e.g. TPU enabling device.

all personnel 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.

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4 Repair
4.7.4. Replacement of gearbox, axis 6

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5 Calibration information
5.1. Introduction

5 Calibration information
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.

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5 Calibration information
5.2. Calibration methods

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

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5 Calibration information
5.2. Calibration methods

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.

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5 Calibration information
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

Calibration scale, axis 2 (early design)

B2

Calibration mark, axis 2 (later design)

C1

Calibration scale, axis 3 (early design)

C2

Calibration mark, axis 3 (later design)

Calibration scale, axis 4

Calibration scale, axis 5

Calibration scale, axis 6

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

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5 Calibration information
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

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5 Calibration information
5.5. Updating revolution counters

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

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5 Calibration information
5.5. Updating revolution counters

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.

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5 Calibration information
5.5. Updating revolution counters

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

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5 Calibration information
5.5. Updating revolution counters

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.

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5 Calibration information
5.6. Checking the calibration position

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.

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.

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5 Calibration information
5.6. Checking the calibration position

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
correctly. If they do not, update the revolution
shown in section Calibration
counters!
scales and correct axis
position on page 340.
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.

Check that the calibration marks for the axes align

correctly. If they do not, update the revolution
counters!

3HAC 020938-001 Revision: C

Note

The calibration marks are

shown in section Calibration
scales and correct axis
position on page 340.
How to update the counters
is detailed in section
Updating revolution counters
on page 342.

347

5 Calibration information
5.6. Checking the calibration position

348

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6 Decommissioning
5.6. Checking the calibration position

6 Decommissioning

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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.

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6 Decommissioning
6.2. Decommissioning of balancing device

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

The contents are defined in section

Standard toolkit in the Product manual,
reference information!

Cutting torch

For opening housing and cutting coils

Other tools and procedures may

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

These procedures include references

to the tools required.

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.

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6 Decommissioning
6.2. Decommissioning of balancing device

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.

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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

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353