IRC5-IRB7600 Prod Man Part13HAC022033-001 Procedures RevB en

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Product manual (part 1 of 2), procedures

IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
IRB 7600 - 150/3.5
M2000
M2000A
M2004
Document ID: 3HAC 022033-001
Revision: B
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Safety
11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.4.3 Emergency release of the robots arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.3 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 34
1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.6 WARNING - Mixed oils may cause severe damage to gearbox! . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Installation and commissioning
39
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.2.2 Working range, IRB 7600 - 150/3.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2.3 Working range, IRB 7600 - 340/2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2.4 Working range, IRB 7600 - 400/2.55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2.5 Working range, IRB 7600 - 500/2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.6 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 On-site Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.2 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3.3 Lifting manipulator with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3.5 Manually releasing the brakes, external brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3.6 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3.7 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3HAC 022033-001 Revision: B
Table of Contents
2.3.8 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.9 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.10 Installation of chip and dust protection (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.11 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
75
80
88
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
90
92
94
96
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.5.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3 Maintenance
103
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.2 Maintenance schedule and expected life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.9 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.10 Inspection, mechanical stop, axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.11 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.12 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.13 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.14 Inspection, UL-lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
112
115
118
121
124
126
132
135
137
139
141
145
148
3.4 Changing/replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150
154
158
161
164
168
172
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.5.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.6.1 Flushing a contaminated gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.6.2 Cleaning, manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.7 Service Information System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3.7.2 Description of Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3.7.3 SIS system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3.7.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.7.5 Reading the SIS output logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Table of Contents
3.7.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

4 Repair
193
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

4.3.2 Replacement of cable harness, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.3.3 Removal of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.3.4 Refitting of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.4.1 Removal of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.4.2 Refitting of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.4.3 Removal of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.4.4 Refitting of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.4.5 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.4.6 Refitting of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.5.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

4.5.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

4.6.2 Refitting of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.6.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.6.4 Refitting of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.6.5 Removal of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.6.6 Refitting of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.6.7 Unloading the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.6.8 Restoring the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

4.7.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
4.7.10 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
4.7.11 Removal of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
4.7.12 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
4.8.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

4.8.2 Removal of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.8.3 Refitting of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Table of Contents
4.8.8 Removal of gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.9 Refitting of gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.10 Removal of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.11 Refitting of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Calibration information
365
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Decommissioning
350
354
360
362
365
366
368
369
370
374
377
6.1 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

6.2 Decommissioning of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Overview
Overview
About this manual
This manual contains instructions for
installing the manipulator, mechanically as well as electrically
maintenance of the manipulator
mechanical and electrical repair of the manipulator.
Usage
This manual should be used during
installation, from lifting the manipulator to its work site and securing it to the
foundation to making it ready for operation
maintenance work
repair work.
Who should read this manual?

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

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

ranges, lifting instructions, on-site installation, fitting of extra
equipment, etc.
Maintenance
Information about maintenance work, including maintenance

schedules.
Repair
Information about repair work. Each procedure include necessary

spare parts, tools, etc.
Calibration information
Procedures that do not require specific calibration equipment.

General information about calibration.
Decommissioning
Environmental information about the manipulator.
Revisions
Revision
Description
First edition.
Replaces previous manuals:
Installation and Commissioning Manual
Maintenance Manual
Repair Manual, part 1
Repair Manual, part 2.
Changes made in the material from the previous manuals:
Model M2004 implemented.
Various corrections due to technical revisions, changes in the toolkits
etc.
Chapter Calibration replaced with chapter Calibration information.

Following corrections are made:
In chapter 3: Maintenance in section Exporting the SIS data, the unit
seconds for different SIS parameters is replaced by the unit hours. The
change is only valid for RobotWare release 5.0.
Following updates are made:
In chapter 4: Repair, the sections Removal of complete lower arm and
Refitting of complete lower arm are completed with more detailed
information about how to use the glycerin pump.
New lubricating oil in the gearboxes. Changes 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.
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:
10
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.
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:
Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)
11
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
13.
12
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 14.
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 33.
13
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.
14
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
Signal lamp (optional)
1 Safety
1.2.2.1. Safety, service
1.2.2. General information

1.2.2.1. Safety, service
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. Users Guide and Product
Manual.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for
connecting safety devices between the robot and the peripheral equipment.
15
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.
16
1 Safety
1.2.2.3. Related information
1.2.2.3. Related information

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

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

manipulator
Installation and commissioning
17
1 Safety
1.2.3.1. Safety risks during service work on robot
1.2.3. Safety risks

Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.
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!
18
1 Safety
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!
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!
19
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.
20
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.
21
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
22
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.
23
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
24
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
1 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.
25
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.
26
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)!
27
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 63.
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!
28
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.
29
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.
30
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:
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.
31
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:
32
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 29.
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions

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

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

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

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

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

are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
danger
warning
Electrical shock
caution
33
1 Safety
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates

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

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

to find additional information or how to perform a
certain operation in an easier way.
Note
Tip
34
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
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.
35
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
36
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!
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
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.
37
1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

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

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

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

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

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

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

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

cold oil.
When changing gearbox oil, first

run the robot for a time to heat
up the oil.
Do not mix types of oil!
Heat up the oil!
38
1 Safety
Warning
Specified amount
depends on drained
volume!
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.
39
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
Note
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.
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
1.
40
Action
Note
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.

2.1. Introduction

2.1. Introduction
General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
41

2.2.1. Pre-installation procedure
2.2 Unpacking
General
This instruction is primarily intended for use when unpacking and installing the manipulator
(mechanical robot) for the first time. It also contains information useful during later reinstallation of the manipulator.
Checking the pre-requisites for installation
The checklist below details what must be observed before proceeding with the actual
installation of the manipulator:
Step
42
Action
Info/Illustration
1.
Make sure only qualified installation personnel

conforming to all national and local codes are allowed
to perform the installation.
2.
Make sure the manipulator has not been damaged,

by visually inspecting the manipulator and control
cabinet exterior.
3.
Make sure the lifting device used is dimensioned to

handle the weight of the manipulator.
4.
If the manipulator is not to be installed directly, it must Specified in Storage

be stored.
conditions, manipulator on
page 44.
5.
Make sure the appointed operating environment of

the manipulator conforms to the specifications.
Specified in Operating
conditions, manipulator on
page 44.
6.
Before taking the manipulator to its installation site,

make sure the site conforms to the demands.
Specified in Loads on
foundation, manipulator on
page 43, Requirements on
foundation, manipulator on
page 43 and Protection
classes, manipulator on
page 44Protection classes,
manipulator on page 44
respectively.
7.
Before moving the manipulator, please observe the

risk of tipping!
Described in Risk of tipping /

stability on page 49.
8.
When these prerequisites have been met, the

manipulator may be taken to its installation site.
Specified in Lifting robot with

fork lift on page 50.
Specified in Weight,
manipulator on page 43.

Weight, manipulator
The table below shows the weights of the different models (without DressPack):
Manipulator model
Weight
IRB 7600 - 500/2.3
2400 kg
IRB 7600 - 400/2.55
2400 kg
IRB 7600 - 340/2.8
2450 kg
IRB 7600 - 150/3.5
2450 kg
Loads on foundation, manipulator

The table below shows the different forces and torques working on the manipulator 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
14000 N
31000 N
Force z
32000 10000 N
39000 16000 N
Torque xy
42000 Nm
72000 Nm
Torque z
11000 Nm
19500 Nm
Requirements on foundation, manipulator

The table below shows the requirements for the foundation where the manipulator is to be
fitted:
Requirement
Value
Min. levelness
0.5 mm
Max. tilt
Min. resonance
frequency
22 Hz
Note
The limit for the maximum payload on the
manipulator is reduced if the manipulator is
tilted from 0.
Contact ABB for further information about
acceptable payload.
43

Storage conditions, manipulator

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

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

The table below shows the protection class of the manipulator:
44
Equipment
Protection class
Manipulator, IRB 7600
IP 67

2.2.2. Working range, IRB 7600 - 150/3.5

Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5:
xx0100000101
45


Illustration
xx0300000296
46


Illustration
xx0100000100
47


Illustration
en0100000099
48

2.2.6. Risk of tipping / stability
2.2.6. 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!
49

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

General
The robot may be moved using a fork lift, provided that available special aids are used.
This section describes how to attach the fork lift equipment to the robot.
Different designs
There are two different versions of the fork lift that fit one design of the frame respectevily.
The different designs of the frame and of the fork lift attachments are shown in the figure
below. Determine which fork lift set fits the current robot.
Note! The distance between the attachment holes for the fork lift pockets, shown in the figure
below, are different depending on the design of the frame. This means that the fork lift sets
are unique for one type of frame and not compatible!
Except for the shorter distance between the attachment holes, the later design of the frame
also includes an extra oil plug, located as shown in the figure below.
xx0200000386
50
Frame version without an oil plug, use the fork lift set: 3HAC 0604-2
Frame version with an oil plug (C), use the fork lift set: 3HAC 0604-1
Attachment holes, fork lift 3HAC 0604-2
Attachment holes, fork lift 3HAC 0604-1
Oil plug

Attachment points
The attachment points for the fork lift equipment are shown in the figure below.
xx0400000707
Attachment points, spacer and horizontal attachment screws
Attachment points, horizontal attachment screws
Attachment points, vertical attachment screws
Attachment points, horizontal attachment screws
Required equipment
To determine which fork lift set to use, see the section Different designs on page 50.
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 52.
Fork lift set, incl. all required 3HAC 0604-1

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

on page 53.
51

Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 1557-1
The contents are defined in section

Standard toolkit in the Product manual,
reference information!
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
52
Vertical attachment screws (4 pcs / fork lift pocket)
Fork lift pockets (2 pcs)
Spacer (2 pcs)

Fork lift set, 3HAC 0604-1

The fork lift set, 3HAC 0604-1, is fitted to the robot as shown in the figure below.
xx0200000379
Fork lift pocket (2 pcs, different from each other)
Spacer (2 pcs)
Horizontal attachment screws (4 pcs / fork lift pocket)
Vertical attachment screws (2 pcs)
53

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 63.
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!
xx0200000387
3.
54
Fit the two spacers to the robot and

secure.
Attachment points on the robot are

shown in the figure Attachment points
on page 51.

Step
Action
Info/Illustration
4.
Caution!
Caution!
The fork lift pocket weighs 60 kg!
5.
Secure the longer fork lift pocket to the

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

always used (or replacements of
equivalent quality: M16, quality 12.9)!
on page 51.
xx0400001068
6.
A: horizontal attachment
screws, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
B: spacers, 2 pcs.
Make sure the securing screw is removed

from the fork lift pocket!
It is only used for robot model IRB 6650S.
xx0400000977
A: securing screw
55

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

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

pcs, M16x60; tightening torque:
270 Nm.
on page 51.
8.
Caution!
Caution!
The fork lift pocket weighs 22 kg!
9.
Secure the shorter fork lift pocket on the

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

Nm.
on page 51.
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!
56

Step
Action
Info/Illustration
11.
Caution!
Caution!
The robot weighs 2550 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!
57

2.3.2. 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
58
Load hook
Swivelling lifting eyes, 4 pcs
Shortening hook
Chain
M12 lifting eye
Lifting devices eye
Lifting slings, 4 pcs
Hook

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

The section below details how to lift and move the robot using lifting slings when these are
attached directly onto the robot frame.
Step
Action
Note
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.
3.
Fit the lifting device, manipulator to the Art. no. is specified in Required
robot as described in the enclosed
equipment on page 59!
instruction!
Release the brakes if required as detailed

in section Manually releasing the brakes
on page 63.
xx0100000103
4.
Caution!
Caution!
The robot weighs 2550 kg! All lifting
accordingly!
59

Step
Action
Note
5.
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under the
suspended load!
6.
60
Raise the overhead crane to lift the

robot.
Make sure all hooks and attachments

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

2.3.3. Lifting manipulator with roundslings

General
The figure below shows how to lift the complete manipulator with roundslings.
Note the recommended manipulator position shown in the figure below!
Roundslings attached to the manipulator
xx0200000315
Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m)
Roundsling, 1000 kg, 2 pcs
Roundsling, 2000 kg, 3 pcs (4 m)
Required equipment
Equipment
Note
Chain sling with shortener, 4250 kg, 3 pcs
Lengths: 0.5 m (2 pcs), 0.265 m (1 pc).
Roundslings, 1000 kg, 2 pcs

Roundslings, 2000 kg, 3 pcs
Lengths: 4 m (3 pcs).
61

Safety information
Read the safety information before lifting the manipulator!
CAUTION!
The manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
Slings attached directly on to manipulator
The section below details how to attach roundslings to the manipulator in order to lift the
complete robot.
Step
Action
1.
Note
Recommended manipulator
position is described in section
Risk of tipping / stability on page
49.
Caution!
Attempting to lift a manipulator in any other

position than the recommended may result in
the manipulator tipping over and causing
severe damage or injury!
62
2.
Run the overhead crane to a position above the

manipulator.
3.
Attach the three chain slings with shorteners to Shown in the figure Roundslings
the overhead crane hook.
attached to the manipulator on
page 61!
Lengths are specified in Required
4.
Fit the three roundslings, 2000 kg to the robot. Shown in the figure Roundslings
Attach the roundslings to the chain slings
hanging from the overhead crane.
page 61!
Lengths are specified in Required
5.
Attach the two roundslings, 1000 kg to the

upper arm and the overhead crane hook!
Shown in the figure Roundslings

page 61!
6.
Raise the overhead crane to lift the robot.
Make sure all hooks and

attachments maintain correct
position while lifting the
manipulator!
Always move the manipulator at
very low speeds, making sure it
does not tip.

2.3.4. Manually releasing the brakes

General
This section details how to release the holding brakes of each axis motor.
The brakes may be released by:
Internal brake release unit: using push buttons on the robot. This requires either the
controller to be connected or that power is supplied to the R1.MP connector, according
to section Supplying power to connector R1.MP on page 65.
External brake release unit: using push buttons on an external brake release unit. This
does NOT require the controller to be connected. The external unit is used when there
are no push buttons on the robot. Read about how to use the external brake release unit
in section Manually releasing the brakes, external brake release unit on page 66
Location of brake release unit at base

The internal brake release unit is located either at the base or at the frame. The figure below
shows the unit located at the base.
xx0200000375
Internal brake release unit with push buttons, located on the robot base
63

Location of brake release unit at frame

The internal brake release unit is located either at the base or at the frame. The figure below
shows the unit located at the frame.
xx0200000376
Internal brake release unit with push buttons, located on the robot frame
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 65.
The buttons are shown

in the figure Location of
brake release unit at
base on page 63 or
Location of brake
release unit at frame on
page 64.
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!
3.
64
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
65

2.3.5. Manually releasing the brakes, external brake release unit

General
The section below details how to release the holding brakes of each axis motor using push
buttons on an external brake release unit. This does not require the controller to be connected.
When to use the external brake release unit
The external brake release unit must only be used when the manipulator does not have an
internal brake release unit (when there are no push buttons on the manipulator).
Internal brake release unit
How to use the internal brake release unit, if available, is detailed in section Manually
releasing the brakes on page 63.
Required equipment
Equipment
Art. no.
External brake release unit
3HAC 12987-1
Connections, manipulator
The illustration below shows where to connect the external brake release unit in order to
release the holding brakes of the manipulator.
xx0100000104
66
Connector R1.BU
Rear connector plate
Rear cover plate

Connectors, external brake release unit

The illustration below shows the connectors on the manipulator and on the external brake
release unit.
xx0200000081
Rear connector plate
Connector R1.MP
Connector R1.BU
Connect to R1.BU
Releasing the brakes

This section describes how to release the holding brakes when the manipulator is equipped
with an external brake release unit.
DANGER!
When releasing the holding brakes, the manipulator axes may move very quickly and
sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Step
Action
Note/Illustration
1.
Remove the rear cover plate from the base of the

Shown in the figure
manipulator by unscrewing its attachment screws and Connections, manipulator
plain washers.
on page 66.
2.
Locate the free connector, connected to the rear of

connector R1.MP, behind the rear connector plate.
Make sure it is designated R1.BU.
Shown in the figure

Connectors, external brake
release unit on page 67.
67

Step
68
Action
Note/Illustration
3.
Connect the external brake release unit to the

connector R1.BU.
Art. no. is specified in

section Required equipment
on page 66.
4.
Release the holding brake of each manipulator axis

by pressing the respective button on the external
brake release unit.
5.
Disconnect the external brake release unit.
6.
Refit the rear cover plate with its attachment screws.

2.3.6. Lifting the base plate
2.3.6. Lifting the base plate

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

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

device.
Shown in the figure Hole

configuration on page 69!
69

2.3.7. Securing the base plate

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

xx0400000715
Note1
Four holes for alternative clamping

71

Base plate, grooves and holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.
xx0300000045
Guide sleeve holes (2 pcs)
Orienting grooves (3 pcs)
Levelling bolts, attachment holes (4 pcs)
Required equipment
Equipment
Art. no.
Note
Base plate
3HAC 12937-7
Includes
guide sleeves, 3HAC 12937-3
levelling screws, 9ADA 120-79
attachment screws and
washers for securing the
manipulator to the base plate.
A drawing of the base plate itself may
be ordered from ABB Robotics!
Standard toolkit
3HAC 15571-1

Other tools and procedures may

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

to the tools required.

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

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

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

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

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

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

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

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

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

screws and sleeves.
8.
Recheck the four manipulator contact

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

2.3.8. 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.
xx0100000107
Robot attachment bolts and washers, 12 pcs (M24 x 140)
Orienting grooves in the robot base and in the base plate
Levelling screws
Base plate attachment screws
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
robot to the base plate/foundation.
74
Suitable screws, lightly lubricated:
M24 x 140
Quality:
Quality 8.8
Suitable washer:
Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque:
725 Nm

Securing the robot

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

lifting slings on page 58.
2.
Move the robot to the vicinity of its

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

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

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

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

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

attachment holes.
Specified inAttachment 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.
xx0300000046
75

Cross section, guide sleeve hole

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

2.3.9. 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!
xx0100000115
77

xx0100000120
Illustration, fitting of extra equipment on upper arm

upper arm.
xx0100000116
78

xx0300000299
Illustration, fitting of extra equipment on frame

frame.
xx0100000117
79

xx0100000118
80

Illustration, fitting on mounting flange

The illustration below shows the mounting holes available for fitting equipment on the
mounting flange.
xx0100000119
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.
81

2.3.10. 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
82
Bearing unit, lower arm shaft
Bearing unit, axis 2 motor
Stop
Shield (4 pcs)
Cover, balancing device
Sliding cover
Cover, lower arm

Required equipment
Equipment
Art. no.
Note
Chip and dust protection
3HAC 020529-004
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 82
83

Step
Action
2.
Remove the attachment plate

from the bearing unit and fit the
unit to the robot by passing the
motor cabling through the
opening of the package of rings.
Refit the attachment plate and
attach the bearing unit as
described in next step.
3.
Attach the bearing unit, axis 2

motor in the existing M10 holes
(A) in the frame with 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).
Illustration
xx0400001096
xx0400001095
xx0400001079
Attachment screws: 2 pcs, M10 x 50.

Also shown in the figure Illustration, equipment
mounted on robot on page 82
84

Step
4.
Action
Illustration
Remove the securing screws that

are fitted to the bearing unit
during transport and installation.
The separate rings are now
movable.
xx0400001098
5.
Fit the stop to the robot. Use the

enclosed attachment screws.
xx0400001081
6.
C: Attachment screws: 2 pcs, M6x25.
Remove the rear bracket from the

upper shield.
xx0400001099
85

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.
xx0400001083
8.
D: Attachment screws, 2 pcs, M12 x 20

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

attachment screws (shown in the
figure to the right) from the rear
cover of the balancing device.
xx0400001086
86

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 83
10.
Fit the sliding cover to the robot.
xx0400001087
J: Bushing
K: Hub
87

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
88
1.
2.
3.
4.
Shields
Stop
Remove the sliding cover.

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

Part to be removed
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.
89

2.3.11. Loads
2.3.11. 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.
90

2.4.1. Introduction
2.4 Restricting the working range

2.4.1. Introduction
General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited.
The working range of following axes may be restricted:
Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
switch)
switch)
As standard configuration, axis 1 is allowed to move 180. The working range may however
be increased to 220 with option 561-1 "Extended working range axis 1". Notice that this
option also requires installation of a position switch on axis 1.
This section describes how to install hardware that restricts the working range.
Notice that adjustments must be made also in the software, references to software manuals
are given in following installation procedures.
91

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
92
Equipment, etc.
Art. no.
Note
Mechanical stop for axis 1, 7.5
3HAC 11076-1
Includes attachment screws and an

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

assembly drawing.
Standard toolkit
3HAC 15571-1

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

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

Document references in the Product
manual, reference information.

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 92.
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!
93


General
adding up to six additional mechanical stops with 15 graduation in respective direction.
xx0300000047
Additional mechanical stops
Required equipment
Equipment, etc.
Art. no.
Mechanical stop set, axis 2
3HAC 11077-1 Includes six stops, 3HAC 11407-1, each

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

Users Guide (RobotWare 4.0) Operator's manual

(RobotWare 5.0)
94
Note
Art. no. is specified in section Document

references in the Product manual,
reference information.


The procedure below details how to fit the mechanical stops for axis 2, on to the robot. An
Step
Action
Note/Illustration
1.
Danger!
2.
Fit and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop.
Shown in the figure Mechanical stops,
axis 2 on page 94.
3.
The software working range limitations

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

RobotWare 4.0 is detailed in the Users
Guide - chapter System Parameters topic Manipulator.
RobotWare 5.0 is detailed in the
4.
Warning!
95


General
adding additional mechanical stops with 20 graduation in respective direction.
xx0300000048
Additional mechanical stops
Required equipment
96
Equipment, etc.
Art. no.
Note
Mechanical stop set, axis 3
3HAC 13128-2 Includes six stops, one with 80

restriction, 3HAC 12708-4 (use
when limitation angle >=80), and five
with 20, 3HAC 12708-2.
Includes attachment screws.
Standard toolkit
3HAC 15571-1 The contents are defined in section

Users Guide (RobotWare 4.0)

Operator's manual (RobotWare 5.0)



The procedure below details how to fit the mechanical stops for axis 3 on to the robot. An
Step
Action
Note/Illustration
1.
Danger!
2.
Mount and tighten the additional stops in a Shown in the figure Mechanical stops,
row, starting from the fixed stop.
axis 3 on page 96
3.
The software working range limitations

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

RobotWare 4.0 is detailed in the Users
Guide - chapter System Parameters topic Manipulator.
RobotWare 5.0 is detailed in the
4.
Warning!
97

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 12750-1
3HAC 12785-1
3HAC 12788-1
Axis 1
The illustration below shows the position switch for axis 1:
xx0100000158
98
Position switch, axis 1
Cam
Set screw, cam (cam stop)
Protection sheet

Rail
Rail attachment
Axis 2
xx0100000159
Cam
Rail
Rail Attachment
99

Axis 3
xx0100000160
Cam
Rail
Rail attachment
Specifications
Maximum voltage/current for the position switches:
100
Parameter
Value
Voltage
Max. 50 VDC
Current
Max. 1 A

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 98!
R1.SW2/3 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 98!
Further information about the cables and connection points, see section Robot cabling and
connection points on page 103.
Fitting and adjusting cams and stops
The instruction below details how to fit and adjust the parts of the position switches:
Step
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 102.
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 102
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
102.
101

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
102
Remove the gray section

2.5.1. Robot cabling and connection points
2.5 Electrical connections

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

as well as feedback from the serial measurement board.
Specified in table Robot cables on page 103
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
104.
Customer cables (option)
Handles communication with equipment fitted on the robot

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

motors as well as feedback from the servo system.
See the product manual for external axes.
Art. no. is specified in section Document references in the
These categories are divided into sub-categories which are specified below:
Robot cables
These cables are included in the standard delivery. They are completely pre-manufactured
and ready to plug in.
Cable sub-category Description
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
103

Robot cable, power

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

These cables are not included in the standard delivery, but are included in the delivery if the
position switch option is ordered. The position switches can also be ordered without cables.
The cables are completely pre-manufactured and ready to plug in.
104
Cable
Art. no.
Connection
Connection
point,
point, robot
cabinet
Position switch cable, axis 1, 7 m
3HAC 13175-1
XS8
R1.SW
3HAC 13175-2
XS8
R1.SW
3HAC 13175-4
XS8
R1.SW
Position switch cable, axes 2 and 3, 7 m
3HAC 13176-1
XS8
R1.SW2/3
Position switch cable, axes 2 and 3, 15 m 3HAC 13176-2
XS8
R1.SW2/3
Position switch cable, axes 2 and 3, 30 m 3HAC 13176-4
XS8
R1.SW2/3
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 13.
105
3 Maintenance
3.2.1. Specification of maintenance intervals
3.2 Maintenance schedule and expected 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:
106
Calendar time: specified in months regardless of whether the robot system is run or not
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
SIS: specified by the robot's SIS (Service Information System). A typical value is
given for a typical work cycle, but the value will differ depending on how hard each
part is run. The SIS is further detailed in section Service Information System on page
183
3 Maintenance
3.2.2. Maintenance schedule

General
The robot must be maintained regularly to ensure proper function. The maintenance activities
and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Values for these are specified in Expected component life on page 110.
Activities and intervals, standard equipment
The sections referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
activity
Equipment
Interval
Inspection
Axis 1 gear, oil level
12 mths
Inspection
12 mths 1
Inspection, oil level

gearbox axis 2 on
page 114
Inspection
12 mths 1

gearbox axis 3 on
page 117
Inspection
12 mths

gearbox axis 4 on
page 120
Inspection
12 mths
Inspection, oil level,

gearbox axis 5 on
page 123
Inspection
12 mths 1

gearbox axis 6 on
page 126
Inspection
Balancing device
12 mths
Inspection, balancing
device on page 128
Inspection
Manipulator harness
12 mths
Inspection, cable
harness on page 134
Inspection
Information labels
12 mths
Inspection,
information labels on
page 147
Inspection
Damper axis 2-5
12 mths
Inspection, damper
axes 2-5 on page 141
Inspection
Mechanical stop, axis 1
12 mths
Inspection,
mechanical stop, axis
1 on page 137
Changing
Axis 1 gear, oil: Optimol

Optigear RMO 150
12 000 h
Detailed in
section
1

gearbox axis 1 on
page 111
Oil change, gearbox

axis 1 on page 156
107
3 Maintenance
Maintenance
activity
108
Equipment
Detailed in
section
Interval
Changing
Axis 1 gear oil: Shell Tivela - 5

S 150
Changing

Optigear RMO 150
Changing

S 150
Changing

Optigear RMO 150
Changing

S 150
Changing
Axis 4, primary gear, oil
Changing
Axis 4 secondary gear, oil: 12 000 h1

Mobil Gearlube X320
Oil change, gearbox,

axis 4 on page 166
Changing
Axis 4 secondary gear, oil: - 5

Shell Tivela S 150
Changing
Axis 5 primary gear, oil
Changing
Axis 5 secondary gear, oil: 12 000 h1

Mobil Gearlube X320

axis 5 on page 170
Changing
Axis 5 secondary gear, oil: - 5

Shell Tivela S 150
Changing

Optigear RMO 150 5
Changing

S 150
Replacement
Axis 1 gear
As specified by the
SIS, or typically 96
mths
Replacement of
gearbox, axis 1 on
page 320
Replacement
Axis 2 gear
As specified by the
mths
Removal of gearbox,
axis 2 on page 328
Replacement
Axis 3 gear
As specified by the
mths
Removal of gearbox,
axis 3 on page 337
Replacement
Axis 4 gear
96 mths
Removal of gearbox,
axis 4 on page 344
Replacement
Axis 5 gear
96 mths
Removal of gearbox,
axis 5 on page 350
Replacement
Axis 6 gear
As specified by the
mths
Removal of gearbox,
axis 6 on page 360
Replacement
Manipulator harness
See note below 2
Replacement of cable
harness, axes 1-4 on
page 200
Replacement
SMB Battery pack
12- 36 mths 3
Removal of SMB
related equipment on
page 250
12 000 h 1
Oil change, gearbox

axis 2 on page 160
-
12 000 h 1

axis 3 on page 163
-
-5
-5

axis 5 on page 170
12 000 h1
Oil change, gearbox

axis 6 on page 174
3 Maintenance
Maintenance
activity
Equipment
Interval
Lubrication
Balancing device bearing
12 000 h 4
Detailed in
section
Lubrication, balancing
device bearing on
page 177
1. If the robot is run at ambient temperatures higher than 50C, the manipulator may
require maintenance more frequently.
2. Replace when damage is detected or when approaching the life limit, specified in
Expected component life on page 110.
3. The battery is used as a back-up when the robot system is switched off. Therefore, the
life of a lithium battery depends on how frequently the power to the system is switched
off and also if the environment temperature is higher than recommended operating
temperature. The life varies from 12 - 36 mths, depending on current conditions. An
alert is given on the TPU when the battery is nearly discharged and it must then be
replaced within a month.
4. The interval is the same as with the interval for changing axis 2 gear oil, because the
type and degree of operation is similar.
5. 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
UL lamp
Inspection
Mechanical stop 12 mths

axis 1, 2 and 3
Inspection
Position
12 mths
switches, axis 1,
2 and 3
Interval
Note
Detailed in
section
Inspection, ULlamp on page 150
Mechanical stops in
addition to the fixed
stops
Inspection,
mechanical stop,
axes 1, 2 and 3 on
page 139
Inspection, position
switch axes 1, 2
and 3 on page 143
109
3 Maintenance
3.2.3. Expected component life
3.2.3. Expected component life

General
The life of any component depends on how hard it is run, and it can vary greatly.
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
40,000 h
See note 3)
1. The expected life can also be affected by grouping harnesses/cables other than
standard options.
2. The given life for the balancing device is based on a test cycle that goes from the initial
position to maximum extension, and back again. Deviations from this test cycle will
result in differences in expected life! The given life is based on a test cycle that for
every axis goes from the calibration position to minimum angle, to maximum angle
and back to the calibration position. Deviations from this test cycle will result in
differences in expected life!
3. The robot is dimensioned for a service 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 SIS (Service
Information System) 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 on page 183.
110
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
3.3 Inspection activities

Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
xx0200000111
Gearbox axis 1
Oil plug, filling
Motor, axis 1
Oil plug, inspection (not available in all designs)
Label, specifies type of oil in the axis 1 gearbox
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

information.
111
3 Maintenance
Equipment, etc.
Art. no.
Other tools and procedures may be

required. See references to these
procedures in the step-by-step
instructions below.
Note
These procedures include
references to the tools required.
Inspection through the oil plug, filling

The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug
for inspection (shown in figure Location of gearbox on page 111) is not available .
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 38.
2.
Danger!
3.
Remove the motor, axis 1.
Detailed in section Removal of

motor, axis 1 on page 280.
4.
Measure the oil level through the motor hole.

Required oil level: 40 mm 5 mm to the motor
hole.
5.
If necessary, fill with lubricating oil or drain.

Filling and draining detailed in Oil
change, gearbox axis 1 on page
156.
6.
Refit the motor, axis 1.
Detailed in section Refitting of

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 40!
112
3 Maintenance
Inspection through the oil plug, inspection

The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug
for inspection (shown in the figure Location of gearbox on page 111) is available.
Step
Action
Note
1.
Warning!
page 38.
2.
Danger!
3.
Open the oil plug, inspection .

gearbox on page 111!
4.
Required oil level: max 10 mm below the oil

plug hole!
5.
Add oil if required.

Detailed in section Oil change,
gearbox axis 1 on page 156.
6.
Refit the oil plug, inspection.
7.
Warning!
113
3 Maintenance

Different designs
The cover of gearbox axis 2 is made in different designs, with different locations of the oil
plug hole for filling. The oil plug hole of the later design is located 33 mm below the original
placement. The measured distance to the oil level varies, depending on the design of the
cover.
Oil plug, early design
The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the
early design of the gearbox cover.
xx0300000068
114
Gearbox, axis 2 (behind motor attachment not shown in figure )
Oil plug, filling (early design)
Oil plug, draining
Label, specifies the type of oil in axis 2 gearbox
3 Maintenance
Oil plug, later design

The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the
later design of the gearbox cover, where the oil plug for filling is located 33 mm below the
original placement.
xx0200000112
Oil plug, filling (later design)
Oil plug, draining
Label, specifies the type of oil in axis 2 gearbox
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
3HAC 16483-1 /
3HAC 021469-001

Standard toolkit
3HAC 15571-1

information.


115
3 Maintenance
Inspection, oil level gearbox axis 2

The procedure below details how to inspect the oil level in gearbox axis 2.
Step
Action
Note
1.
Warning!
page 38.
2.
Danger!
3.
Open the oil plug, filling (two different

designs).
Read more about the differences in

Oil change, gearbox axis 2 on page
160!
4.
Measure the oil level.

Required oil level, to oil plug (early design):
35 mm 5 mm.
Required oil level, to oil plug (later design):
max. 10 mm below the oil plug hole.
Shown in the figures Oil plug, early

design on page 114 or Oil plug, later
design on page 115!
5.

Detailed in section Filling, oil on
page 162.
6.
Refit the oil plug, filling.
7.
Warning!
116
3 Maintenance

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
xx0200000113
Gearbox, axis 3
Oil plug, filling
Oil plug, draining
Label, specifies the oil type of axis 3 gearbox
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001

117
3 Maintenance
Equipment
Art. no.
Note
Standard toolkit
3HAC 15571-1

information.



Step
Action
Note
1.
Warning!
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
2.
Danger!
3. Run the robot to the calibration position.
Detailed in section Calibration

scales and correct axis position on
page 368.
4. Open the oil plug, filling .

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

plug hole.
118
6. Add oil if required.

gearbox, axis 3 on page 163.
7. Refit the oil plug, filling.
3 Maintenance
Step
Action
Note
8.
Warning!
119
3 Maintenance

Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.
xx0200000107
120
Upper arm housing
Cover, axis 4 gearbox
Oil plug, filling, secondary gear
Oil plug, draining, secondary gear
Oil plug, filling, primary gearbox (draining not shown in figure)
Label, specifies the type of oil in the secondary gear of axis 4
Label, specifies the type of oil in the primary gear of axis 4
3 Maintenance
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
1171 2016-604 /
3HAC 021469-001
Mobil Gearlube X320 / Shell

Tivela S 150 (001A9646)
To be used in the secondary
gear.
The Mobile Gearlube X320 is a
common oil that can be replaced
with an equivalent oil rom
another manufacturer!
Lubricating oil
3HAC 021469-001

To be used in the primary
gearbox.
Standard toolkit
3HAC 15571-1

information.



Step
Action
Note
1.
Warning!
2.
Danger!
121
3 Maintenance
Step
Action
Note
3.
Run the robot to the calibration position.
Shown in section Calibration

scales and correct axis position
on page 368.
4.
Open the oil plug, filling, in the primary gearbox.

5.

Required oil level: 35 mm 5 mm to the oil plug
hole.
6.

equipment on page 121.
7.
Open the oil plug, filling, in the secondary

gearbox.

8.
Required oil level: max. 10 mm to the oil plug

hole.
9.
10. Refit both oil plugs.

Tivela S 150 (001A9646)
11.
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 40!
122
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5

Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000108
Wrist housing
Oil plug, filling secondary gear
Oil plug, draining secondary gear
Oil plug, filling, primary gearbox (draining on opposite side of wrist housing, not
shown in figure)
Label, specifies the type of oil in primary gear axis 5
Label, specifies the type of oil in secondary gear axis 5
123
3 Maintenance
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
1171 2016-604 /
3HAC 021469-001

Tivela S 150 (001A9646)
To be used for the secondary
gear.
with an equivalent oil from
another manufacturer!
Lubricating oil
3HAC 021469-001

To be used for the primary
gearbox.
Standard toolkit
3HAC 15571-1

information.



The procedure below details how to inspect the oil level in the gearbox axis 5.
Step
Action
Note
1.
Warning!
2.
Danger!
124
3 Maintenance
Step
Action
Note
3.
Run the robot to the calibration position.
Shown in section Calibration

scales and correct axis position
on page 368.
4.
Open the oil plug, filling, in the primary gearbox. Shown in the figure Location of
5.

Required oil level: 80 mm 5 mm to the oil plug
hole.
6.
7.
Open the oil plug, filling, in the secondary gear . Shown in the figure Location of
8.

Required oil level: max. 10 mm to the oil plug
hole.
9.
10. Refit both oil plugs.


Tivela S 150 (001A9646)
11.
Warning!
125
3 Maintenance

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
xx0200000114
Gearbox, axis 6
Oil plug, filling
Oil plug, draining
Label, specifies the type of oil in gearbox axis 6
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC 021469-001
Standard toolkit
3HAC 15571-1

information.

126

3 Maintenance

The procedure below details how to inspect the oil level in the gearbox axis 6.
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 38.
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 126!
4.

Required oil level: 65 mm 5 mm to the oil plug hole.
5.

Required equipment on
page 126!
Detailed in section Oil
change, gearbox axis 6 on
page 174.
6.
7.
Warning!
WARNING - Mixed oils may cause severe damage to
gearbox! on page 40!
127
3 Maintenance
3.3.7. Inspection, balancing device

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

If any faults are detected during the inspection, a maintenance may be performed according
to specific maintenance kits.
If the balancing device is an older model, it must in some cases be upgraded instead! The
instruction for the current inspection details if a fault requires a maintenance / upgrade and
the table below specifies the different models and which of the two actions they require.
The article number of the balancing device is located on a label at the rear cover, shown in
the figure Inspection points, balancing device on page 129.
128
Balancing device, art. no.
Action at detected faults
3HAC 10538-1
Upgrade
3HAC 14675-1
Maintenance
3 Maintenance
Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure below. The
figure also shows the inspection points, further detailed in the instructions.
xx0300000580
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
129
3 Maintenance
Required equipment
The table below specifies the equipment used if damage is detected on the balancing device.
See section Action at detected faults on page 128 to determine whether to perform
maintenance or upgrade!
Equipment, etc.
Spare part no.
Art. no.
Maintenance kit,
complete
3HAC 15834-1
Includes:
complete kit including the
kit with bearings and
seals
instructions for
maintenance.
Maintenance kit,
bearings and seals
3HAC 14962-1
Includes:
kit with bearings, o-rings
and seals only
instructions for
maintenance.
Upgrade kit
3HAC 14965-1
Includes
kit with piston rod, support
shaft etc.
instruction for conversion,
3HAC 15864-2.
Securing screw
Securing screw in the shaft.

M16 x 180
Locking liquid must be used
when fitting the screw (Loctite
245)!
Toolkit for
maintenance
3HAC 15943-1
Puller for separator
4552-2
(Bahco)
Used for removing the spherical

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

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

information!
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
130
Note

3 Maintenance
Check for dissonance

The check points are shown in the figure Inspection points, balancing device on page 129.
Step
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 130.
To decide whether to perform
maintenance or upgrade, see section
Action at detected faults on page 128.
2.
cylinder (a tapping sound, caused ...replace the balancing device or

by the springs inside the cylinder). consult ABB Robotics.
How to remove the device is detailed in
section Removal of balancing device on
page 266. This section also specifies
the spare part number!
3.
piston rod (squeaking may indicate

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

Maintenance kit, complete / Upgrade
kit.
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 129.
Step
Check for damage on...
1.
2.
If damage is detected...
the piston rod (part of the piston rod ... perform maintenance or upgrade
that is visible at the front of the
balancing device).
Maintenance kit, complete / Upgrade
kit.
the securing screw in the front ear ...replace.

shaft.
Dimension is specified in section
Also check the tightening torque (50 Nm). Required equipment on page 130.
131
3 Maintenance
Check for leakage

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

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

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

Maintenance kit, bearings and
seals, already assembled with
sealing spacers and sealing
rings.
Art. no. for the kit is specified in
Required equipment on page 130
!
Check for contamination / lack of free space

Step
Action
1.
Danger!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 129.
Keep the areas around the balancing device clean and free from objects, such as
service tools.
133
3 Maintenance
3.3.8. Inspection, cable harness

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


These procedures include references to

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

3 Maintenance
Inspection, cable harness 1-4

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

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

and at the base.

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

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

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

is detected.
cable harness, axes 5-6!
Location of cabling axes 5-6

The manipulator cable harness, axes 5-6, is located as shown in the figure below.
xx0200000155
Cable attachment, upper arm tube
Cable attachment, rear of upper arm
Connectors at cable harness division point, R2.M5/6
135
3 Maintenance
Inspection, cable harness, axes 5-6

The procedure below details how to inspect the cable harness of axes 5-6.
Step
Action
Note
1.
Danger!
136
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!

cabling axes 5-6 on page 135!
3 Maintenance
3.3.9. 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 10499-3
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!
137
3 Maintenance
Inspection, mechanical stop

The procedure below details how to inspect the mechanical stop axis 1.
Step
Action
Note/Illustration
1.
Danger!
138
2.
Inspect the mechanical stop, axis 1.

mechanical stop on page 137!
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!
3 Maintenance
3.3.10. Inspection, mechanical stop, axes 1, 2 and 3

Location of the mechanical stops
The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3.
xx0200000150
Additional stop
Fixed stop
Required equipment
Equipment etc.
Art. no.
Note
3HAC 11076-1
Limits the robot working range to

7.5.
3HAC 11076-2
Limits the robot working range to

15.
3HAC 11077-1
3HAC 13128-2
Standard toolkit
3HAC 15571-1

139
3 Maintenance
Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and
3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
140
Action
1.
Check the additional stops on axes 1, 2 and 3 for

damage.
2.
Make sure the stops are properly attached.

Correct tightening torque: 115 Nm.
3.
If any damage is detected, the mechanical stops

must be replaced!
Correct attachment screws:
Axis 1: M16 x 35
Axis 2: M16 x 50
Axis 3: M16 x 80
Note/Illustration
of the mechanical stops on
page 139!
Art. no. specified in Required

3 Maintenance
3.3.11. Inspection, damper axes 2-5

Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0200000099
Damper, axis 2 (2 pcs)
141
3 Maintenance
Required equipment
Equipment
Art. no.
Note
Damper axis 2
3HAC 12990-1
Replace if damaged!
Damper axis 3
3HAC 11750-1
Replace if damaged!
Damper axis 4
3HAC 13564-1
Replace if damaged!
Damper axis 5
3HAC 10503-8
Replace if damaged!
Standard toolkit
3HAC 15571-1

Inspection, damper axis 2-5

The procedure below details how to inspect the dampers, axis 2-5
WARNING!
result in burns!
Step
142
Action
Note/Illustration
1.
Check all dampers for damage, such as cracks or Shown in the figure Location
existing impressions larger than 1 mm.
of dampers on page 141!
In order to inspect dampers, axis 4, the two covers on
top of the upper arm must be removed!
2.
Check attachment screws for deformation.
3.
If any damage is detected, the damper must be

replaced with a new one!

page 142!
3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3

Location of position switches
The position switches, axes 1, 2 and 3, are located as shown in the figures below.
xx0100000158
Cam
Set screw, cam
Protection sheet
Rail
Rail attachment
143
3 Maintenance
The illustration below shows the position switch for axis 2.
xx0100000159
144
Cam
Set screw, cam
Rail
Rail attachment
3 Maintenance
The illustration below shows the position switch for axis 3.
xx0100000160
Cam
Set screw, cam
Rail
Rail attachment
Required equipment
Equipment, etc.
Spare part no.
3HAC 15715-1
To be replaced in case of
detected damage.
3HAC 15715-2
detected damage.
3HAC 15715-2
detected damage.
Art. no.
Note
145
3 Maintenance
Equipment, etc.
Standard toolkit
Other tools and

procedures may be
required. See
references to these
procedures in the stepby-step instructions
below.
Spare part no.
Art. no.
Note
3HAC 15571-1

information.
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 figure Location of position switches on page 143 to locate the different components
to be inspected.
WARNING!
result in burns!
Step
146
Action
1.
Check the position switch!

Check that the rollers are easy to push in and that they roll freely.
2.
Check the rail!

Check that the rail is firmly attached with the attachment screws.
3.
Check the cams!

Check that the rollers has 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.
4.
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 space inside the sheets is clean enough not to disturb the
function of the position switch.
5.
If any damage is detected, the position switch must be replaced.
3 Maintenance
3.3.13. Inspection, information labels

Location of labels
The figures below show the location of the information labels to be inspected.
xx0200000100
Warning label "High temperature", 3HAC 4431-1
Warning sign, symbol of a lightning flash (located on motor cover), 3HAC 1589-1
Instruction label "Safety instructions", 3HAC 4591-1
Warning label "Brake release", 3HAC 15334-1
Warning label, tools are not allowed around the balancing device during operation,
3HAC 020611-001
Warning label, "Shut off power", 3HAC 17804-1
Label, type of oil in gearbox, 3HAC 021482-001
Label, type of grease in ear, 3HAC 021525-001
Information labels at gearboxes and at robot base, if gearboxes are filled with
Shell Tivela S 150
147
3 Maintenance
xx0200000101
Instruction label "Lifting the robot", 3HAC 16420-1
Warning label "Robot can tip forward...", 3HAC 9191-1
Foundry logotype, 3HAC 8256-1
Warning label "Stored energy", 3HAC 9526-1
Information label, types of oil in gearboxes of each axis, 3HAC 021505-001
Required equipment
148
Equipment
Art. no.
Note
Labels and plate set
3HAC 13191-1
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.
3 Maintenance
Inspection, labels
Step
Action
Note/Illustration
1.
Danger!
2.
Check the labels, located as shown in the

figures Location of labels on page 147.
3.
Replace any missing or damaged labels.

149
3 Maintenance
3.3.14. Inspection, UL-lamp

Location of UL-lamp
The UL-lamp is located as shown in figure below. Notice that the location can vary depending
on how the customer harness for axes 4-6 is mounted.
xx0200000117
UL signal lamp
Warning sign
Warning label
Position for cable gland
Required equipment
Equipment, etc.
Spare part no. Art. no.
Note
Signal lamp
3HAC 10830-1
detected damage.
Includes UL signal lamp,
3HAC 13097-1, Warning
label, 3HAC 4431-1,
Warning sign, 3HAC 1589-1
Standard toolkit
150
3HAC 15571-1

section Standard toolkit in
the Product manual,
3 Maintenance
Equipment, etc.
Other tools and

procedures may be
required. See references
to these procedures in
the step-by-step
instructions below.
Note
required.
Inspection, UL-lamp
The procedure below details how to inspect the function of the UL-lamp.
Step
Action
Note/Illustration
1.
Check that the UL-lamp is lit, when the motors are in

operation ("motors ON").
2.
If the lamp is not lit, trace the fault!

Part no. is specified in
Check whether the UL-lamp is broken. If so, Required equipment on
page 150!
replace it.
Check the cable connections.
Measure the voltage in connectors motor axis
3 (=24V).
Check the cabling. Replace cabling if a fault is
detected.
151
3 Maintenance
3.4.1. Oil in gearboxes
3.4 Changing/replacement activities

Location of gearboxes
The gearboxes are located as shown in the figure below.
xx0400000798
152
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 4 gearbox
Axis 5 gearbox
Axis 6 gearbox
3 Maintenance
Type of oil
The table below specifies the types of oil used in the gearboxes of each axis. For some of the
axes, there are two different types specified. Normally, the same oil should be refilled as the
one drained. Read the sectionWhich type of oil does the gearbox contain? on page 154 in
order to determine which type of oil is currently used in the gearbox.
As the Shell Tivela S 150 is not compatible with mineral oil, contamination with other types
of oils used in the gearboxes is not accepted. Equipment used in handling of Tivela S 150
must be carefully cleaned. In case of changing the type of oil to another, the gearbox must
therefor be thoroughly rinsed! Contact ABB for further instructions.
The primary gearboxes of axes 4 and 5 are rinsed as detailed in section Flushing a
contaminated gearbox on page 179.
The Shell Global Product Code for Shell Tivela S 150 is specified within parentheses in table.
Gearbox
Type of oil
Axis 1

3HAC 16843-1 /
Shell Tivela S 150 (001A9646) 3HAC 021469-001
7,600 ml
Axis 2

3HAC 16483-1 /
4,800 ml
Axis 3

3HAC 16843-1 /
4,200 ml
Axis 4, primary
gear
900 ml
Axis 4, secondary Mobil Gearlube X320 / Shell

gear
Tivela S 150 (001A9646)
Axis 5, primary
gear
1171 2016-604 /
3HAC 021469-001
Axis 5, secondary Mobil Gearlube X320 / Shell

gear
Tivela S 150 (001A9646)
Axis 6
Art. no.
1171 2016-604 /
3HAC 021469-001
Amount
3,850 ml
750 ml
3,800 ml
850 ml
WARNING!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the type of oil specified by the manufacturer!
If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further
instructions!
153
3 Maintenance
Which type of oil does the gearbox contain?

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

At delivery, the following robots are filled with Tivela S 150:
Robot
Serial number as from
Type of oil
IRB 7600 M2000
76-27000
Tivela S 150
IRB 7600 M2000A
76-34000
Tivela S 150
IRB 7600 M2004
76-51000
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!
xx0500001399
154
Label located next to each oil plug on the gearbox
3 Maintenance
xx0500001397
Label at the robot base
Equipment, change of oil type

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

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

Location of gearbox
The oil is drained with a hose that may be reached behind the rear cover of the manipulator
base.
xx0200000111
156
Gearbox, axis 1
Oil plug, filling
Motor, axis 1
Oil plug, inspection (not in all designs)
Label, specifies the type of oil in the gearbox
3 Maintenance
Oil plug in the base

In some early versions of the manipulator, the oil plug for draining may be located in the base,
as shown in the figure below.
xx0300000065
Oil plug in the base
Required equipment
Equipment, etc.
Art. no.
Amount Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001
7,600 ml
Oil collecting vessel

Do not mix the oils! Check
which oil is currently filled in the
Capacity: 8,000 ml.
Oil exchange equipment
3HAC 17313-1

section Special tools in the
information.
Standard toolkit
3HAC 15571-1

information.
Other tools and

procedures may be
the step-by-step
instructions below.

required.
157
3 Maintenance
NOTE!
The specified amount of oil is 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.
Draining, oil, gearbox axis 1
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 157.
Step
Action
Note
1.
Warning!
page 38.
2.
Danger!
158
3.
Remove the rear cover on the base by

unscrewing its attachment screws.
4.
Pull the oil hose out of the rear of the base.

Some early versions of the robot has the oil
draining plug in the base as shown in the figure
Oil plug in the base on page 157 instead of the
hose.
5.
Place an oil vessel close to the hose end.
6.
Remove the oil plug, filling, in order to drain the

oil quicker!
7.
Open the hose end and drain the oil into the
vessel.
8.
Close the oil drain hose, and put it back inside

the base.
9.
Close the rear cover by securing it with its

attachment screws.
Vessel capacity specified in

Note! The draining is timeconsuming. Elapsed time depends

on the temperature of the oil.
3 Maintenance
Filling, oil, gearbox axis 1

The procedure below details how to fill oil in gearbox, axis 1.
Step
Action
Note
1.
Warning!
information in section WARNING - Safety risks
during work with gearbox oil on page 38.
2.
Danger!
3.
Open the oil plug, filling.

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
Art. no. and the total amount

are specified in Required
5.
Warning!
WARNING - Mixed oils may cause severe damage
to gearbox! on page 40!
6.
159
3 Maintenance

Location of oil plugs
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor
attachment.
xx0200000112
Gearbox, axis 2
Oil plug, filling (later design)
Oil plug, draining
Label, specifies the type of oil in the gearbox
Required equipment
Equipment, etc. Art. no.
Lubricating oil
3HAC 16483-1 /
4,800 ml
3HAC 021469-001
Oil collecting vessel -
160
Amount
Note
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!
Capacity: 5,000 ml.
3 Maintenance
Equipment, etc. Art. no.
Amount
Note
Oil exchange
equipment
3HAC 021745-001

information.
Standard toolkit
3HAC 15571-1

information!
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
Step
Action
Note/Illustration
1.
Danger!
2.
Warning!
page 38.
3.
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 160!
Draining is time-consuming.
Elapsed time varies depending on
the temperature of the oil.
4.
Refit the oil plug.
161
3 Maintenance
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
Step
Action
Note
1.
Danger!
2.
Warning!
3.
Remove the oil plug, filling and the plug from the Shown in the figure Location of
vent hole.
oil plugs on page 160!
4.

Art. no. and total amount are
specified in Required equipment
amount previously being drained. The correct oil on page 160!
5.
Warning!
6.
162
Refit the oil plug .
3 Maintenance
3.4.4. Oil change, gearbox, axis 3

Location of gearbox
xx0200000113
Gearbox, axis 3
Oil plug, filling
Oil plug, draining
Label, specifies the type of oil in gearbox
163
3 Maintenance
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC 16843-1 /
4,200 ml
3HAC 021469-001

Oil exchange
equipment
3HAC 021745-001

information.
Capacity: 5,000 ml.
Standard toolkit
3HAC 15571-1

information!
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
Step
Action
Note
1.
Danger!
2.
Warning!
page 38.
164
3 Maintenance
Step
Action
Note
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!

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.
Filling, oil
The procedure below details how to fill oil to the gearbox, axis 3.
Step
Action
Note
1.
Danger!
2.
Warning!
3.
Remove the oil plug, filling.

4.

Art. no. and total amount are
amount previously being drained. The correct oil on page 164!
5.
Warning!
6.
Refit the oil plug.
165
3 Maintenance

Different types of oil
The primary and secondary gear may require different types of oil, that must never be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a contaminated
gearbox on page 179.
Location of gearbox
xx0200000107
166
Upper arm housing
Oil plug, filling, secondary gear
Oil plug, draining, secondary gear
Oil plug, filling, primary gearbox (draining not shown in figure, located further down
on the motor flange)
Label, specifies the type of oil in the secondary gear
Label, specifies the type of oil in the primary gear
3 Maintenance
Required equipment
Equipment, etc.
Art. no.
Amount Note
Lubricating oil
3HAC 021469-001 900 ml

To be used in the primary gearbox.
Lubricating oil
1171 2016-604 /
3,850 ml
3HAC 021469-001
Mobil Gearlube X320 / Shell Tivela S

150 (001A9646)
To be used in the secondary gear.
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!
with an equivalent oil from another
manufacturer!
Oil collecting vessel,

primary gearbox
Capacity: 1,000 ml.
Oil collecting vessel,

secondary gearbox
Capacity: 4,000 ml.
Oil exchange
equipment
3HAC 17313-1

Special tools in the Product manual,
Standard toolkit
3HAC 15571-1

167
3 Maintenance

The procedure below details how to drain the oil from the gearbox, axis 4.
Step
Action
Note
1.
Warning!
information in section WARNING - Safety risks
during work with gearbox oil on page 38.
2.
Danger!
168
3.
Open the oil plug, draining, secondary gear.

4.
Drain the oil from the secondary gearbox by running Vessel capacity specified in
the upper arm -45 from calibration position.
Required equipment on page
167.
5.
Run the robot back to its calibration position.
Detailed in section Calibration

scales and correct axis
position on page 368.
6.
Drain the primary gear by opening the oil plug,

draining, primary gearbox.
Vessel capacity specified in

167.
7.
Refit the both oil plugs, draining.
3 Maintenance

Step
Action
Note
1.
Warning!
2.
Danger!
3.
Refill the secondary gear with lubricating oil

through the oil plug, filling, secondary gear.

Tivela S 150 (001A9646)
Art. no. and amount is specified in
167.
4.
Refill the primary gearbox with oil through the oil

plug, filling, primary gear. Make sure the air is
ventilated through the oil plug during filling, to
avoid overpressure in the gearbox.

Art. no. and total amount is
on page 167.
5.
Warning!
the gearbox must be rinsed as detailed in section
6.
Refit the both oil plugs, filling.

169
3 Maintenance

The primary and secondary gear may require different types of oil, that must never be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a contaminated
gearbox on page 179.
Location of gearbox
xx0200000108
170
Wrist housing
Oil plug, filling secondary gear
Oil plug, draining secondary gear
Oil plug, filling primary gearbox (draining on opposite side of wrist housing, not
shown in figure)
Label, specifies the type of oil in primary gear
Label, specifies the type of oil in secondary gear
3 Maintenance
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC 021469-001
750 ml

To be used in the primary gearbox.
Lubricating oil
1171 2016-604 /
3HAC 021469-001
3,800 ml
Mobil Gearlube X320 / Shell Tivela

S 150 (001A9646)
To be used in the secondary gear.
oil is currently filled in the gearbox,
as detailed in section Which type
of oil does the gearbox contain? on
page 154!
with an equivalent oil from another
manufacturer!
Capacity: 1,000 ml.
Capacity: 4,000 ml.
Oil exchange
equipment
3HAC 17313-1

Special tools in the Product
Standard toolkit
3HAC 15571-1

NOTE!
171
3 Maintenance

The procedure below details how to drain the oil from the gearbox, axis 5.
Step
Action
Note
1.
Warning!
information in section WARNING - Safety risks during
work with gearbox oil on page 38.
2.
Danger!
172
3.
Open the oil plug, draining, primary gearbox.
4.
Drain the oil from the primary gearbox.
5.
Run axis 4 to a position +90 from the calibration

position.
6.
Open the oil plug, draining, secondary gearbox.

7.
Drain the oil from the secondary gear.
Vessel capacity: 4,000 ml.
8.
Refit the both oil plugs, draining.

3 Maintenance

Step
Action
Note
1.
Warning!
2.
Danger!
3.
Refill the primary gearbox with lubricating

oilthrough the oil plug, filling. Make sure the air is
ventilated through the oil plug during filling, to
avoid overpressure in the gearbox.
level is detailed in section Inspection, oil level,

on page 171.
4.
Refill the secondary gearbox with lubricating

oilthrough the oil plug, filling.
level is detailed in section Inspection, oil level,

Tivela S 150 (001A9646)
on page 171.
5.
Warning!
6.
Refit the both oil plugs, filling.

173
3 Maintenance

Location of gearbox
xx0200000114
Gearbox, axis 6
Oil plug, filling
Oil plug, draining
Label, specifies the type of oil in gearbox axis 6
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC 021469-001
850 ml
Shell Tivela S 150

(001A9646)
Oil exchange equipment
3HAC 17313-1

information.
Standard toolkit
3HAC 15571-1

the Product manual,
NOTE!
174
3 Maintenance

The procedure below details how to drain the oil in gearbox, axis 6.
Step
Action
Note
1.
Warning!
page 38.
2.
Danger!
3.
Move the wrist so that the oil plug, filling of axis Shown in the figure Location of
6 gearbox faces upwards. Turn the turning disk gearbox on page 174!
so that the oil plug, draining faces downwards.
4.
Drain the oil from gearbox 6 by removing the oil Vessel capacity: 1000 ml.
plug. Collect the oil with a suitable vessel.
175
3 Maintenance

The procedure below details how to fill oil in gearbox axis 6.
Step
Action
Note
1.
Warning!
page 38.
2.
Danger!
3.
Turn the turning disk so that the oil plug,

draining, faces upwards.
4.
Remove the oil plug, filling from top of the

wrist.
5.
Refill the wrist with lubricating oil .

Art. no. and total amount specified
The air is ventilated through the open plug hole in Required equipment on page
for draining. If the draining plug is not opened, 174!
make sure the air is ventilated through the oil
plug during filling, to avoid overpressure in the
gearbox.
amount previously being drained. The correct
oil level is detailed in section Inspection, oil
level gearbox axis 6 on page 126.

6.
Warning!
7.
176
Refit the both oil plugs.
3 Maintenance
3.5.1. Lubrication, balancing device bearing
3.5 Lubrication activities

Location of bearing
The figure below shows the location of the lubrication nipple etc.
Note! The balancing device must be mounted on the manipulator when lubricating the
bearing!
xx0200000109
Ear (spherical roller bearing located inside)
Lubrication nipple
Sealing spacer
Hole through which the shaft is pressed
Required equipment
Equipment, etc.
Art. no.
Note
Grease
3HAA 1001-294
Optimol PDO, 150 ml

For lubrication of the spherical roller bearing.
Grease pump
177
3 Maintenance
Lubrication, balancing device bearing

The procedure below details how to lubricate the spherical roller bearing.
Step
Action
Note
1.
Danger!
178
2.
Lubricate the spherical roller bearing through

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

bearing on page 177!
The balancing device must be
mounted on the manipulator when
lubricating the bearing!
3.
Clean the area from any excessive grease

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

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.
This section details how to flush the primary gears of axis 4 and 5, and the gearbox of axis 6
in case of contamination with other type of oil.
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC 021469-001

Amount: 700 ml for each gearbox and
flush. Three flushes required.
Syringe + plastic hose
Dinside=4 mm, L= 400 mm.
Standard toolkit
3HAC 15571-1

Service program
Create a program with motions on axis 3, 4, 5 and 6. There is no need to remove the tool and
equipment installed on the robot if the Service program can be created and is possible to run.
Recommended motion
axis 3: 15 degrees
axis 4-6: maximum working range with regard to the installation (limitation: axis 4
and 5: 90 degrees, axis 6: 180 degrees).
Draining the gearbox properly

The contaminated gearbox must be drained properly before and during the flushing
procedure:
Axis 4 gearbox: open both oil plugs (filling and draining) and run axis 3 in different
directions. Draw out the last volume (approx. 40 -60 ml) by using a syringe with a
prepared hose end.
Axis 5 gearbox: open both oil plugs (filling and draining) and run axis 4 back and
forward until the oil draining has stopped.
Axis 6 gearbox: open both oil plugs (filling and draining) and run axis 5 and 6 in
different directions until the oil draining has stopped.
179
3 Maintenance
Flushing
The procedure below details how to flush a contaminated gearbox. The procedure is the same
for all gearboxes.
Step
180
Action
Note
1.
Run the Service program until the castings of the

Recommended service
gearboxes axis 4, 5 and 6 have reached a
program detailed in section
temperature of about 30-35 C. Use the finger tips to above: Service program.
measure the temperature.
2.
Drain the gearbox properly.
Described in section above:

Draining the gearbox
properly.
3.
Fill the gearbox with 700 ml of lubricating oil.
Shell Tivela S 150

(001A9646)
Art. no . is specified in
page 179.
4.
Refit the oil plug.
5.
Run the Service program at low speed (25%) during

10 minutes.
6.
Drain the gearbox properly.
7.
Repeat the steps above until the gearbox is flushed

three times.
3 Maintenance
3.6.2. Cleaning, manipulator

General
The protection class is IP 67, i.e. the manipulator is watertight.
Activities
This instruction specifies cleaning of the manipulator.
Periodicity
The periodicity of cleaning the manipulator varies a great deal depending on the actual
environment and function of the robot. A contaminated manipulator should be cleaned as
required.
Special points
Special points to be observed are shown in the figure below:
xx0100000265
Spiral cables to motor 5
Inside of upper arm tube
Rear of upper arm tube
Inside of lower arm
Inside of base/axis 1
181
3 Maintenance
Required equipment
Equipment, etc.
Art. no.
Steam cleaner
Note
High pressure water

cleaner
Water pressure at nozzle: max. 2500 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 manipulator may be exposed to fluids that
dry to make a crusty surface, e.g. release agents, clean the cable harnesses so that the crust
does not damage the cables:
182
Clean the spiral wound cables to motor 5 (item A in the figure Special points on page
181!) with water and a cloth!
Clean the remaining sections of the cable harnesses as detailed above!
3 Maintenance
3.7.1. Using the SIS system
3.7 Service Information System

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

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

these are given in SIS system
parameters on page 187.
Maintenance intervals recommended
by ABB are specified in section
Maintenance schedule on page 107.
3.
Enter these parameters in the system.
How to do this is detailed in Setting

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

How to set the limit is detailed in section Setting the
SIS parameters on page 189.
Proceed with the required service as detailed in
chapter Repair on page 195 or chapter
Maintenance on page 105 depending on which
type of service.
Calendar time
Service Message
X calendar days to
next service.
X number of calendar days remain until the

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

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

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

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

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

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

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

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

last reset of the operation time counter.
Corresponds to the operating time counter on
the control cabinet.
sisL10h_1
hrs
Gearbox time
Estimated life of gearbox axis 1
sisL10h_Time_1
hrs*
Gearbox time
Operation time of gearbox axis 1
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2
hrs*
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3
hrs*
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6
hrs
Gearbox time
* For RobotWare releases earlier than 5.05, the unit is seconds.
193
3 Maintenance
194
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter
This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate procedures, each detailing a specific repair activity. Each procedure
contains all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.
195
4 Repair
4.2.1. Performing a leak-down test
4.2 General procedures

4.2.1. Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Art. no.
Leakdown tester
3HAC 0207-1
Leak detection spray
Note
Procedure
Step
196
Action
Note/Illustration
1.
Finish the refitting procedure of the motor or gear in

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

Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7.
Spray suspected leak areas with leak detection spray Art. no. is specified above!
.
Bubbles indicate a leak.
8.
When the leak has been localized: take the

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

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

specified otherwise.
Assembly of all bearings

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

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

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

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

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

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

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

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

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

Location of cable harness
The cable harness for axes 1-4 is located throughout the manipulator as shown in the figure
below.
The brake release unit can be located at two alternative places, either at the rear of the base
or at the side of the frame. Depending on the location, the two types of harnesses are
distinguished some from each other! Any differences are pointed out in the instructions!
xx0100000140
200
Alternative with brake release at frame
Alternative with brake release at base
Connector at manipulator base, R1.MP and R1.SMB
Connectors at motor 1; R2.FB1 and R2.MP1
Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,

R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release
located at the frame: also connectors X8, X9 and X10!
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and
R2.H2
4 Repair
Connectors at cable harness separation; R2.M5/6
Rear cover plate
Connector R1.MP
Connector R1.SMB
Connection of earth cable
Required equipment
Equipment, etc.
Note
Cable harness, axes 1-4
3HAC 12782-1
Brake release located at

base.
Cable harness, axes 1-4
3HAC 14940-1
Brake release located in

frame.
Locking liquid
Standard toolkit
Loctite 638
Used to secure the
attachment screws for the
attachment plate inside the
frame.
3HAC 15571-1

the Product manual,
Other tools and

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

required.
Circuit Diagram
See chapter Circuit diagram

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

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

by removing its attachment screws.

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

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

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

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

The cable between the battery and the SMB-unit
may stay connected, in order to avoid an update
of the revolution counter. Be careful not to let the
weight of the cover strain the cable!
In order to remove the cover completely, the
connector R1.G must be disconnected! This
causes a necessary updating of the revolution
counter!
9.
Disconnect connectors R2.SMB, R1.SMB1-3,

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

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

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

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

The procedure below details how to refit the cable harness, axes 1-4.
Step
Action
Note/Illustration
1.
Danger!
2.
204
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
4 Repair
Step
Action
Note/Illustration
3.
Pull the cable and connectors down through

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

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

with its attachment screws.

7.
Reconnect all connectors at motor 1 and

motor 2.
Specified and shown in the figure

Location of cable harness on page
200!
205
4 Repair
Step
8.
Action
Note/Illustration
Secure the cable gland (A) with four

Locking liquid is specified in
attachment screws (B) from inside the SMB
recess.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws,
using locking liquid.
Refit the velcro strap (D).
Note! Different manipulator versions are fitted
with different versions of the attachment plate.
Make sure the correct one is used to avoid
cable failure.
xx0300000560
206
A: Cable gland
B: Attachment screws, cable
gland
C: Attachment plate
D: Velcro strap
4 Repair
Step
9.
Action
Note/Illustration
Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 if the brake
release board is located in frame.
Reconnect R1.G if it has been disconnected.
xx0200000118
10. Secure the SMB cover with its attachment

screws.
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 36!
12. Pull the cable harness through the lower arm.
13. Refit the cable gland securing the cables
xx0100000142
207
4 Repair
Step
Action
Note/Illustration
14. Refit the cable gland securing the cables to

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

motor 4.
Specified and shown in the figure

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

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

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

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

counters on page 370.
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.
4 Repair

Location of cable harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
xx0100000145
Cable attachment, upper arm
Cable attachment, rear
Connector at cable harness division; R2.M5/6
Required equipment
Equipment, etc.
Note
3HAC 11440-1
Cable harness axis 5
Standard toolkit
3HAC 15571-1

the Product manual,
209
4 Repair
Equipment, etc.
Note
Other tools and

procedures may be
the step-by-step
instructions below.

required.
Circuit Diagram
See chapter Circuit diagram

Removal, cable harness, axes 5-6

The procedure below details how to remove the upper arm cable harness.
Step
Action
Note
1.
Danger!
2.
Remove the left hand side wrist cover by unscrewing

its attachment screws.
3.
Note!
Axis 5 must be oriented in the correct position (+90)
to allow the motor 6 cover to open!
4.
Disconnect all connectors at motor 5 and motor 6.
5.
Remove the plastic cover on the rear of the upper

arm, by removing the attachment screws.
6.
Remove the spiral plate by unscrewing the screw at

the bottom of the spiral cup.
7.
Remove eventual cable straps from the harness.
8.
Disconnect connector R2.M5/6 at the cable harness

division.
9.
Remove the cable attachment inside the upper arm.
Specified in the figure

Location of cable harness ax
5-6 on page 209!

of cable harness ax 5-6 on
page 209!
10. Gently pull the cable harness out.
210
4 Repair
Refitting, cable harness, axes 5-6

The procedure below details how to refit the upper cable harness.
Step
Action
Note
1.
Danger!
2.
The manipulator is required to positioned in the

following position:
Axis 4: 0 degrees
Axis 5: +90 degrees
3.
Gently insert the cable harness from the rear into the
upper arm.
4.
Pull the small spiral plate past motor 5.
5.
Route the cables outside the heat protection plate.
6.
Secure the small plate to the large plate. Secure the

spiral cup with its attachment screw in the bottom of
the cup.
7.
Secure any excess cable length tightly to the large

Excess cable length may be
plate in the wrist housing, using cable straps.
present if upper arm length
Use the attachment holes in the large plate intended is not the maximum.
for the cable straps!
8.
Reconnect all connectors at motor 5 and motor 6.
9.
Secure the cable with the cable attachment inside the

upper arm.
Specified in the figure

Location of cable harness ax
5-6 on page 209!
10. Refit the left hand side wrist cover with its attachment
screws.
11. Reconnect connector R2.M5/6 gently at thecable
harness division with two screws, M6.
Be careful not to bend the attachment plate when
fastening the screws!

of cable harness ax 5-6 on
page 209!
M6, 2 pcs.
12. Refit the plastic cover on the rear of the upper arm.
13. Update the revolution counters.
Detailed in chapter
Calibration - section
Updating revolution counters
on page 370.
211
4 Repair
DANGER!
it is vital that:
212
4 Repair
4.3.3. Removal of complete arm system

Location of complete 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.
xx0100000150
Gearbox, axis 1
Motor, axis 1
Base attachment screws
Upper arm
Lower arm
Frame
Balancing device
Block for calibration
213
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 15607-1
Instruction 3HAC 15971-2 enclosed!
Standard toolkit
3HAC 15571-1

Other tools and procedures

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

Removal, complete arm system

The procedure below details how to lift and remove the complete arm system.
WARNING!
result in burns!
CAUTION!
The complete arm system weighs 2000 kg! All lifting equipment used must be dimensioned
accordingly!
Step
Action
Note/Illustration
1.
Make sure the manipulator is positioned as shown in If the brakes need to be

the figure to the right.
released, this is detailed in
section Manually releasing
the brakes on page 63.
2.
Drain the oil from the gearbox, axis 1.
xx0100000103
214

page 156.
4 Repair
Step
Action
Note/Illustration
3.
Detailed in section Removal

of motor, axis 1 on page 280.
4.
Run the overhead crane to a position above the

manipulator.
5.
Fit the lifting device and adjust it as detailed in

enclosed instruction.
6.
Remove the block for calibration from the bottom of Shown in the figure Location
the frame.
of complete arm system on
page 213!
7.
Remove the arm system from the base by

unscrewing the 24 base attachment screws.

of complete arm system on
page 213!
8.
Lift the arm system and secure it in a safe area.
Make sure all hooks and

attachments maintain in
correct position while lifting
the manipulator!
Always move the
manipulator at very low
speeds, making sure it does
not tip.

page 214!
Make sure the lift is done
completely level! How to
adjust the lift is described in
the enclosed instruction to
the lifting device! Follow the
instructions before
continuing the lift!
215
4 Repair
4.3.4. Refitting of complete arm system

Location of complete 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.
xx0100000150
216
Gearbox, axis 1
Motor, axis 1
Base attachment screws
Upper arm
Lower arm
Frame
Balancing device
Block for calibration
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 15607-1
Instruction 3HAC 15971-2 is

enclosed!
Guide pins, M12 x 130
Standard toolkit
Used to guide the complete arm

system when refitting.
Always use the guide pins in pairs.
3HAC 15571-1


instructions below.

Calibration Pendulum Instruction

Refitting, complete arm system

The procedure below details how to lift and refit the complete arm system.
WARNING!
result in burns!
CAUTION!
The complete arm system weighs 2000 kg! All lifting equipment used must be dimensioned
accordingly!
Step
Action
Note/Illustration
1.
Fit and adjust the lifting device as

detailed in enclosed instruction.

2.
Lift the complete arm system and move it Make sure all the hooks and
at very low speed, making sure it does not attachments maintain in correct position
tip!
while lifting the manipulator!
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
217
4 Repair
Step
3.
Action
Note/Illustration
Fit two guide pins, M12 x 130, in the frame

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

below of the frame.
Attachment holes for the guide
pins, M12.
Guiding hole for the spring pin
located in the gearbox, axis 1.
4.
Look through the empty mounting hole of This is a complex task to be performed
motor axis 1, to assist in aligning the
with outmost care in order to avoid injury
assembly during refitting of the arm
or damage!
system.
The guiding 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.
5.
Refit 22 of the 24 attachment screws

before the arm system is completely
lowered.
6.
Remove the guide pins and secure the

arm system to the base with the 24 base complete arm system on page 216!
24 pcs, M12 x 110; 12.9 quality
UNBRAKO, tightening torque: 110 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints in the Product manual,
reference information before fitting.
7.
Refit the block for calibration at the bottom Shown in the figure Location of
of the frame.
complete arm system on page 216!
8.
Detailed in section Refitting of motor,

axis 1 on page 283.
9.
Refill the gearbox axis 1 with lubricating

oil.
Detailed in section Oil change, gearbox

axis 1 on page 156.
10. Recalibrate the robot.
218
Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
4 Repair
DANGER!
it is vital that:
219
4 Repair
4.4.1. Removal of turning disk
4.4 Upper arm

Location of turning disk
The turning disk 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.
xx0100000129
Turning disk
Oil plug, draining
Oil plug, filling
Turning disk attachment screws, 33 pcs
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1


references to these
procedures in the step-bystep instructions below.
220

the tools required.
4 Repair
Removal, turning disk

The procedure below details how to remove the turning disk.
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Run the robot to a position where the oil plug,

draining of axis 6 gearbox faces downwards.
2.
Drain the oil from gearbox 6.

3.
Remove the turning disk by unscrewing its 33

attachment screws .

turning disk on page 220!
221
4 Repair
4.4.2. Refitting of turning disk

Location of turning disk
The turning disk is located in the center of the wrist unit as shown in the figure below.
xx0100000129
Turning disk
Oil plug, draining
Oil plug, filling
Turning disk attachment screws, 33 pcs
Required equipment
Equipment, etc.
Note
Turning disk
3HAC 13193-1
Does not include o-ring!
O-ring
2152 2012-433
Must be replaced when

replacing the turning disk!
Grease
3HAB 3537-1
Used to lubricate the o-ring.
Standard toolkit
3HAC 15571-1

the Product manual,
Other tools and

procedures may be
below.
222

required.
4 Repair
Refitting, turning disk

The procedure below details how to refit the turning disk.
WARNING!
result in burns!
Step
1.
Action
Note/Illustration
Lubricate the turning disk o-ring with

grease.
Fit the o-ring to the rear of the turning disk.
xx0100000130
A: O-ring, turning disk

B: Turning disk
C: Gearbox, axis 6
2.
Secure the turning disk with 33

attachment screws.
M10 x 25, 12.9 quality UNBRAKO,

tightening torque: 50 Nm.
3.
Refill the gearbox 6 with oil.

axis 6 on page 174.
DANGER!
it is vital that:
223
4 Repair
4.4.3. Removal of complete wrist unit

Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
xx0100000147
Wrist unit
Wrist unit attachment screws and washers
Attachment, cable harness axis 5-6
Connectors at cable harness division; R2.M5/6
Turning disc
Cover, axis 5
Rear cover
View with cable harness mounted on robot
Required equipment
224
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Lifting tool, wrist unit
3HAC 12734-1
4 Repair
Equipment, etc.
Art. no.
Note

instructions below.

Circuit diagram

information.
Removal, wrist unit

The procedure below details how to remove the complete wrist unit.
WARNING!
result in burns!
CAUTION!
The wrist unit weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Remove all equipment fitted to the turning disk.

of wrist unit on page 224!
2.
Turn axis 4 to a position where the cover, axis 5

faces upwards.

3.
Remove the cover, axis 5, by unscrewing its

attachment screws.
4.
Fit the Lifting tool, wrist unit to the two holes on the
sealing surface against the cover, axis 5.

page 224!
If required to fit the tool, cut
any cable ties securing the
cables.
5.
Remove the rear cover by unscrewing its

attachments.

6.
Disconnect connector R2.M5/6 at the rear cable

division point .

7.
Remove all cable attachment inside the upper arm

and on the rear of the robot.
Do not remove the

attachments from the
cabling!
8.
Slightly raise the wrist unit to unload the screw joint,

facilitating removing the attachment screws.
9.
Remove the wrist unit attachment screws and

washers .
10. Pull the cabling forwards through the upper arm tube. Make sure the attachments
do not get stuck inside the
tube!
225
4 Repair
Step
Action
11. Remove the friction washer between the wrist unit

and the upper arm tube.
Note/Illustration
A new washer must always
be used on reassembly.
12. Lift the wrist unit down and place it on a secure

surface.
226
4 Repair
4.4.4. Refitting of complete wrist unit

Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
xx0100000147
Wrist unit
Wrist unit attachment screws and washers
Attachment, cable harness axis 5-6
Turning disc
Cover, axis 5
Rear cover
View with cable harness mounted on robot
Required equipment
Equipment, etc.
Note
Wrist unit
3HAC 16628-1
Includes all hardware

except attachment
screws!
227
4 Repair
Equipment, etc.
Note
Friction washer
3HAC 11755-1
A new friction washer

must always be used on
reassembly.
Standard toolkit
3HAC 15571-1
The contents are defined

in section Standard
toolkit in the Product
manual, reference
information.
Lifting tool, wrist unit
3HAC 12734-1

references to these
These procedures
include references to the
tools required.
Circuit Diagram
See chapter Circuit

diagram in the Product
manual, reference
information.
Calibration Pendulum
Instruction

section Document
references in the Product
manual, reference
information.
Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
WARNING!
result in burns!
CAUTION!
The wrist unit weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
Step
228
Action
Note/Illustration
1.
Remove the cover, axis 5 from the wrist unit to be

fitted. Fit the Lifting tool, wrist unit to the wrist unit.

page 227!
2.
Lift the wrist unit and run it to its mounting position.
3.
Fit a new friction washer between the upper arm

assembly and the wrist unit.
4.
Gently pull the wrist unit cable harness through the

upper arm and out the rear.

page 227!
4 Repair
Step
Action
Note/Illustration
5.
Secure the wrist unit with its attachment screws and

washers.
Screws: M12 x 50,

UNBRAKO quality 12.9,
Reused screws may be
used, providing they are
lubricated as detailed in
section Screw joints in the
information before fitting.
6.
Secure the cable harness with the cable attachment

inside the upper arm as well as on the rear of the
upper arm.
Make sure the cabling is not

twisted!
7.
Remove the lifting tool, wrist unit and refit the cover, Shown in the figure Location
axis 5 with its attachment screws.
8.
Refit any cable ties that were previously cut during

disassembly.
9.
Reconnect connector R2.M5/6 at the rear cable

division point.

10. Refit the rear cover with its attachment screws.

11. Check the oil level at gearbox axis 5 and 6.
Detailed in sections
Inspection, oil level,
gearbox axis 5 on
page 123
gearbox axis 6 on
page 126.
12. Recalibrate the robot!
Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
information.
13. Refit any equipment previously removed from the

turning disk.
DANGER!
it is vital that:
229
4 Repair
4.4.5. Removal of complete upper arm

Location of upper arm
The upper arm is located on top of the manipulator as shown in the figure below.
xx0100000148
230
Upper arm
Upper arm attachment screws
Rear cable attachment
Oil plug, draining
Oil plug, filling
Attachment hole, M12
Sealing between lower arm and gearbox 3
Attachment holes for lifting device, upper arm
Attachment holes for lifting eye
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

information.
Lifting eye, M12
3HAC 14457-3
Lifting device, upper arm
3HAC 15536-1
Lifting tool (chain)
3HAC 15556-1
Hoisting block
Standard hoisting block,

capacity 200 kg.

instructions below.

required.
Removal, upper arm

The procedure below details how to remove the complete upper arm.
WARNING!
result in burns!
CAUTION!
The complete upper arm weighs 450 kg without any additional equipment fitted! Use a
suitable lifting device to avoid injury to personnel!
Step
Action
Note/Illustration
1.
Run the manipulator arm to a horizontal position.
2.
Fit the lifting eye to the attachment hole in the wrist

unit.
3.
Fit one of the pieces included in the Lifting device,

Shown in the figure
upper arm to the Attachment holes for lifting device, Location of upper arm on
upper arm using the included attachment screws.
page 230!
page 231!
4.
Run the lifting chain from the rear lifting point through Part no. is specified in
the overhead crane hook, through the hoisting block to Required equipment on
the lifting eye in the front.
page 231!
Shown in the figure

Location of upper arm on
page 230!
page 231!
231
4 Repair
Step
Action
Note/Illustration
5.
Use the hoisting block to adjust the tension in the

chain in order to lift the upper arm completely level.
6.
Drain the oil from gear box 3.
7.
Disconnect connector R2.M5/6 at the rear cable

division point as well as all remaining connections to
the upper arm.
8.
Disconnect all connectors inside motors 3 and 4.
9.
Remove all brackets securing cabling to the upper arm

by unscrewing their attachment screws respectively.

change, gearbox, axis 3 on
page 163.
10. Raise the lifting equipment to take the weight of the

upper arm.
11. Carefully remove the upper arm attachment screws .
Make sure that the upper arm is lifted in a completely
level position in all planes in order not to damage the
upper arm!
Shown in the figure

Location of upper arm on
page 230!
30 pcs.
12. Lift the upper arm and place it on a secure surface.

13. Remove the sealing from the lower arm.
232
4 Repair
4.4.6. Refitting of complete upper arm

Location of upper arm
The upper arm is located on top of the manipulator as shown in the figure below.
xx0100000148
Upper arm
Rear cable attachment
Oil plug, draining
Oil plug, filling
Attachment hole, M12
Sealing between lower arm and gearbox 3
Attachment holes for lifting device, upper arm
Attachment holes for lifting eye
233
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Sealing, axis 2/3
3HAC 11054-1
Always use a new sealing when

reassembling!
Washer
3HAC 11828-1
Replacement washer, gearbox 3

attachment, replaced if damaged.
Standard toolkit
3HAC 15571-1

Lifting eye, M12
3HAC 14457-3
Lifting device, upper arm
3HAC 15536-1
3HAC 15556-1
Hoisting block
234
Standard hoisting block, capacity 200

kg.
Guide pins, sealing axis 2/3
3HAC 14627-2
80 mm.
For guiding "Sealing, axis 2/3".
Guide pins, sealing axis 2/3
3HAC 14627-3
100 mm.

references to these

Instruction

4 Repair
Refitting, upper arm

The procedure below details how to refit the complete upper arm.
WARNING!
result in burns!
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The complete upper arm weighs 450 kg without any additional equipment fitted! Use a
suitable lifting device to avoid injury to personnel!
Step
1.
Action
Note/Illustration
Fit the two guide pins, sealing axis 2/3 in two of the
attachment screw holes on gearbox 3, see figure
beside.
Guide the new sealing, axis 2/3 into position with the
guide pins, on gearbox 3.
Always use a new sealing

when reassembling!
page 234!
xx0200000125
A: Holes for guide

pins on the gearbox.
2.
Fit the lifting eye to the attachment hole in the wrist Shown in the figure Location
unit.
of upper arm on page 233!
page 234!
3.
Fit one of the pieces included in the Lifting device,

upper arm to the Attachment holes for lifting device, of upper arm on page 233!
upper arm using the included attachment screws.
page 234!
4.
Run the lifting chain from the rear lifting point through Art. no. is specified in
the overhead crane hook, through the hoisting block Required equipment on
to the lifting eye in the front.
page 234!
235
4 Repair
Step
Action
Note/Illustration
5.
Use the hoisting block to adjust the tension in the

chain in order to lift the upper arm completely level.
6.
Lift the upper arm and run it to its mounting position.
7.
Fit the three washers to be placed beneath the

attachment screws.
Make sure the washers are

not scarred or pitted in the
surface facing the screw
heads. If both washer sides
are damaged, replace the
washer. Art. no. is specified
in Required equipment on
page 234!
8.
Insert the attachment screws.

Do not remove the guide pins until the attachment
screws are drawn as detailed below!
In some cases, 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.
9.
Secure the lower arm to gearbox 3 with the Upper

arm attachment screws .

of upper arm on page 233!
30 pcs: M16 x 50.
10. Remove the guide pins and fit the two remaining
attachment screws. Tighten them as detailed above!
11. Refit any cabling removed during the removal
process.
12. Reconnect all connectors inside motors 3 and 4.
13. Reconnect connector R2.M5/6 gently at the rear
cable division point.
Be careful not to bend the attachment plate when
fastening the screws!
236
14. Refill the gear box with oil.

page 163.
manuals.
information.
4 Repair
DANGER!
it is vital that:
237
4 Repair
4.5.1. Removal of complete lower arm
4.5 Lower arm

Location of lower arm
The lower arm is located as shown in the figure below.
xx0100000149
238
Lower arm
Pivot point, axis 2
Front shaft, balancing device, including securing screw
Attachment for lifting eye, M12, balancing device
4 Repair
Attachment points, lower arm

The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation to the
gearbox is identical for axis 3.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
xx0200000031
Gear box
Lower arm
Balancing device piston rod ear
Frame
Shaft hole
201
Sealing, axis 2/3
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
239
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Lifting tool, lower arm
3HAC 14691-1
Tool that may be rent from

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

device.
Puller tool, balancing device shaft
3HAC 12475-1
Used to pull out the shaft from

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

press tool, axis 2 shaft and the
puller tool.
Hydraulic pump 80Mpa (Glycerin)
3HAC 13086-2

press tool, axis 2 shaft and the
puller tool.
Retaining ring pliers
Standard toolkit
3HAC 15571-1


information.
required.
Removal, lower arm

The procedure below details how to remove the complete lower arm.
WARNING!
result in burns!
CAUTION!
The lower arm weighs 225 kg! All lifting equipment used must be dimensioned accordingly!
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!
Step
1.
240
Action
Note/Illustration
Remove the upper arm.

complete upper arm on page 230.
4 Repair
Step
Action
Note/Illustration
2.
Disconnect and remove the cables from

Release any cable attachments.
Detailed in section Replacement of

cable harness, axes 1-4 on page 200.
3.
Apply the lifting eye to the balancing device Art. no. is specified in Required
and raise to unload the device.
Attachment shown in the figure
Location of lower arm on page 238.
4.
Unload the balancing device in order to

Detailed in section Unloading the
make the piston rod and front ear
balancing device on page 274.
adjustable when pulling the front shaft out.
5.
Remove the securing screw from the

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

arm on page 238.
6.
Apply the shaft puller tool to the shaft

through the hole in the frame.
The shaft has a M20 thread diameter and a
40 mm depth of thread, as shown in the
figure to the right.
Pull the shaft out using the puller tool and
the hydraulic pump.
xx0300000060
Note! The dimension of the shaft puller

tool is M20. Do not mix up with the shaft
press tool used when mounting the
shaft.
7.
Lower the balancing device until it rests

safely against the bottom of the frame, out
of reach from the lower arm.
8.
Move the lower arm backwards to the

lowest position possible.
9.
Apply the lifting tool to the lower arm.
xx0300000015
10. Drain the oil from gearbox 2.

axis 2 on page 160.
11. Raise the tool to unload the lower arm.

12. Remove the protection plug .
Shown in the figure Attachment points,

lower arm on page 239!
241
4 Repair
Step
Action
13. Remove the protection washer and the

retaining ring .
Note/Illustration
Use a pliers for the retaining ring.
14. Fit the press (/puller) tool as shown in the Art. no. is specified in Required
figure to the right and mount both the
hydraulic pump and the glycerin pump to it.
xx0300000010
15. Increase the pressure of the glycerin pump Do not exceed the limit of maximum
and, at the same time, pull out the shaft
pressure classified for the pumps!
with the puller tool by increasing the
pressure of the hydraulic pump.
16. Remove the lower arm attachment screws Shown in the figure Attachment points,
and washers that attaches the lower arm lower arm on page 239!
to the gearbox 2.
17. Lift the lower arm down and place it on a
secure surface.
242
18. Remove the bearing and thrust washer

from the shaft hole in the lower arm.

On reassembly a new bearing must be
used!

On reassembly a new sealing must be
used!
4 Repair
4.5.2. Refitting of complete lower arm

Location of lower arm
The lower arm is located as shown in the figure below.
xx0100000149
Lower arm
Pivot point, axis 2
Front shaft, balancing device, including securing screw
Attachment for lifting eye, M12, balancing device
243
4 Repair
Attachment points, lower arm

The lower arm attachment points are located as shown in the figure below:
The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation to the
gearbox is identical for axis 3.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
xx0200000031
244
Gear box
Lower arm
Balancing device piston rod ear
Frame
Shaft hole
201
Sealing, axis 2/3
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
4 Repair
Required equipment
Equipment, etc.
Note
Bearing
3HAC 4310-1
Always use a new bearing

when reassembling!
Sealing, axis 2/3
3HAC 11054-1
Always use a new sealing

when reassembling!
VK-cover
3HAA 2166-23
Mount on new lower arm or

replace if damaged.
Lifting tool, lower arm
3HAC 14691-1

ABB.
Two guidings, 3HAC 144451, that must be used for
guiding the sealing, axis 2/
3, is accompanying the tool.
Guidings
3HAC 14445-1
For guiding the sealing, axis

2/3.
2 pcs enclosed with the
lifting tool, lower arm.
Rotation tool, motor
3HAC 17105-1
Used to rotate the motor

pinion and gear if
necessary, when brakes are
released.
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Press tool, axis 2 shaft
3HAC 13452-1
Press tool, axis 2 bearing
3HAC 13453-1
Hydraulic pump 80 Mpa
3HAC 13086-1

press tools.
Hydraulic pump 80 Mpa

(glycerin)
3HAC 13086-2

press tools.
ABB.
Retaining ring pliers
Grease
3HAB 3537-1
For lubricating shaft hole
Standard toolkit
3HAC 15571-1

the Product manual,
Other tools and

procedures may be
below.

required.
Instruction

section Document
manual, reference
information.
245
4 Repair
Refitting, lower arm

The procedure below details how to refit the complete lower arm.
WARNING!
result in burns!
CAUTION!
The lower arm weighs 225 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Fit a new VK-cover on new lower arm or

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

2.
Fit the two guidings in the attachment

holes of the lower arm.

xx0200000262
246
A: Attachment holes for the two

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

guidings.

reassembling!
4.
Apply the lifting tool to the lower arm.

5.
Lift the lower arm and run it to its mounting

position.
4 Repair
Step
6.
Action
Note/Illustration
In case the holes of the lower arm and the Connect power supply to connector
ones of the gearbox axis 2 doesnt match, R2.MP2:
use power supply to release the motor axis
+ : pin 2
2 brakes and rotate the pinion and gear
- : pin 5
with the rotation tool.
xx0200000165
The rotation tool (A) is used beneath

the motor cover, directly on the motor
shaft as shown in the figure above!
7.
Secure the lower arm with 28 of the 30

attachment screws and washers in
gearbox 2.
8.
Remove the guidings and secure the two

remaining attachment screws as detailed
above!
9.
Apply grease to the shaft hole.
30 pcs: M16 x 50; tightening torque:

300 Nm.

10. Push the shaft in by hand.
xx0300000014
A: Retaining ring
B: Protection washer
C: Bearing
D: Thrust washer
E: Shaft
F: Protection washer
247
4 Repair
Step
Action
Note/Illustration
11. Apply the press tool, axis 2 shaft.

12. Tighten the M16 nut.
13. Fit both the hydraulic pump and the

glycerin pump to the press tool.
14. Set the indicator on the press tool to zero
15. 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..
16. Increase the pressure of the both pumps
alternately until the correct value is
reached with the indicator on the press
tool.
Correct value: 2.45 mm 0.15 mm

Note! Do not exceed the limit of
maximum pressure classified for the
pumps!
17. Remove the press tool, axis 2 shaft.
Release the pressure from the glycerin

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

19. Apply grease to the location of the shaft

where the bearing is to be mounted.
248
20. Press the bearing in with the press tool,

axis 2 bearing.
Always use a new bearing when

reassembling!
21. Refit the protection washer and the

retaining ring.

22. Refit the protection plug.

23. Refit and restore the balancing device.

24. Refit the upper arm.
Detailed in section Refitting of complete

upper arm on page 233.
25. Perform a leak-down test.
Detailed in section Performing a leakdown test on page 196.
26. Refill the gearbox with oil.

axis 2 on page 160.
27. Refit and reconnect all cables inside the

lower arm.
Resecure any cable attachments.
Detailed in section Replacement of

cable harness, axes 1-4 on page 200.

4 Repair
DANGER!
it is vital that:
249
4 Repair
4.6.1. Removal of SMB related equipment
4.6 Frame and base

Location of SMB related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below.
Note that the manipulator is shown with the SMB cover already removed!
xx0100000138
Attachment screw, SMB battery cover
SMB battery cover
SMB battery
SMB cover
Attachment screw, SMB cover
SMB unit
Battery cable
Pins
Connector F2.FB7 (option)
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.
Circuit Diagram
250
See chapter Circuit diagram in the Product

4 Repair
Removal, battery
The procedure below details how to remove the SMB battery.
WARNING!
result in burns!
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to

electrostatic voltages.
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
Step
Action
Note/Illustration
1.
If replacing only the battery, the power to the robot

does not need to be turned off!
Turning off the power requires a synchronization of
the robot!
2.
Remove the SMB battery cover by unscrewing its

attachment screws .

of SMB related equipment
on page 250!
3.
Disconnect the battery from the cable, battery/SMB

board .

on page 250!
4.
Remove the SMB battery.

Battery includes protection circuits. Replace it only
with the specified spare part in the refitting instruction on page 250!
or with an ABB approved eqvivalent.
251
4 Repair
Removal, SMB unit

The procedure below details how to remove the SMB unit.
WARNING!
result in burns!
DANGER!

similar.
Step
Action
Note/Illustration
1.
Danger!
Danger!
Make sure that the main power has been switched
off!
252
2.
Remove the SMB battery.
Detailed in the previous

procedure: Removal, battery
on page 251.
3.
Remove the SMB cover by unscrewing its

attachment screws.
Pull the battery cable through the hole in the SMB
cover and disconnect the connector R2.FB7, if any.

on page 250!
4.
Remove the two locknuts and washers from the pins Shown in the figure Location
securing the board.
on page 250!
5.
Gently disconnect the connectors from the SMB unit Connectors R1.SMB1-3,
when pulling the board out.
R1.SMB4-6 and R2.SMB
6.
Also disconnect the battery cable from the SMB unit.
4 Repair
4.6.2. Refitting of SMB related equipment

Location of SMB related equipment
The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below.
Note that the manipulator is shown with the SMB cover already removed!
xx0100000138
Attachment screw, SMB battery cover
SMB battery cover
SMB battery
SMB cover
Attachment screw, SMB cover
SMB unit
Battery cable
Pins
Connector F2.FB7 (option)
Required equipment
Equipment, etc. Spare part no. Art. no.
SMB Unit
3HAC 16014-1
SMB Battery
3HAC 16831-1
Cable, battery/
SMB board
Note
Battery includes protection circuits.
Replace it only with given spare
part no. or an ABB approved
eqvivalent.
3HAC 13151-1
253
4 Repair
Equipment, etc. Spare part no. Art. no.
Note
Standard toolkit

3HAC 15571-1
Circuit Diagram

information.
Refitting, battery
The procedure below details how to refit the SMB battery.
WARNING!
result in burns!
DANGER!

similar.
Step
254
Action
Note/Illustration
1.
Refit the SMB battery and connect the cable,

battery/SMB board to the battery.

page 253!
on page 253!
2.
Secure the SMB battery cover with its attachment

screws.

on page 253!
3.
Synchronize the robot, if the power has been turned

off!
Detailed in chapter
Calibration information on
page 365.
4 Repair
Refitting, SMB board

The procedure below details how to refit the SMB board.
WARNING!
result in burns!
DANGER!

similar.
Step
Action
Note/Illustration
1.
Connect the battery cable to the SMB board.
2.
Fit the SMB unit onto the pins and connect all
connectors to the board.
3.
Secure the SMB unit to the pins with two locknuts and
washers.
4.
Pull the battery cable through the hole in the SMB

cover and reconnect the connector R2.FB7, if any.
5.
Secure the SMB cover with its attachment screws. Shown in the figure Location
If the brake release unit is located at the frame, the of SMB related equipment
push buttons must be checked as detailed below! The on page 253!
push button guard must first be removed!
Art. no. is specified Required

on page 253!
R1.SMB1-3, R1.SMB4-6
and R2.SMB

on page 253!
6.
Warning!
Make sure the power is turned off and that the push
button guard is removed.
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.
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!
255
4 Repair
Step
Action
Note/Illustration
7.
Refit the battery.
Detailed in the previous

section Refitting, battery on
page 254.
8.
Synchronize the robot!
Detailed in chapter
Calibration information on
page 365.
DANGER!
it is vital that:
256
4 Repair
4.6.3. Removal of brake release unit

Different designs
Depending on the robot version, the brake release unit may be located either at the base or at
the frame. The following two figures show the different locations.
The early design includes a brake release unit with or without push buttons, located at the
base. The later design instead includes a brake release unit with push buttons, placed together
with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake release unit, base
The early design includes a brake release unit with or without push buttons, located at the base
xx0200000127
Brake release circuit (brake release unit inside)
Attachment screws, brake release circuit, 4 pcs
257
4 Repair
Location of brake release unit, frame

The later design includes a brake release unit with push buttons, placed together with the
SMB unit on the left hand side of the frame as shown in the figure below.
xx0200000226
Brake release unit
Attachment screws, brake release unit (4 pcs)
Buttons
SMB cover
Push button guard
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1


instructions below.
258

4 Repair
Removal of brake release unit, located at base

The procedure below details how to remove the brake release unit, located at the rear of the
base. See the figure Location of brake release unit, base on page 257.
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Danger!
Danger!
Make sure that the main power has been switched
off!
2.
Remove the cover at the rear of the base.
3.
Unscrew the four attachment screws, brake release Shown in the figure Location
circuit on the outside of the base.
of brake release unit, base
on page 257!
4.
Disconnect the cable from the brake release circuit

and remove the circuit from the base.
Removal of brake release unit, located on frame

The procedure below details how to remove the brake release unit, located on the side of the
frame. See the figure Location of brake release unit, frame on page 258.
WARNING!
result in burns!
DANGER!

similar.
259
4 Repair
Step
Action
Note/Illustration
1.
Danger!
Danger!
Make sure that the main power has been
switched off!
2.
Remove the push button guardfrom the Shown in the figure Location of brake
SMB cover.
release unit, frame on page 258.
The guard must be removed to ensure a
correct refitting of the brake release unit.
3.
Remove the SMB cover by unscrewing Shown in the figure Location of brake
the attachment screws.
Let the battery stay connected, to avoid
the need of synchronization of the robot!
4.
Disconnect the connectors X8, X9 and

X10 from the brake release unit.
xx0200000129
5.
260
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons for each axis
Remove the brake release unit from the Shown in the figure Location of brake
plate by unscrewing the four attachment release unit, frame on page 258!
screws, brake release unit.
4 Repair
4.6.4. Refitting of brake release unit

Different designs
Depending on the robot version, the brake release unit may be located either at the base or at
the frame. The following two figures show the different locations.
The early design includes a brake release unit with or without push buttons, located at the
base. The later design instead includes a brake release unit with push buttons, placed together
with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake release unit, base
The early design includes a brake release unit with or without push buttons, located at the base
xx0200000127
Brake release circuit (brake release unit inside)
Attachment screws, brake release circuit, 4 pcs
261
4 Repair
Location of brake release unit, frame

The later design includes a brake release unit with push buttons, placed together with the
SMB unit on the left hand side of the frame as shown in the figure below.
xx0200000226
Brake release unit
Attachment screws, brake release unit (4 pcs)
Buttons
SMB cover
Push button guard
Required equipment
262
Equipment, etc.
Note
Brake release circuit

without buttons, at base
3HAC 14219-1
Brake release at the base,

according to figure 1.
Includes brake release
unit 3HAC 14228-1.
Brake release circuit with

buttons, at base
3HAC 12989-1
Brake release at the base,

according to figure 1.
Includes brake release
unit 3HAC 16036-1.
Brake release unit with

buttons, at frame
3HAC 16036-1
Brake release unit at the

frame, according to figure
2.
4 Repair
Equipment, etc.
Push button guard
3HAC 2744-1
Standard toolkit
3HAC 15571-1

references to these
Note
in section Standard toolkit
required.
Refitting of brake release circuit, located at base

The procedure below details how to refit the brake release circuit, located at the rear of the
base. See the figure Location of brake release unit, base on page 261.
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Place the brake release circuit in the base of the

robot.

page 262!
on page 261!
2.
Reconnect the cable to the brake release circuit.
3.
Fasten the attachment screws, brake release circuit

on the outside of the rear of the base.
4.
Refit the cover of the rear of the base.

on page 261!
263
4 Repair
Refitting of brake release unit, located on frame

The procedure below details how to refit the brake release unit, located on the side of the
frame. See the figure Location of brake release unit, frame on page 262.
WARNING!
result in burns!
DANGER!

similar.
Step
Action
Note/Illustration
1.
Fit the brake release unit on the plate with

the attachment screws.
Make sure the unit is positioned as
straight as possible on the plate! The push
buttons can otherwise get jammed when
the SMB-cover is refitted.
Shown in the figure Location of brake

release unit, frame on page 262!
2.
Connect the connectors X8, X9 and X10

to the brake release unit.
xx0200000129
3.
264
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

4 Repair
Step
Action
Note/Illustration
4.
Warning!
Make sure the power is turned off and that

the push button guard is removed.
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.
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!
5.
Refit the push button guard on the SMB

cover.

6.
If the battery has been disconnected the

robot must be synchronized.
Eventual synchronization is detailed in

the chapter Calibration information on
page 365.
DANGER!
it is vital that:
265
4 Repair
4.6.5. Removal of balancing device

Location of balancing device
The balancing device is located on rear top of the frame as shown in the figure below.
xx0100000139
266
Balancing device
Bearing attachment
Attachment screws, bearing attachments
Rear cover
Attachment screws, rear cover
Hole through which shaft puller tool is to be inserted
Mounting hole, shaft puller tool
Balancing device front eye shaft, including securing screw and washer
Hole for lower arm locking screw, M16 x 90
Attachment hole for lifting eye, M12
Parallel pin (inside bearing attachment)
Support shaft inside (included in balancing device 3HAC 14675-1)
Plug
4 Repair
Required equipment
Equipment, etc
Art. no.
Note
Locking screw, lower arm
3HAB 3409-90
M16 x 90
Lifting eye, M12
3HAC 14457-3
Press tool, balancing device 3HAC 15767-1

Shaft puller tool, balancing
device
3HAC 12475-1
Hydraulic cylinder
3HAC 11731-1
To be used with press tool 3HAC 15767-1

and shaft puller tool 3HAC 12475-1.
Hydraulic pump
3HAC 13086-1
To be used with hydraulic cylinder 3HAC

11731-1.
Securing screw
9ADA 183-66
M12 x 35, 2 pcs required.

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

Removal, balancing device

The procedure below details how to remove the balancing device.
WARNING!
result in burns!
CAUTION!
The balancing device weighs 300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Note/Illustration
Run the lower arm to a position close to the

calibration position.
267
4 Repair
Step
2.
Action
Note/Illustration
Secure the lower arm to the frame by

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

3.
Apply lifting eye, M12 to the balancing

device and raise to unload the device.

4.
Unload the balancing device with the press Detailed in section Unloading the
tool in order to make the piston rod and front balancing device on page 274
ear adjustable when pulling the shaft out.
5.
Remove the securing screw and washer

from the shaft.
6.
Apply shaft puller tool to the shaft through

the hole in the frame.
The shaft has a thread dimension of M20
and a 40 mm depth of thread, as shown in
Pull the shaft out using the puller tool and the
hydraulic cylinder and pump.

balancing device on page 266!
xx0300000060
Note! The dimension of the shaft

puller tool is M20. Do not mix up with
the shaft press tool used when
mounting the shaft.
The hole in the frame is shown in the
figure Location of balancing device on
page 266!
7.
Restore the balancing device.
Detailed in section Restoring the

balancing device on page 277
8.
Secure the two bearing attachments to the Shown in the figure Location of
balancing device by replacing the plug on
the outside of each attachment, with a
M12 x 35
screw.
9.
Remove the two bearing attachments from Shown in the figure Location of
the frame by unscrewing their four
attachment screws.
Make sure the parallel pins are not
lost!
10. Fit two guide pins, through the upper holes Art. no. is specified in Required
of the bearing attachments, to the frame.
11. Lift the balancing device gently backwards
to a secure area, allowing the bearing
attachments to slide on the guide pins.
268
Note! Make sure not to burden the

guide pins with the weight of the
balancing device!
4 Repair
4.6.6. Refitting of balancing device

The balancing device is located on rear top of the frame as shown in the figure below.
xx0100000139
Balancing device
Bearing attachment
Attachment screws, bearing attachments
Rear cover
Attachment screws, rear cover
Hole through which shaft puller tool is to be inserted
Mounting hole, shaft puller tool
Balancing device front eye shaft, including securing screw and washer
Hole for lower arm locking screw, M16 x 90
Attachment hole for lifting eye, M12
Parallel pin (inside bearing attachment)
Support shaft inside (included in balancing device 3HAC 14675-1)
Plug
269
4 Repair
Required equipment
Equipment
Note
Balancing device
3HAC 14214-1
Includes balancing device

3HAC 14675-1!
Includes o-ring 3HAB 3772-44
(2 pcs).
O-ring, 2 pcs
3HAB 3772-44
Locking screw, lower

arm
3HAB 3409-90
M16 x 90
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 1001-294 150 ml, Optimol PDO

For lubrication of spherical
roller bearing in ear, in case of
new balancing device
Locking liquid
Loctite 243.
To apply to the securing screw
in the shaft.
Grease pump
To lubricate spherical roller

bearing.
3HAC 13120-5
Lifting eye, M12
3HAC 14457-3
Hydraulic pump
3HAC 13086-1
To be used with hydraulic

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

3HAC 15767-1 and shaft press
tool 3HAC 17129-1.
Press tool, balancing

device
3HAC 15767-1
Shaft press tool,

balancing device
3HAC 17129-1
Standard toolkit
3HAC 15571-1
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
270
Always use guide pins in pairs!

information.
4 Repair
Refitting, balancing device

The procedure below details how to refit the balancing device.
WARNING!
result in burns!
DANGER!
CAUTION!
The balancing device weighs 300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Secure the lower arm to the frame by inserting the
locking screw into the hole (1).
Note/Illustration
of balancing device on page
269!
xx0200000454

page 270!
2.
Secure the bearing attachments to the balancing

device with two screws, on the outside of the
attachments.
M12 x 35.
3.
Refit the two parallel pins in the frame.

page 270!
4.
Fit two guide pins in the upper holes in the frame,

where the bearing attachments are to be attached.
271
4 Repair
Step
Action
Note/Illustration
5.
Fit the lifting eye to the balancing device.

page 270!
6.
Lift the balancing device behind the manipulator.

Bring the device forward, gliding the bearing
attachments on to the guide pins (upper holes).
Note! Make sure not to

burden the guide pins with
the weight of the balancing
device!
7.
Remove the guide pins.
8.
Secure the rear of the balancing device by fitting the Shown in the figure Location
two bearing attachments with their four attachment of balancing device on page
screws to the frame.
269!
4 pcs, M16x90; 12.9 quality
UNBRAKO, tightening
torque: 300 Nm 30 Nm.
Reused screws may be
used, providing they are
lubricated as detailed in
section Screw joints in the
9.
Remove the screws from outside of the bearing

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

front shaft may be inserted through the piston shaft
front eye.
272
11. Unload the balancing device with the press tool.

For an easier assembly of the shaft, the piston rod
may be pressed out more than necessary and then
pressed in when fitting the shaft.
Detailed in section
Unloading the balancing
device on page 274.
page 270!
12. Lubricate the shaft with grease.

page 270!
13. Apply the shaft press tool to the lubricated shaft

through the hole in the frame.
Fit the shaft using the press tool and thehydraulic
pump.
The shaft and the hole in the

frame are shown in the figure
on page 269!
page 270!
Note! Make sure the shaft is
pressed all the way to the
bottom.
14. Refit the securing screw and washer in to the shaft

using locking liquid.
M16x180, tightening torque:

50 Nm.
Locking liquid is specified in
page 270!
4 Repair
Step
Action
Note/Illustration
15. When assembling a new device:

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

specified in Required
Lubrication further detailed
in section Lubrication,
balancing device bearing on
page 177.
16. Restore the balancing device.
Detailed in section Restoring

the balancing device on
page 277.
Danger!
Danger!
The rear cover of the balancing device must be
mounted before commissioning of the robot! The rear
cover is a safety device for the piston rod during
operation!
17. Remove the locking screw (1) that secures the lower
arm to the frame.
xx0200000454
DANGER!
it is vital that:
273
4 Repair
4.6.7. 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
274
Press block
Hydraulic cylinder
Press device
Bolt, press device
Moving pin with marking
Bolt (4 pcs)
Pin, attached to the fix plate
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Press tool, balancing device
3HAC 020902-001 Includes

press device 3HAC 15767-2
press device 3HAC 18100-1
Choose the correct device, depending
on model of balancing device.
Hydraulic cylinder
3HAC 11731-1
To be used with the press tool.
Hydraulic pump, 80 MPa
3HAC 13086-1
To be used with the hydraulic cylinder.
Standard toolkit
3HAC 15571-1

Using the correct press device

The different designs of the balancing device require different versions of the press device,
included in the complete press tool. The table below specifies which press device to use to
which balancing device.
The article number of the balancing device may be found on a label at the rear of the balancing
device.
Balancing device
Press device
Art. no: 3HAC 14675-1
Art. no: 3HAC 15767-2
xx0300000605
xx0300000600
275
4 Repair
Unloading the balancing device

The procedure below details how to use the press tool in order to unload the balancing device.
How to remove the press tool, is detailed in section Restoring the balancing device on page
277.
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 275.
The moving pin is shown in the
figure Press tool and hydraulic
cylinder on page 274.
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 274.
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.
Remove the o-ring from the balancing device

end.
5.
Fit the press tool to the rear of the balancing

device with enclosed bolts. Tighten them
properly!

See the figure Press tool and
hydraulic cylinder on page 274!
6.
Fit the hydraulic cylinder to the press tool.

7.
Connect the hydraulic pump to the cylinder.

8.
Increase the pressure and press until the

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

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

11. The hydraulic cylinder may now be removed
from the tool, when necessary.
276
4 Repair
4.6.8. 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
Required equipment
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.
277
4 Repair
Equipment, etc.
Art. no.
Note
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

Restoring the balancing device

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

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

Do not apply more pressure than
necessary, it could damage bearings
and sealings at the shaft.
3.
Unload the cylinder and make sure the

moving pin indicates that the tool has
returned to its starting position.

4.
Remove the hydraulic cylinder.
5.
Remove the press tool by unscrewing the

bolts.
6.
Lubricate and refit the o-ring at the end of the Make sure the o-ring is seated
balancing device.
properly! Replace if damaged.
7.
Refit the support shaft to the balancing

device.
8.
Lubricate and refit the o-ring on the support

shaft.
9.
Refit the rear cover to the balancing device

with its attachment screws, using locking
liquid.

Make sure the o-ring is seated

properly! Replace if damaged.
xx0200000175
4 pcs: M10x30, tightening

torque: 50 Nm.
Locking liquid is specified in Required
278
4 Repair
Step
Action
Note/Illustration
10.
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!
279
4 Repair
4.7.1. Removal of motor, axis 1
4.7 Motors
Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below:
xx0100000123
Motor, axis 1
Cable gland cover, motor axis 1
Cover for connector access
Motor attachment screws
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Lifting tool, motor axis 1, 4, 5
3HAC 14459-1
Power supply
Extension, 300 mm for bits 1/2"
280
24 VDC, 1.5 A.
3HAC 12342-1
4 Repair
Equipment, etc.
Art. no.
Note
Removal tool, motor M12
3HAC 14973-1
Always use the removal tools in pairs!


the tools required.
Circuit Diagram

Removal, motor
The procedure below details how to remove motor, axis 1.
WARNING!
result in burns!
NOTE!
used!
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Remove the Cover for connector access on top of Shown in the figure Location
the motor by unscrewing its four attachment screws. of motor on page 280!
2.
Remove the cable gland cover at the cable exit by

unscrewing its two attachment screws.

of motor on page 280!
xx0200000199
A: Cable gland cover

Make sure the gasket is not
damaged!
3.
Disconnect all connectors beneath the motor cover.
4.
Apply Lifting tool, motor axis 1, 4, 5 to the motor.
Art. no. specified in Required

281
4 Repair
Step
282
Action
Note/Illustration
5.
In order to release the brakes, connect the 24 VDC

power supply:
Connect to connector
R2.MP1
+: pin 2
-: pin 5
6.
Remove the motor by unscrewing its four attachment Art. no. is specified in
screws and plain washers.
page 280!
If required, use the Extension 300mm for bits 1/2.
7.
If required, press the motor out of position by fitting

Removal tool, motor to the motor attachment screw
holes.
8.
Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
9.
Remove the motor by gently lifting it straight up.

page 280!
Always use the removal
tools in pairs!
4 Repair
4.7.2. Refitting of motor, axis 1

Location of motor
below:
xx0100000123
Motor, axis 1
Cover for connector access
Required equipment
Equipment, etc.
Spare part no. Art no.
Note
Motor, axis 1
3HAC 14207-1
Includes motor 3HAC 17484-1.

Includes pinion 3HAC 11350-1.
Includes o-ring 2152 2012-430.
O-ring
2152 2012-430

replacing motor!
Grease
3HAB 3537-1
Used to lubricate the o-ring.
283
4 Repair
Equipment, etc.
Spare part no. Art no.
Standard toolkit
3HAC 15571-1
Lifting tool, motor axis

1, 4, 5
3HAC 14459-1
Extension, 300 mm
for bits 1/2"
3HAC 12342-1
Note
information.
Power supply
24 VDC, max. 1,5 A.

Other tools and

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

Circuit Diagram
See chapter Circuit diagram in

the Product manual, reference
information.
Instruction

information.
Refitting, motor
The procedure below details how to refit motor, axis 1.
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
284
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of the

motor is seated properly. Lightly lubricate the o-ring
with grease .
Art no. is specified in

page 283!
2.
Apply Lifting tool, motor axis 1, 4, 5 to the motor.

page 283!
4 Repair
Step
Action
Note/Illustration
3.
In order to release the brake, connect the 24 VDC

power supply:
R2.MP1
+: pin 2
-: pin 5
4.
Fit the motor, making sure the motor pinion is properly Make sure the motor is
mated to gearbox 1.
turned the right way, i.e.
connections forwards.
Make sure the motor pinion
does not get damaged!
5.
Secure the motor with four attachment screws and

plain washers.
If required, use the Extension 300mm for bits 1/2.
6.
Disconnect the brake release voltage.
7.
Reconnect all connectors beneath the motor cover.
8.
Refit the cable gland cover at the cable exit with its
two attachment screws.
Make sure the cover is

tightly sealed!
9.
Refit the cover for connector access of the motor

with its four attachment screws.

tightly sealed!
M10 x 40, tightening torque:

50 Nm.
page 283!
Detailed in section
Performing a leak-down test
on page 196.

page 156.
manuals.
information.
DANGER!
it is vital that:
285
4 Repair

Location of motor
below.
xx0100000124
Motor, axis 2
Lock screw hole
Required equipment
286
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

3HAC 15534-1
Power supply
24 VDC, 1.5 A.
Lock screw
M16 x 60 8.8.
For securing the lower arm.
Extension 300mm for bits 1/2"
3HAC 12342-1
3HAC 14973-1
3HAC 15521-1
For guiding the motor.
3HAC 15521-2
4 Repair
Equipment, etc.
Art. no.
Note


Circuit Diagram

information.
Removal, motor
The procedure below details how to remove the motor, axis 2.
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
Action
Note/Illustration
1.
Run the manipulator to a position close enough to its Calibration positions are
calibration position, to allow the lock screw to be
shown in chapter Calibration
inserted into the lock screw hole .
information on page 365.
Dimension is specified in
page 286!
2.

page 160.
3.
Lock the lower arm by inserting a lock screw in the

lock screw hole.

page 286!
Dimension is specified in
page 286!
4.
Remove the cover on top of the motor by unscrewing

its four attachment screws.
5.


damaged!
287
4 Repair
Step
Action
Note/Illustration
6.
7.

power supply:
8.
Remove the motor by unscrewing its four attachment

9.
Fit the two guide pins in two of the motor attachment Art. no. is specified in
holes.
page 286!
R2.MP2
+: pin 2
-: pin 5
10. If required, press the motor out of position by fitting

holes.

page 286!
tools in pairs!
11. Fit the Lifting tool, motor axis 2, 3, 4 to the motor.

page 286!
12. Lift the motor to get the pinion away from the gear and
13. Remove the motor by gently lifting it straight out.
288

is not damaged!
4 Repair

Location of motor
below.
xx0100000124
Motor, axis 2
Lock screw hole
Required equipment
Equipment, etc.
Note
Motor, axis 2
3HAC 14209-1
Includes motor 3HAC

17484-1.
Includes pinion 3HAC
11632-1.
Includes o-ring 2152
2012-430.
O-ring
2152 2012-430

replacing motor!
Grease
3HAB 3537-1
For lubricating the o-ring.
Standard toolkit
3HAC 15571-1

3HAC 15521-1
3HAC 15521-2
289
4 Repair
Equipment, etc.
Note
Lifting tool, motor axis 2, 3,

4
3HAC 15534-1
Extension 300 mm for bits

1/2"
3HAC 12342-1
Power supply
24 VDC, 1.5 A.
3HAC 17105-1

pinion when brakes are
released.

references to these

required.
Circuit Diagram
See chapter Circuit

manual, reference
information.
Instruction

section Document
manual, reference
information.
Refitting, motor
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
290
Action
Note/Illustration
1.
Make sure the o-ring on the circumference Art no. is specified in Required
of the motor is seated properly. Lightly
lubricate the o-ring with grease .
2.
Fit the Lifting tool, motor axis 2, 3, 4 to the Art no. is specified in Required
motor.
4 Repair
Step
Action
Note/Illustration
3.
In order to release the brake, connect the 24 Connect to connector R2.MP2

VDC power supply:
+: pin 2
-: pin 5
4.
Fit the two guide pins in two of the motor

attachment holes.
5.
Fit the motor, with guidance from the guide Make sure the motor pinion does not
pins, making sure the motor pinion is
get damaged!
properly mated to the gear of gearbox 2.
Make sure the motor is turned the right
direction, i.e. the cables facing
downwards.
6.
If necessary, use the rotation tool in order to Art no. is specified in Required
rotate the motor pinion when mating it to the equipment on page 289!
gear!
Art no. is specified in Required

xx0200000165

shaft as shown in figure above.
7.
8.
Secure the motor with four attachment

If required, use the Extension 300 mm for
bits 1/2.
9.
10. Reconnect all connectors beneath the

motor cover.
M10 x 40, tightening torque: 50 Nm.

Connect in accordance with markings

on connectors.
11. 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 289!
12. Refit the cover on top of the motor with its
four attachment screws.
Make sure the cover is tightly sealed!
13. Remove the lock screw from the lock screw Shown in the figure Location of motor
hole .
on page 289!

291
4 Repair
Step
Action
Note/Illustration
Art. no. for the manuals are specified
in section Document references in the
information.
DANGER!
it is vital that:
292
4 Repair

Location of motor
below.
xx0100000125
Motor, axis 3
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

3HAC 15534-1
Power supply
24 VDC, 1.5 A.
Extension 300mm for bits 1/2" 3HAC 12342-1

3HAC 14973-1
3HAC 15521-1
3HAC 15521-2
Mech stop axis 3
3HAC 12708-2
Used to fix axis 3 (one method of three,

see step one in the removal procedure).
Use attachment screws 3HAB 3409-89
(M16 x 80).
Washers for Mech stop axis 3
3HAA 1001-186
293
4 Repair
Equipment, etc.
Art. no.
Note

references to these
instructions below.

the tools required.
Circuit Diagram

Removal, motor
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
294
Action
Note/Illustration
1.
Unload the manipulator upper arm by either:

Run the manipulator to a position
where the turning disk rests against the
foundation (recommended).
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 xx0300000051
torque: 115 Nm.
Fit the mechanical stop to the third
The upper arm must be positioned as
and final attachment hole (A), below
horizontal as possible!
the fixed stop (B) in the upper arm.
See the figure above!
2.
3.
Remove any equipment hindering access to

motor 3.
4.
Remove the cover on top of the motor by

unscrewing its four attachment screws.

4 Repair
Step
Action
Note/Illustration
5.
Remove the cable gland cover at the cable

exit by unscrewing its two securing screws.

motor on page 293!
damaged!
6.
Disconnect all connectors beneath the motor

cover.
7.

VDC power supply.
+: pin 2
Make sure the weight of the complete upper
-: pin 5
arm rests safely on the equipment chosen for
unloading the arm, before removing the motor.
8.
Remove the motor by unscrewing its four

attachment screws and plain washers.
9.

attachment screw holes.
10. If required, press the motor out of position by

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

Always use the removal tools in
pairs!
11. Apply the Lifting tool, motor axis 2, 3, 4 to the Art. no. is specified in Required
motor.
12. Lift the motor to get the pinion away from the
gear and disconnect the brake release
voltage.
13. Remove the motor by gently lifting it straight
out.
Make sure the motor pinion is not

damaged!
295
4 Repair

Location of motor
below.
xx0100000125
Motor, axis 3
Required equipment
296
Equipment, etc.
Note
Motor, axis 3
3HAC 14209-1
Includes motor 3HAC

17484-1.
11350-1.
2012-430.
O-ring
2152 2012-430

replacing motor!
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1

3HAC 15521-1
3HAC 15521-2
Lifting tool, motor axis 2, 3,

4
3HAC 15534-1
4 Repair
Equipment, etc.
Extension 300 mm for bits
1/2"
Note
3HAC 12342-1
Power supply
24 VDC, max. 1.5 A.

3HAC 17105-1

released.

references to these

required.
Circuit Diagram
See chapter Circuit

manual, reference
information.
Instruction

section Document
manual, reference
information.
Refitting, motor
WARNING!
result in burns!
NOTE!
Whenever mating motor and gearbox, misalignment of the gears may severely damage them.
Avoid this risk:
Fit the gearbox.
Turn the gears of the gearbox to the correct position using the gearbox crank. The part
number is specified in the table above!
Fit the motor.
CAUTION!
Step
1.
Action
Note/Illustration
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 296!
the o-ring with grease .
297
4 Repair
Step
Action
Note/Illustration
2.
Fit the Lifting tool, motor axis 2, 3, 4 to the

motor.

3.
In order to release the brake, connect the 24

VDC power supply:
Connect to connector R2.MP3

+: pin 2
-: pin 5
4.

attachment holes

5.
Fit the motor, with guidance from the guide

Make sure the motor pinion does
pins, making sure the motor pinion is properly not get damaged!
mated to the gear of gearbox 3.
Make sure the motor is turned the
right direction, i.e. the cables facing
forwards.
6.
If necessary, use the rotation tool in order to

rotate the motor pinion when mating it to the
gear!

xx0200000165
The rotation tool (A) is used

beneath the motor cover, directly on
the motor shaft as shown in figure
above.
7.
8.
Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
and plain washers.
If required, use the Extension 300mm for bits equipment on page 296.
1/2.
9.
10. Reconnect all connectors beneath the motor

cover.
Connect in accordance with

markings on connectors.
11. Refit the cable gland cover at the cable exit

Make sure the cover is tightly

sealed!
motor on page 296!
12. Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
298
4 Repair
Step
Action
Note/Illustration
13. Remove the equipment used to unload the

upper arm:
Run the manipulator to a normal
position.
Fork lift
Lifting slings
Mechanical stop
Detailed in section Performing a

leak-down test on page 196.


specified in section Document
DANGER!
it is vital that:
299
4 Repair

Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0100000126
Motor, axis 4
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

3HAC 15534-1
To be used when manipulator arm is in

a horizontal position.
3HAC 14459-1
To be used when manipulator arm is in

a vertical position.
Power supply
300
24 VDC, 1.5 A.
Extension 300mm for bits 1/2"
3HAC 12342-1
3HAC 14973-1
3HAC 15521-1
3HAC 15521-2
For guiding the motor


Circuit Diagram

information.
4 Repair
Removal, motor
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
Action
Note/Illustration
1.
Two basic positions for the upper arm are possible:

Run the robot to a position where the upper
arm is pointed straight up. This position
enables the motor to be replaced without
draining the gear oil, which in turn saves time.
Run the robot to a position where the upper
arm is close to horizontal. This position may
be selected when the gearbox is to be
replaced, i.e. when the gearbox oil has to be
drained anyway.
Depending on which upper

arm position was selected,
two versions of lifting tools
are available. See below!
2.
In horizontal position: avoid movement of the axis by

unloading the manipulator upper arm by either:
Run the manipulator to a position where the
turning disk rests against the foundation
(recommended).
Use a fork lift to rest the upper arm onto.
Use lifting slings and an overhead crane to
rest the upper arm.
3.

4.

5.
6.

power supply:
7.
Remove the motor by unscrewing its four attachment


damaged!
R2.MP3
+: pin 2
-: pin 5
301
4 Repair
Step
Action
8.
Fit the two guide pins in two of the motor attachment

screw holes.
9.

holes.
10. Apply the Lifting tool to the motor.
Note/Illustration

page 300!
tools in pairs!
Two lifting tools are possible:
Lifting tool, motor
axis 2, 3, 4 if the
manipulator arm is in
a horizontal position
Lifting tool, motor
axis 1, 4, 5 if the
manipulator arm is in
a position close to
vertical
page 300!
302

is not damaged!
4 Repair

Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0100000126
Motor, axis 4
Required equipment
Equipment, etc.
Spare part no.
Motor, axis 4
3HAC 14210-1
Art. no.
Note
Includes motor 3HAC
17484-2.
10122-17.
2012-430.
O-ring
2152 2012-430
Must be replaced
when replacing motor!
Grease
3HAC 3537-1
Used to lubricate the

o-ring.
Standard toolkit
3HAC 15571-1
The contents are

defined in section
Standard toolkit in the
Product manual,

2, 3, 4
3HAC 15534-1
To be used when
lifting when the motor
is in a horizontal
position.
303
4 Repair
Equipment, etc.
Spare part no.
Art. no.
Note

1, 4, 5
3HAC 14459-1
To be used when
lifting when the motor
is in a vertical position.
3HAC 15521-1
3HAC 15521-2
Power supply
304
24 VDC, max. 1,5 A.

For releasing the
brakes.
3HAC 17105-1
Extension 300 mm for

bits 1/2"
3HAC 12342-1
Used to rotate the

motor pinion when
brakes are released.
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

manual, reference
information.
Instruction

section Document
references in the
Product manual,
4 Repair
Refitting, motor
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art. no. is specified in Required
2.
Apply the Lifting tool to the motor.
3.
In order to release the brakes, connect the 24 Connect to connector R2.MP4

VDC power supply:
+: pin 2
-: pin 5
4.

attachment holes.
5.
Fit the motor, with guidance of the pins, making Make sure the motor pinion does
sure the motor pinion is properly mated to the not get damaged!
gear of gearbox 4.
downwards.
Two lifting tools are possible:

if the manipulator arm is in a
horizontal position
if the manipulator arm is in a
position close to vertical

305
4 Repair
Step
6.
Action
Note/Illustration
If necessary, use the rotation tool in order to

rotate the motor pinion when mating it to the
gear!

xx0200000165
The rotation tool (A) is used

beneath the motor cover, directly on
the motor shaft as shown in figure
above.
7.
8.
Secure the motor with four attachment screws M10 x 80, tightening torque: 50 Nm.
and plain washers.
If required, use the "Extension 300mm for bits equipment on page 303!
1/2".
9.
10. Reconnect all connectors beneath the motor

cover.
11. Refit the cable gland cover at the cable exit

motor on page 303!
12. Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
13. Remove the equipment used to unload the
upper arm:
Run the manipulator to a normal
position.
Fork lift.
Lifting slings.
306

15. Refill with oil if drained.


4 Repair
DANGER!
it is vital that:
307
4 Repair

Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!
xx0100000127
Motor, axis 5
Heat protection plate
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

3HAC 14459-1
For lifting the motor in a vertical position
Power supply
308
24 VDC, 1.5 A.
Extension 300 mm for bits 1/2"
3HAC 12342-1
3HAC 14973-1
3HAC 15521-1
3HAC 15521-2

below.

Circuit Diagram

4 Repair
Removal, motor
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
Action
Note/Illustration
1.
Move the robot to a position where the motor in axis

5 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
2.
Remove the left hand side cover of the wrist unit by

unscrewing its six attachment screws.
3.
Remove the heat protection plate by unscrewing its Shown in the figure Location
two attachment screws.
4.

5.

6.
7.

power supply :
8.
page 308!
If required, use the Extension 300 mm for bits 1/2.
9.
Apply the lifting tool, motor axis 1, 4, 5 to the motor Art. no. is specified in
for a vertical lift.
page 308!
The motor is accessible

behind the rear part of the
cover.

R3.MP5
+: pin 2
-: pin 5
10. Fit the two guide pins in two of the motor attachment Art. no. is specified in
screw holes.
page 308!
309
4 Repair
Step
Action
11. If required, press the motor out of position by fitting

removal tool, motor to the motor attachment screw
holes.
Note/Illustration
page 308!
tools in pairs and diagonally!
310

is not damaged!
4 Repair

Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!
xx0100000127
Motor, axis 5
Heat protection plate
Required equipment
Equipment, etc.
Note
Motor, axis 5
3HAC 14725-1
Includes motor 3HAC

14673-2.
10122-17.
Includes o-ring 2152 2012430.
O-ring
2152 2012-430

replacing motor!
Grease
3HAC 3537-1
Standard toolkit
3HAC 15571-1

the Product manual,
3HAC 15521-1
3HAC 15521-2
Lifting tool, motor axis 1,

4, 5
3HAC 14459-1
For lifting the motor in a

vertical position.
311
4 Repair
Equipment, etc.
Extension 300 mm for

bits 1/2"
Note
3HAC 12342-1
Power supply
24 VDC, 1.5 A.
3HAC 17105-1

released.
Other tools and

procedures may be
the step-by-step
instructions below.

required.
Instruction

section Document
manual, reference
information.
Instruction

section Document
manual, reference
information.
Refitting, motor
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
312
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of Art. no. is specified in Required
2.
Apply the lifting tool to the motor.

4 Repair
Step
Action
Note/Illustration
3.

VDC power supply :
+: pin 2
-: pin 5
4.

attachment holes.

5.
Fit the motor, with guidance from the pins,

making sure the motor pinion is properly
mated to the gear of gearbox, axis 5.
Make sure the motor pinion does not

get damaged!
forward.
6.
If necessary, use the rotation tool in order to Art. no. is specified in Required
rotate the motor pinion when mating it to the equipment on page 311!
gear!
xx0200000165

shaft as shown in figure above.
7.
Secure the motor with four attachment

If required, use the "Extension 300 mm for
bits 1/2".
8.
9.
Reconnect all connectors beneath the motor

cover.
M10 x 40, 12.9 quality

10. Refit the cable gland cover at the cable exit Shown in the figure Location of motor
on page 311!
11. Refit the cover on top of the motor with its
four attachment screws.
Make sure the cover is tightly sealed!
12. Refit the heat protection plate with its two

attachment screws.
Shown in the figure Location of motor

on page 311!
13. If cables are loose, place them correctly and

tie them up with cable ties.
14. Refit the left hand side cover of the wrist unit
with its six attachment screws.

in section Document references in
information.
313
4 Repair
DANGER!
it is vital that:
314
4 Repair

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0100000128
Motor, axis 6
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Power supply
24 VDC, 1.5 A.
3HAC 14972-1
Extension 300 mm for bits 1/2"
3HAC 12342-1


the tools required.
Circuit Diagram

315
4 Repair
Removal, motor
WARNING!
result in burns!
NOTE!
used!
Step
316
Action
Note/Illustration
1.
Two basic positions for the axis 6 are possible:

Move the robot to a position where the motor Required equipment on
in axis 6 is pointed straight up. This position page 315!
enables the motor to be replaced without
draining the gear oil, which in turn saves time.
Move the robot to a position where the motor
in axis 6 is close to horizontal. This position
may be selected when the gearbox is to be
replaced, i.e. when the gearbox oil has to be
drained anyway.
Move axis 6 to a vertical or horizontal position.
2.
In horizontal position: drain the oil from gearbox, axis Detailed in section Oil
6.
page 174.
3.
Remove the rear motor cover by unscrewing its six

attachment screws.
4.
Disconnect all connectors beneath the cover.
5.

power supply :
6.
If required, use the "Extension 300mm for bits 1/2". page 315!
7.

holes.
8.
Lift the motor to get the pinion away from the gear and
9.
Remove the motor by gently lifting it straight out.
R3.MP6
+: pin 2
-: pin 5

page 315!
tools in pairs!

is not damaged!
4 Repair

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0100000128
Motor, axis 6
Required equipment
Equipment, etc.
Note
Motor, axis 6
3HAC 14211-1
Includes motor 3HAC

17484-3.
10122-19.
2012-430.
O-ring
2152 2012-430
Must be replaced
when replacing motor!
Standard toolkit
3HAC 15571-1
The contents are

defined in section
Product manual,
Guide pin, M8 x 100
3HAC 15520-1
317
4 Repair
Equipment, etc.
Note
Guide pin, M8 x 150
3HAC 15520-2
Extension, 300 mm for bits 1/2"
3HAC 12342-1
Power supply
Grease

24 VDC, 1.5 A.
For releasing the
brakes.
3HAB 3537-1
For lubricating the oring.

below.
These procedures
the tools required.
Circuit Diagram
See chapter Circuit

diagram in the
Product manual,
Instruction

section Document
references in the
Product manual,
Refitting, motor
WARNING!
result in burns!
NOTE!
used!
Step
318
Action
Note/Illustration
1.
Make sure the o-ring on the circumference of the

motor is seated properly. Lightly lubricate the o-ring
with grease .

page 317!
2.

power supply :
R3.MP6
+: pin 2
-: pin 5
3.
Fit the two guide pins in two of the motor attachment Art. no. is specified in
holes.
page 317!
4 Repair
Step
Action
Note/Illustration
4.
Fit the motor, with guidance from the pins, making

Make sure the pinion on the
sure the motor pinion is properly mated to the gear of motor shaft is not damaged!
gearbox, axis 6.
5.
6.
Secure the motor with four attachment screws and

plain washers.
If required, use the "Extension 300mm for bits 1/2".
7.
8.
Reconnect all connectors beneath the motor cover.
9.
Refit the cover on top of the motor with its six

attachment screws.
M8 x 25, 12.9 quality,

page 317!

tightly sealed!
10. Perform a leak-down test (if gearbox drained).
Detailed in section
Performing a leak-down test
on page 196.
11. Refill the gearbox with oil, if drained.

page 174.
manuals.
information.
DANGER!
it is vital that:
319
4 Repair
4.8.1. Replacement of gearbox, axis 1
4.8 Gearboxes
Location of gearbox
xx0100000133
320
Gearbox, axis 1
Oil plug, filling
Attachment screws, gearbox to frame
Frame
Base
Attachment screws, base to gearbox (not shown in figure)
4 Repair
Required equipment
Equipment, etc.
Gearbox axis 1
Note
Includes:
gearbox
all o-rings and sealing
rings
O-ring
3HAB 3772-54
Replace only when damaged!
O-ring
3HAB 3772-55
Sealing ring
3HAC 11581-4
Grease
3HAC 3537-1
For lubricating the o-rings.
Support, base
3HAC 15535-1
Lifting device, base
3HAC 15560-1
3HAC 15556-1
Standard toolkit
3HAC 15571-1
Other tools and

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

information!
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!
321
4 Repair
Step
2.
Action
Note/Illustration
Move the robot to its most stable

position, shown in the figure to the
right.
xx0300000022
3.
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 Oil change, gearbox axis

1 on page 156.
1 on page 156.
Detailed in section Removal, complete arm

system on page 214.
Art. no. is specified in Required equipment

on page 321!
9.
Caution!
The base (without gearbox 1) weighs
310 kg! All lifting equipment used must
be dimensioned accordingly!
10. Lift the manipulator base to allow
fitting the support, base and gear 1
on each sides of the base.
Art. no. is specified in Required equipment

on page 321!
11. Fit the support, base.

Make sure the base remains in a
stable position before performing any
work underneath the base!
322
4 Repair
Step
Action
Note/Illustration
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
xx0200000227
A view from below:

A: Oil drain hose
B: Attachment screws, gearbox axis
1, 18 pcs
C: Washers, 3 pcs
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)
323
4 Repair
Step
Action
Note/Illustration
15.
Caution!
The gearbox weighs 200 kg! All lifting
accordingly!
16. Lift the gearbox away with the already
mounted lifting tools.
Refitting, gearbox axis 1

The procedure below details how to refit gearbox, axis 1.
Step
Action
Note/Illustration
1.
Danger!
2.
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,
3.
Make sure the two o-rings (C, D) on the

circumference of the gearbox are seated
properly in their grooves respectively.
Lubricate them with grease .
Make sure the small o-ring around the oil
hole is fitted properly!

xx0200000055
324
A: Guide pin
C: O-ring 3HAB 3772-54
D: O-ring 3HAB 3772-55
E: Sealing ring 3HAC 11581-4
4 Repair
Step
4.
Action
Note/Illustration
Refit the cable guide in the center of

gearbox 1 with its attachment screws.
xx0200000256
5.
A: Location for attachment

screws, cable guide (cable guide
removed in figure)
Fit the lifting device, base and the lifting Art no. is specified in Required
tool (chain) to the gearbox.
6.
Caution!
The gearbox weighs 200 kg! All lifting
accordingly!
7.
Lift the gearbox to its mounting position in

the center of the base.
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 90, 12.9 quality
with the 18 attachment screws, gearbox UNBRAKO, tightening torque: 300 Nm.
axis 1 .
xx0200000227
A view from below:

A: Oil drain hose
B: Attachment screws, gearbox
axis 1, 18 pcs
C: Washers, 3 pcs
325
4 Repair
Step
Action
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.
Note/Illustration
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 310
kg! All lifting equipment used must be
dimensioned accordingly!
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, complete

arm system on page 217.
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.
326

axis 1 on page 156.

4 Repair
DANGER!
it is vital that:
327
4 Repair
4.8.2. Removal of gearbox, axis 2

Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below.
xx0100000135
328
Motor, axis 2
Oil plug, filling
Oil plug, draining
Front gearbox attachment screws
Attachment holes, fixture lower arm
Motor attachment
Sealing (between gearbox and lower arm, not shown in figure )
Hole for locking screw, lower arm, M16 x 60
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Lifting tool, gearbox axis 2
3HAC 12731-1
Fixture, lower arm
3HAC 13660-1
Locking screw, lower arm

Guide pins, M16 x 300
references to these
M16 x 60 8.8.
Included in the fixture, lower arm.
3HAC 13120-5
For guiding the gearbox.

Always use the guide pins in pairs.
Removal, gearbox
WARNING!
result in burns!
CAUTION!
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
1.
Remove any equipment fitted to the turning disk.
2.
Run the robot to the calibration position. The

upper arm may be directed in three different
ways, shown in figure to the right.
The lowered position, as in figure A, is
recommended as it gives the least load on the
tool.
Note/Illustration
xx0200000260
329
4 Repair
Step
Action
Note/Illustration
3.
If the manipulator is fitted with moveable

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

the locking screw into the hole.

5.
Fit the fixture, lower arm to prevent the lower

arm from falling.
Make sure that both adjusters (B) on the
fixture are screwed back.
Align the fixture with the frame and lower
arm.
Tighten the four M16 bolts (C) on the
inside of the frame, in attachment holes,
with tightening torque: 220 Nm.
Screw in the two adjusters (B) until they
rest against the flats on the lower arm.
Tighten by hand.
Lock, using the two ring nuts (D).
Tighten the two M12 bolts (E) in the
attachment holes, fixture lower arm with

Attachment holes for the fixture
are shown in the figure Location of
Make sure the fixture is pressed
tightly against the lower arm
before securing with screws!
xx0200000261
A: Locking screw, lower

arm
6.
Unload the balancing device shaft by using a

specific press tool.
Detailed in section Unloading the

7.
Drain the gearbox, axis 2.

8.

9.
Remove the 30 rear gearbox attachment screws

(A) from inside the lower section of the lower
arm.
xx0300000064
330
4 Repair
Step
Action
10. Remove the motor attachment by unscrewing

the front gearbox attachment screws.
Note/Illustration
11. Fit the Lifting tool, gearbox axis 2 , to the motor Art. no. is specified in Required
attachment and secure it with the hook on the
tool.
Remove the motor attachment.
12. Fit the Lifting tool, gearbox axis 2 , to the
gearbox.

13. Fit two guide pins in 180 relation to each other Art. no. is specified in Required
instead of the removed front attachment screws. equipment on page 329!
14. If required, apply an M16 screw to the hole
shown in the figure to press it free.

xx0200000033
A: M16 holes for pressing

the gearbox out
15. Remove the gearbox using an overhead crane

or similar.
On reassembly a new sealing

must be used!
Art. no. is specified in the refitting
instructions Required equipment
on page 333!
331
4 Repair
4.8.3. Refitting of gearbox, axis 2

Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below.
xx0100000135
332
Motor, axis 2
Oil plug, filling
Oil plug, draining
Front gearbox attachment screws
Attachment holes, fixture lower arm
Motor attachment
Sealing (between gearbox and lower arm, not shown in figure )
Hole for locking screw, lower arm, M16 x 60
4 Repair
Required equipment
Equipment, etc.
Note
Gearbox, axis 2
3HAC 12641-1
Includes gearbox 3HAC

10122-21
Includes o-ring!
O-ring
3HAB 3772-51
Sealing, axis 2/3
3HAC 17213-1
A new sealing must be

used on each assembly!
Grease
3HAB 3537-1
For lubricating the o-ring
Standard toolkit
3HAC 15571-1

in section Standard
manual, reference
information.
Lifting tool, gearbox axis 2
3HAC 12731-1
Guide pin, M16 x 150 mm
3HAC 13120-2
Guide are to be used in

pairs.
3HAC 13120-3

pairs.
Guide pin, sealing axis 2/3
3HAC 14627-2
80 mm.
For guiding "Sealing, axis
2/3".
pairs.
Guide pin, sealing axis 2/3
3HAC 14627-3
100 mm.
For guiding "Sealing, axis
2/3".
pairs.

references to these
These procedures
tools required.
Instruction

section Document
manual, reference
information.
333
4 Repair
Refitting, gearbox
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
1.
Action
Note/Illustration
Fit the guide pins, sealing axis 2/3

on gearbox, axis 2.
Only the holes showed in figure
beside are allowed to be used to the
guide pins!
xx0200000125
A: Holes for guide pins, sealing axis 2/

3 on gearbox 2.
reassembling!
Art. no. is specified in Required equipment on
page 333!
334
2.
Fit the new Sealing, axis 2/3 on

gearbox, axis 2, with guidance from
the guide pins.
3.
Fit two guide pins, M16 180 in

relation to each other in the
attachment holes in the frame.

page 333!
4.
Fit the Lifting tool, gearbox axis 2 ,

to the gearbox.

page 333!
4 Repair
Step
5.
Action
Note/Illustration
Make sure the o-ring is fitted to the Art. no. is specified in Required equipment on
rear of the gearbox. Lightly grease page 333!
the o-ring.
xx0100000136
6.
Lift the gearbox to its mounting

position.
7.
Fit the gearbox onto the guide pins

and slide it into position.
8.
Remove the lifting tool.
9.
In a similar way, fit the lifting tool to

the motor flange. Lock the tool with
the hook.
Lift it and slide it onto the guide pins.
10. Insert and secure 18 of the 20

attachment screws on the front of
the motor attachment.
Remove the guide pins and tighten
the remaining two screws.
A: O-ring, gearbox, axis 2
Make sure the gearbox is seated properly!

Reused screws may be used, providing they
are lubricated as detailed in section Screw
joints in the Product manual, reference
11. Remove the guide pins and tighten

the remaining two screws as above.
12. Insert and secure 28 of the 30
attachment screws on the inside of
the lower arm.
xx0300000064

Reused screws may be used, providing they
are lubricated as detailed in section Screw
joints in the Product manual, reference
335
4 Repair
Step
Action
Note/Illustration
13. Remove the guide pins, sealing axis

2/3 and tighten the remaining two
screws as above.
14. Refit the motor.
Detailed in section Refitting of motor, axis 2 on

page 289.
Detailed in section Performing a leak-down

test on page 196.
16. Refill the gear box with oil.
Detailed in section Oil change, gearbox axis 2

on page 160.
17. Restore the balancing device by

Detailed in section Restoring the balancing
removing the balancing device tools. device on page 277.
18. Remove the fixture, lower arm.
19. Remove the locking screw, lower
arm.
20. Refit any mechanical stops if such
were removed during disassembly.
21. Refit any equipment to the turning
disc if such was removed during
assembly.
Calibration is detailed in separate calibration

manuals.
section Document references in the Product
DANGER!
it is vital that:
336
4 Repair

Location of gearbox
xx0100000137
Gearbox, axis 3
Gearbox attachment screws
Oil plug, filling
Oil plug, draining
Motor, axis 3
Sealing, axis 2/3 between lower arm and gearbox 3
337
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Lifting eye, M16
3HAC 14457-4
Mechanical stop axis 3
3HAC 12708-2
Washer for Mechanical stop axis 3
3HAA 1001-186

instructions below.
Used to secure the upper arm.

Use attachment screws 3HAB
3409-89 (M16 x 60).
Removal, gearbox
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
1.
Action
Note/Illustration
Secure the upper arm in a horizontal

position using a mechanical stop.
Fit the mechanical stop and the washer 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

338
4 Repair
Step
Action
Note/Illustration
2.
Detailed in section Removal of motor,

axis 3 on page 293.
Note! When removing the motor axis
3, the brake on axis 3 is released.
Make sure the upper arm is secured
and enabled to move!
3.
Remove the upper arm.

4.
Remove the Sealing, axis 2/3 between

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

used!
equipment on page 341, in the refitting
instruction!
5.
Place the upper arm safety on a

workbench, in a fixture or similar.
6.
Remove the gearbox attachment screws . Shown in the figure Location of

7.
If required, apply an M16 screw to the holes

shown in the figure to press the gearbox
free.
xx0200000033
8.
Fit the Lifting eye, M16 to the gearbox.
9.
Remove the gearbox using an overhead

crane or similar.
A: M16 holed for pressing the

gearbox out

339
4 Repair

Location of gearbox
xx0100000137
340
Gearbox, axis 3
Gearbox attachment screws
Oil plug, filling
Oil plug, draining
Motor, axis 3
Sealing, axis 2/3 between lower arm and gearbox 3
4 Repair
Required equipment
Equipment, etc.
Spare part
no.
Gearbox, axis 3
3HAC 12641-1
Art. no.
Note
Includes gearbox 3HAC
10122-21.
Includes all o-rings!
Does not include "Sealing, axis
2/3"!
Sealing, axis 2/3
3HAC 17213-1
A new sealing must be used on

each assembly!
O-ring
3HAB 3772-51
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1

information.
Lifting eye, M16
3HAC 14457-4
3HAC 13120-4
Guide are to be used in pairs.
3HAC 13120-5
Guide pin, sealing axis 2/

3
3HAC 14627-2
80 mm.
Guide pin, sealing axis 2/

3
3HAC 14627-3
100 mm.
Other tools and

procedures may be
the step-by-step
instructions below.

required.
Instruction

information.
341
4 Repair
Refitting, gearbox
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Step
Action
Note/Illustration
1.
Turn the upper arm in such a position that the

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

other in the attachment holes of gearbox 3.

3.
Fit the lifting eye, M16 to the gearbox.

4.
Make sure the o-ring is fitted to the rear of

the gearbox. Apply grease to the o-ring to
make sure it sticks in its groove during
assembly.

xx0100000136
342
5.
Lift the gearbox to its mounting position.
6.
Turn the gearbox to align the attachment

screw holes with those in the upper arm.
A: O-ring, gearbox axis 3
4 Repair
Step
Action
Note/Illustration
7.
Fit the gearbox onto the guide pins and slide Make sure the gearbox and o-ring are
it into position.
seated properly and correctly
oriented!
8.
9.
Secure the gearbox with 18 of the 20

gearbox attachment screws.
Remove the guide pins and tighten the
remaining two screws.
20 pcs: M16 x 90; 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
10. Refit the upper arm with a new sealing, axis Detailed in section Refitting of
2/3 .
11. Refit the motor.

axis 3 on page 296.
12. Remove the mechanical stops that secures

the upper arm.

in section Document references in
information.
DANGER!
it is vital that:
343
4 Repair

Location of gearbox
xx0100000144
344
Upper arm housing
Gearbox, axis 4
Attachment screws, cover axis 4
Oil plug, filling, secondary gearbox
Oil plug, draining, secondary gearbox
Gear, Z3
Gear attachment screws
Motor, axis 4
Motor flange
4 Repair
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1



Removal, gearbox
WARNING!
result in burns!
NOTE!
used!
Step
Action
Note/Illustration
1.
Drain the gearbox oil from the primary gearbox

through the oil plug, draining.
2.
Drain the gearbox oil from the secondary gearbox Detailed in section Oil change,
through the oil plug, draining.
3.
Remove the plastic housing from the cover, axis

4 gearbox.
4.
Remove the cover, axis 4 gearbox by

unscrewing its attachment screws.

5.
Loosen the gear attachment screws but do not

remove the gear Z3.

6.

7.
Remove gear Z3 from the gearbox by

unscrewing the 15 gear attachment screws .
If required, insert screws into three holes in gear
Z3 to press it out.
8.
Remove the motor flange attachment screws

and plain washers.

9.
Pull the motor flange and gearbox, axis 4 out

along with the friction washers.
If required, insert screws into two holes in the
gearbox to press it out.
M10.

345
4 Repair

Location of gearbox
xx0100000144
346
Upper arm housing
Gearbox, axis 4
Oil plug, filling, secondary gearbox
Oil plug, draining, secondary gearbox
Gear, Z3
Gear attachment screws
Motor, axis 4
Motor flange
4 Repair
Required equipment
Equipment, etc
Note
Gearbox, axis 4
3HAC 11384-3
Includes all o-rings!
Gear, Z3
3HAC 11488-1
O-ring
3HAB 3772-49
Replace only when

damaged!
O-ring
3HAB 3772-50
Replace only when

damaged!
Friction washer
3HAC 10122-27
Must be replaced at
assembly!
2 pcs needed at
assembly!
Gasket, cover axis 4
3HAC 11423-3
Grease
3HAB 3537-1
For lubrication of
gearbox, motor and
motor attachment
mating surfaces.
Standard toolkit
3HAC 15571-1
The contents are

defined in section
Product manual,
3HAC 15521-1
Always use the guide

pins in pairs.
For refitting friction
washers, gearbox and
motor flange.
3HAC 15521-2
Always use the guide

pins in pairs.
For refitting friction
washers, gearbox and
motor flange.

references to these
These procedures
the tools required.
Instruction

section Document
references in the
Product manual,
347
4 Repair
Refitting, gearbox
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Make sure the two o-rings on the

circumference of the gearbox are seated equipment on page 347!
Lightly lubricate the o-rings with grease.
2.
Lubricate the gearbox, motor and motor

attachment mating surfaces with grease. equipment on page 347!
3.
Fit four guide pins symmetrically in the

attachment holes in the upper arm
housing.
xx0200000067
A: Attachment holes for guide

pins, M10
348
4.
Fit two new friction washers onto the

guide pins.

Note! Make sure the surface beneath
the friction washers is clean and dry!
5.
Push in the gearbox, axis 4, and the motor Shown in the figure Location of gearbox
flange .
on page 346!
If necessary, use screws in the attachment Note! Make sure the motor flange is
holes to press in the motor flange.
oriented correctly by observing the oil
plugs as shown in the figure Location of
6.
Secure the motor flange to the upper arm 18 pcs: M10 x 40; tightening torque: 65
housing with 16 of the 18 washers and
Nm.
attachment screws.
Secure with locking liquid.
4 Repair
Step
Action
Note/Illustration
7.
Remove the guide pins and secure the

remaining two attachment screws as
specified in previous step.
8.
9.
Refit gear Z3 to the gearbox with its gear Art. no. is specified in Required
attachment screws .
Shown in the figure Location of gearbox
on page 346!
9 pcs: M12 x 50; tightening torque: 115
Nm.
6 pcs: M16 x 60: tightening torque: 300
Nm.

axis 4 on page 303.
10. Replace the gasket, cover axis 4 .

11. Refit the cover, axis 4 gearbox with its

attachment screws and secure with
locking liquid.

on page 346!
13. Refill the primary gearbox with oil.
Detailed in section Oil change, gearbox,

axis 4 on page 166.
14. Refill the secondary gearbox with oil.

axis 4 on page 166.

DANGER!
it is vital that:
349
4 Repair

Location of gearbox
xx0100000146
350
Wrist housing
Oil plug, secondary, filling
Oil plug, secondary, draining
Gear, Z3
Wheel unit
Attachment screws, gear Z3
Gearbox, axis 5
4 Repair
Oil plug, primary, filling (draining plug on the opposite side of the wrist
housing, not shown in figure)
VK-cover
Attachment screws, bearing washer, M6 x 16
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

information.
Lifting eye, M12
3HAC 14457-3
2 pcs required!
For lifting the gearbox.
Removal tool, wheel unit
3HAC 15814-1
For removing and lifting the wheel

unit.

instructions below.

Removal, gearbox
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Drain the oil from the primary gearbox.

page 170.
2.
Drain the oil from the secondary gearbox.

page 170.
3.
Detailed in section Removal

of motor, axis 5 on page 308.
4.
Remove the cover, axis 5 gearbox , by unscrewing its

attachment screws .

5.
Remove gear Z3 from the gearbox by unscrewing its

attachment screws (let axis 6 turn to the stop).
If necessary, insert screws into the three holes in gear
Z3 to remove it.

6 pcs: M16 x 60.
9 pcs: M12 x 50.
6.
Remove the wheel unit.
Detailed in section Removal,

wheel unit on page 352.
351
4 Repair
Step
Action
Note/Illustration
7.
Remove the gearbox, axis 5 , by unscrewing its

attachment screws and removing the washers .

18 pcs: M10 x 40.
8.
Apply two lifting eyes to the gearbox, axis 5, in

opposite positions.

page 351!
9.
Remove the gearbox by gently lifting it straight out.
10. Remove the friction washers, located beneath the

gearbox, from the wrist housing.
Removal, wheel unit

The procedure below details how to remove the wheel unit. Also see the figure above!
WARNING!
result in burns!
Step
352
Action
Note/Illustration
1.
Drain the oil from the secondary gearbox.

2.
Remove the cover, axis 5 gearbox by

unscrewing its attachment screws .

3.
Make a short cut in the centre of the VKcoverand remove it from the wheel unit by
bending.

Note! Avoid damaging screws or
surfaces beneath, when removing
the cover!
4.
Unscrew the attachment screws, bearing

washer located beneath gear Z4.
Turn the gear Z4 in order to reach all the
srews.

gearbox on page 350 and in the
figure below!
7 pcs: M6 x 16.
4 Repair
Step
5.
Action
Note/Illustration
Remove the attachment screws, gear Z4 .
xx0200000068
A: Gear Z4
B: Surface beneath VKcover
C: VK-cover
D: Attachment screws, gear
Z4, 21 pcs: M16
E: Attachment screws,
bearing washer, 7 pcs: M6
6.
Apply removal tool to the center hole of gear Art. no. is specified in Required
Z4 to press the wheel unit free.
7.
Remove the wheel unit by gently lifting it

straight out.
353
4 Repair

Location of gearbox
xx0100000146
354
Wrist housing
Oil plug, secondary, filling
Oil plug, secondary, draining
Gear, Z3
Wheel unit
Attachment screws, gear Z3
Gearbox, axis 5
4 Repair
Oil plug, primary, filling (draining plug on the opposite side of the wrist
housing, not shown in figure)
VK-cover
Attachment screws, bearing washer, M6 x 16
Required equipment
Equipment, etc.
Note
Gearbox, axis 5
3HAC 11384-3
Includes:
gearbox 3HAC
11384-1
all o-rings.
O-ring
3HAB 3772-49
Replace only when

damaged!
O-ring
3HAB 3772-50
Replace only when

damaged!
Friction washer
3HAC 10122-27
Must be replaced at
assembly!
2 pcs needed at assembly!
Gear, Z3
3HAC 11488-1
VK-cover, 170 x 15
3HAA 2166-24
Gasket, cover
3HAC 11409-5
Grease
3HAC 3537-1
For lubricating the O-rings

and the packing box.
Locking liquid
3HAB 7116-1
Loctite 243
Isopropanol
1177 1012-208
To clean surface beneath

VK-cover.
Standard toolkit
3HAC 15571-1

the Product manual,
Lifting eye, M12
3HAC 14457-3
2 pcs required!
For lifting the gearbox.
Removal tool, wheel unit
3HAC 15814-1
M12.
For lifting the wheel unit.
3HAC 15521-1
For refitting gearbox.
3HAC 15521-2
For refitting gearbox.
Must be replaced!
Other tools and

procedures may be
below.

required.
Instruction

section Document
manual, reference
information.
355
4 Repair
Refitting, gearbox
WARNING!
result in burns!
NOTE!
used!
Step
356
Action
Note/Illustration
1.
Make sure the two o-rings on the

circumference of the gearbox are seated equipment on page 355!
Lightly lubricate the o-rings with grease .
2.
Fit two guide pins in the housing.

3.
Refit the two new friction washers (2

pcs)in the wrist housing.

Note! Make sure the surface beneath
the friction washers is clean and dry!
4.
Apply two lifting eyes to the gearbox, axis Art. no. is specified in Required
5 , in opposite positions.
on page 354!
5.
Refit the gearbox, axis 5 to the wrist

housing, by gently lowering it straight
down, using the guide pins.

on page 354!
6.
Secure the gearbox with 16 of the 18


on page 354!
Nm.
7.
Remove the guide pins and fit the

remaining two attachment screws as
specified in previous step.
8.
Refit gear Z3 to the gearbox, axis 5 with Shown in the figure Location of gearbox
its attachment screws.
on page 354!
Nm.
4 Repair
Step
9.
Action
Refit wheel unit.
Note/Illustration
Detailed below in Refitting, wheel unit
on page 357.
10. Replace the gasket.


locking liquid.

12. Refit the motor, axis 5.

axis 5 on page 311.
14. Refill the primary gearbox with oil.

axis 5 on page 170.

axis 5 on page 170.

Refitting, wheel unit

The procedure below details how to refit the wheel unit. Also see the figure Location of
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Clean wheel unit and tube mating

surfaces.
2.
Lubricate packing box with grease.
3.
Apply removal tool to the center hole of Art. no. is specified in Required
the gear Z4.
4.
Refit wheel unit by gently lowering it

straight down.

357
4 Repair
Step
Action
Note/Illustration
5.
Gently knock on the wheel unit with a

Note! Make sure the bearing reaches
plastic mallet, to press it all the way down. the bottom, before continuing the
mounting!
6.
Fasten the bearing washer with its

locking liquid .
Turn the gear Z4 in order to reach all the
screws.
xx0200000068
A: Gear Z4
B: Surface beneath VK-cover
C: VK-cover
D: Attachment screws, gear Z4
E: Attachment screws, bearing
washer
7 pcs: M6 x 16; tightening torque 10 Nm.
358
7.
Clean the surface beneath the VK-cover

with isopropanol.

8.
Secure the wheel unit with attachment

screws, gear Z4.

9.
Refit the VK-cover.

on page 354!
10. Replace the gasket.


locking liquid.

on page 354!
14 pcs; tightening torque: 10 Nm.
4 Repair
Step
Action
Note/Illustration

axis 5 on page 170.

DANGER!
it is vital that:
359
4 Repair

Location of gearbox
xx0100000131
Gearbox, axis 6
Attachment screws, gearbox
Washers
Oil plug, filling
Oil plug, draining
O-ring (not shown in figure)
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Removal tool, motor, M10
3HAC 14972-1
Use the removal tool in pairs!

360

the tools required.
4 Repair
Removal, gearbox
WARNING!
result in burns!
NOTE!
used!
Step
Action
Note/Illustration
1.
Drain the oil from gearbox, axis 6.

6 on page 174.
2.
Remove the turning disk.
Detailed in section Removal of turning disk

on page 220.
3.
Remove the gearbox by unscrewing

its 18 attachment screws and both
washers.
Shown in the figure Location of gearbox on

page 360!
4.
If required, apply the removal tool,

Shown in the figure Location of gearbox on
motor M10 to the holes shown in the page 360!
figure to press it free.
xx0200000032
A: M10 holes for pressing the gearbox

out
Be careful not to damage the motor pinion
when lifting out the gearbox!
361
4 Repair

Location of gearbox
xx0100000131
Gearbox, axis 6
Attachment screws, gearbox
Washers
Oil plug, filling
Oil plug, draining
O-ring (not shown in figure)
Required equipment
362
Equipment, etc.
Note
Gearbox, axis 6
3HAC 10122-22
Includes o-ring 3HAB

3772-49.
Washers
3HAC 10122-13 Not included in gearbox!

Replace when damaged
only!
O-ring
3HAB 3772-49

replacing gearbox!
4 Repair
Equipment, etc.
Note
Grease
3HAB 3537-1
For lubricating o-ring.
Standard toolkit
3HAC 15571-1

in section Standard
manual, reference
information.

references to these
These procedures
tools required.
Instruction

section Document
references in the
Product manual,
Refitting, gearbox
WARNING!
result in burns!
Step
1.
Action
Note/Illustration
Make sure the o-ring is fitted to the rear of the Art. no. is specified in Required
gearbox. Lightly lubricate the o-ring with
grease.
xx0100000132
A: O-ring, gearbox axis 6
363
4 Repair
Step
Action
Note/Illustration
2.
Insert the gearbox, axis 6 into the wrist unit.

Make sure the gears of the gearbox
mate with those of the motor!
3.
Fit the washers and secure the washers and Shown in the figure Location of
gearbox with the attachment screws.
UNBRAKO, tightening torque: 65
Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints in
4.
Refit the turning disk.

turning disk on page 222.
5.
Perform a leak-down test .

6.
Refill the gearbox with oil.

7.
Recalibrate the robot.

DANGER!
it is vital that:
364
5.1. Introduction
5.1. Introduction
General
This chapter includes general information about different calibration methods and details also
procedures that does not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 366, 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 370. 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.
365
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.
(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
366
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.
367
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.
The figure shows IRB 6600, but the scales and their positions are the same for IRB 6650S
and IRB 7600.
xx0200000176
A1
Calibration scale, axis 1 (early design)
A2
Calibration scale, axis 1 (later design)
B1
B2
Calibration mark, axis 2 (later design)
C1
C2
Calibration mark, axis 3 (later design)
Calibration scale, axis 4
Calibration marks at axes 2 and 3

The calibration marks at axes 2 and 3, shown in the figure above, consist of two single marks
that should be positioned opposite to one another when the robot is standing in its calibration
position. One of the marks is more narrow than the other and should be positioned within the
limits of the wider mark.
368
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
369
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 368
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 371
(RobotWare 4.0).
Storing the revolution counter setting
with the FlexPendant on page 372
(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:
370
Robot variant
Axis 4
Axis 6
IRB7600
Yes
Yes
Storing the revolution counter setting with the TPU

This section details the second step when updating the revolution counter; storing the
revolution counter setting with the TPU (RobotWare 4.0).
Step
1.
Action
Note
Press the button "Miscellaneous" then ENTER to select the

service window.
xx0100000194
2.
Select Calibration from the View menu.

The Calibration window appears.
If there is more than one unit connected to the robot, they will
be listed in the window.
xx0100000201
3.
Select the desired unit and choose Rev Counter Update

from the Calib menu.
The Revolution Counter Update window appears.
xx0100000202
4.
Select the desired axis and press Incl to include it (it will
be marked with an x) or press All to select all axes.
5.
Press OK when all axes that are to be updated are marked

with an x.
CANCEL returns to the Calibration window.
371
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 374.
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
372
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 374.
373
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
How to update the revolution
counters is detailed in section
on page 370
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
374
Action
1.
On ABB menu tap Program Editor.
2.
Create a new program.
3.
Use MoveAbsJ in the Motion&Proc menu.
4.
Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff
s, v1000, z50, Tool0
5.
Run the program in manual mode.
6.

counters!
Note

How to update the revolution
counters is detailed in section
on page 370.
Using the Jogging window on the TPU, S4Cplus

This section describes how to jog the robot to all axes zero position.
Step
Action
Illustration/information
1.
Open the Jogging window.
2.
Choose running axes-by-axes.
3.
Manually run the robot axes to a position where the

axis position value read on the TPU, is equal to
zero.
4.
Check that the calibration marks for the axes align The calibration marks are
counters!
Detailed in section Updating
revolution counters on page
370.
xx0100000195
xx0100000196
Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.
Step
Action
1.
Tap Jogging in the ABB menu.
2.
Tap Motion mode to choose group of axes to jog.
3.
Tap axes 1-3 to jog axes 1, 2 or 3.
4.
Manually run the robots axes to a position where the

axis position value read on the FlexPendant, is equal
to zero.
5.

counters!
Note

How to update the counters
is detailed in section
on page 370.
375
376
6 Decommissioning
6 Decommissioning
377
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:
378
Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
Spillage may penetrate the soil causing ground water contamination.
6 Decommissioning
6.2. Decommissioning of balancing device

General
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1

Cutting torch
For opening housing and cutting coils


DANGER!
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 267.
2.
Place it on a workbench or similar.

Make sure it is clamped in position
with a vice or similar.
379
6 Decommissioning
Step
3.
Action
Info/Illustration
Open a hole in the side of the

housing as shown in the figure.
Use a cutting torch.
xx0200000082
380
4.
Cut the coils of the three springs

Use a cutting torch.
inside the housing as specified
below:
Outer spring: cut at least five
(5) coils!
Middle spring: cut at least
four (4) coils!
Inner spring: cut at least four
(4) coils!
5.
After double-checking the number of

coils cut and making sure all the
tension in the springs is removed,
remove the end cover of the
balancing device.
6.
Dismantle the balancing device and

sort its parts for the recycling plant.
Index
C
cabling, position switch 104
cabling, robot 103
cabling, robot axes 1-4 201
cabling, robot axes 5-6 209
calibration position 370
calibration position, checking 374
calibration position, jog to 375
Connection of external safety devices 15
D
direction of axes 369
G
gearbox oil 152
L
Limitation of Liability 16
N
negative directions, axes 369
O
oil, amount 152
oil, types 152
P
positive directions, axes 369
R
Revolution counters 370
S
Safety, service 15
securing, base plate 70
securing, robot 74
U
Updating revolution counters 370
V
Validity and responsibility 15
381
6 Decommissioning
382

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Product manual (part 1 of 2), procedures

Copyright 2004 ABB All right reserved.

1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.2.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.8 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

2.5.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Changing/replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.5.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.6.1 Flushing a contaminated gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3HAC 022033-001 Revision: B

3.7.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

4.4.1 Removal of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.5.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

4.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

4.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

4.8.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

3HAC 022033-001 Revision: B

4.8.8 Removal of gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

3HAC 022033-001 Revision: B

installing the manipulator, mechanically as well as electrically

maintenance of the manipulator

mechanical and electrical repair of the manipulator.

Who should read this manual?

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/

3HAC 022033-001 Revision: B

Information about installation of the manipulator, including working

Information about maintenance work, including maintenance

Information about repair work. Each procedure include necessary

Procedures that do not require specific calibration equipment.

Environmental information about the manipulator.

Chapter Calibration replaced with chapter Calibration information.

New lubricating oil in the gearboxes. Changes made in the chapter

3HAC 022033-001 Revision: B

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views

In addition, spare part information is supplied for the entire option.

3HAC 022033-001 Revision: B

Product documentation, M2004

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