IRB6600 6650 Typeb M2000 M2000A

Product manual
Articulated robot
IRB 6600 - 225/2.55 type B
IRB 6600 - 175/2.8 type B
IRB 6650 - 200/2.75 type B
IRB 6650 - 125/3.2 type B
IRB 6600ID - 185/2.55
IRB 6650ID - 170/2.75
M2000, M2000A, M2004
Product manual
IRB 6600 - 225/2.55 type B
IRB 6600 - 175/2.8 type B
IRB 6650 - 200/2.75 type B
IRB 6650 - 125/3.2 type B
IRB 6600ID - 185/2.55
IRB 6650ID - 170/2.75
M2000
M2000A
M2004
Document ID: 3HAC023082-001
Copyright 2004-2008 ABB. All rights reserved.
Revision: E
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 ABB's 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 2004-2008 ABB All right reserved.

ABB AB
Robotics Products
SE-721 68 Vsters
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Safety
17
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.3 Emergency release of the robots arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2.3.9 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 39
1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2 Installation and commissioning
43
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Robot transportation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.4.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4.3 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.5.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5.3 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.5.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.5.5 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.5.6 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5.7 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.5.8 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.5.9 Installation of chip and dust protection (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5.10 Installation of base spacers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.5.11 Installation of cooling fan for motors, axes 1-3 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.5.12 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3HAC023082-001 Revision: E
Table of Contents
2.6 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.5 Installation of position switches (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
105
107
109
111
2.7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.7.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

2.8 Making robot ready for operation (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.8.1 Additional installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

3 Maintenance
129
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.9 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.10 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.11 Inspection, additional mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.12 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.13 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.14 Inspection, signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.15 Inspection of air hoses (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
139
141
143
146
149
153
158
162
164
166
169
171
173
176
3.4.1 Type of oil in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3 Oil change, gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.7 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.8 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
177
182
185
188
191
194
197
200
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.5.1 Lubrication of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

3.5.2 Rust preventive, bearing axis 1 (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.5.3 Rust preventive, bearing axis 4 (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.5.4 Rust preventive, support bearing in wrist (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

3.7 Service Information System, M2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

3.7.2 Description of Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.7.3 SIS system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.4 Replacement/changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Table of Contents
3.7.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

3.7.5 Reading the SIS output logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.7.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4 Repair
223
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.3.1 Replacement of cable harness, axes 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

4.3.4 Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID . . . . . . . . . . . . . . . . . . . 253
4.3.5 Replacement of cabling, axis 5 motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4.3.6 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.3.7 Replacement of air nipple and hose (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.4.1 Replacement of turning disk, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.4.2 Replacement of complete wrist unit, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.4.3 Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID . . . . . . . . . . . . . . . . . . . . . . 282
4.4.4 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.4.5 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.4.6 Replacement of lower arm shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.4.7 Securing the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4.5 Frame and base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
4.5.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

4.5.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
4.5.3 Replacement of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.5.4 Replacement of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.5.5 Unloading the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4.5.6 Restoring the balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

4.6.2 Replacement of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4.6.5 Replacement of motor, axis 5, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4.6.6 Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
4.6.7 Replacement of motor, axis 6, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
4.6.8 Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

4.7.2 Replacement of gearbox axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
5 Calibration information
409
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Table of Contents
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.7 Additional calibration instruction, IRB4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
6 Decommissioning
423
6.1 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

6.2 Decommissioning of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
7 Robot description
427
7.1 Type A and type B of IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

8 Reference information
429
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Spare part / part list
429
430
431
432
435
436
437
440
441
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

9.2 Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
9.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

9.2.2 Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
9.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
9.3.2 Rebuilding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
9.3.3 Part list, overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
9.3.4 Base incl frame ax 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
9.3.5 Axis 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
9.3.6 Axis 3-4, Foundry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
9.3.7 Axis 3-4 Foundry Prime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
9.3.8 Wrist, type 2, standard, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
9.3.9 Wrist, process, IRB 6600ID and 6650ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
9.3.10 Wrist, type 2, Foundry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
9.3.11 Wrist, type 2, insulated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
9.3.12 Wrist, type 2, Foundry Prime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
9.3.13 Material set, manipulator, 3HAC 13263-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
9.3.14 Material set, axis 1-2, 3HAC 13264-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
9.3.15 Material set, balancing device, 3HAC 13265-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
9.3.16 Arm extension set, 250 mm, 3HAC 12311-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
9.3.17 Arm extension set, 450 mm, 3HAC 12311-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
10 Exploded views
477
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Base incl. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Wrist complete, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7 Wrist complete, IRB 6600ID and IRB 6650ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
477
478
479
480
481
482
483
9.3 Part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Table of Contents
11 Circuit Diagram
485
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485

11.2 Circuit diagram 3HAC 025744-001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
11.2.1 Validity of circuit diagram 3HAC 025744-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

11.3 Circuit diagram 3HAC 13347-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
11.3.1 Validity of circuit diagram 3HAC 13347-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

489
Index
Table of Contents
Overview
Overview
About this manual
This manual contains instructions for
mechanical and electrical installation of the robot
maintenance of the robot
mechanical and electrical repair of the robot.
Usage
This manual should be used during
installation, from lifting the robot 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
A maintenance/repair/ installation craftsman working with an ABB Robot must:
be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:

Chapter
Contents
Safety
Safety information that must be read through before performing

any installation or service work on robot. Contains general safety
aspects as well as more specific information about how to avoid
personal injuries and damage to the product.
Installation and commissioning
Required information about lifting and installation of the robot.
Maintenance
Step-by-step procedures that describe how to perform

maintenance of the robot. Based on a maintenance schedule
that may be used in the work of planning periodical maintenance.
Repair
Step-by-step procedures that describe how to perform repair

activities of the robot. Based on available spare parts.
Calibration Information
Procedures that does not require specific calibration equipment.
Decommissioning
Environmental information about the robot and its components.
Continues on next page

Overview
Continued
References
Following documents are referred to throughout the manual:
Document name
Document ID
Note
Product specification - IRB 6600/6650/6650S 3HAC023933-001

M2004
M2004
Product specification - IRB 6600/6650/6650S 3HAC14064-1

M2000/M2000A
M2000/M2000A
3HAC021313-001
Product manual - S4Cplus M2000
3HAC021333-001
Product manual - S4Cplus M2000A
3HAC022419-001
Operating manual - IRC5 with FlexPendant
3HAC16590-1
Operating manual - Calibration Pendulum
3HAC16578-1
Operating manual - Levelmeter Calibration
3HAC022907-001
Users guide - S4Cplus
3HAC7793-1
Operating manual - Service Information

System
3HAC025709-001
Technical reference manual - System

parameters
3HAC17076-1
Application manual - Additional axes and

stand alone controller
3HAC021395-001
M2004
Application manual - External axes
3HAC9299-1
M2000/M2000A
Product manual - IRC5

10
Overview
Continued
Revisions
Revision Description
-
First edition
Chapter Calibration is replaced with new chapter Calibration information.

Chapter Safety, Service is replaced with new chapter Safety.
Section Document references is completed with article number for calibration
manuals.
New lubricating oil in the gearboxes, axes 1, 2, 3 and 6. Changes are made in
chapter Maintenance and section Part list.
New robot models, IRB 6600ID and IRB 6650ID, are implemented throughout
the manual.
Additional changes made in the manual:
Changes made in the Part list in the Product manual, reference
information (new article numbers for items 101.2.3, 103.1.30, 109.302).
Attachment holes in the frame moved to different location. New figure in
section Illustration, fitting of extra equipment on frame on page 84.
New procedure for optional equipment: Installation of cooling fan for
motors, axes 1-3 (option) on page 97. Additional cabling also added to
section Robot cabling and connection points on page 122.
Supplementary details about required cabling for position switches are
added to section Installation of position switches (option) on page 111,
together with a procedure for how to install the cabling.
A complete (undivided) cabling from axis 1 to axis 6 is added to the spare
parts in Spare part list on page 443. New procedure: Replacement of
cable harness, axes 1-6 on page 228. Also a new circuit diagram is
added to the manual, due to the new cabling.
New procedure: Replacement of spherical roller bearing, balancing
device on page 317 due to added spare parts in Spare part list on page
443.
The section about SIS (Service Information System) is now only valid for
M2000 robot systems. For information regarding SIS for M2004
systems, see additional manual about SIS. Art. no. for the manual is
specified in section References on page 10.
Information about document references are moved to the table

References on page 10.
Foundry Prime Option included.
Changes made in:

Prerequisites in section Overview
Oil change in section Maintenance
New section Robot transportation precautions.
New section Securing the robot
11
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:
Product manuals
All hardware, robots and controllers, 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)
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
The product manual published as a PDF consists of only one file where the two parts are
presented together, as one Product manual.
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.
12
Software manuals
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.
Product manuals
All hardware, robots and controllers, 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)
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
The product manual published as a PDF consists of only one file where the two parts are
presented together, as one Product manual.
Technical reference manuals
The following manuals describe the robot software in general and contain relevant reference
information:
RAPID Overview: An overview of the RAPID programming language.
RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
System parameters: Description of system parameters and configuration workflows.

13

Continued
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, CD
with PC software)
How to use the application
Examples of how to use the application
Operating 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
includes:
Getting started - IRC5 and RobotStudio
IRC5 with FlexPendant
RobotStudio
Trouble shooting - IRC5 for the controller and robot
14
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 a procedure.
8.
Action
Note/Illustration
Remove the rear attachment screws, gearbox.
Shown in the figure Location of

gearbox on page xx.
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 a procedure.
3.
Action
Note/Illustration
Fit a new sealing, axis 2 to the gearbox.
Art. no. is specified in Required

equipment on page xx.
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 17.
15
16
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 18.
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 35.
17
1 Safety
1.2.1. Safety in the robot system
1.2 General safety information

1.2.1. Safety in the robot system
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 are 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 - S4Cplus (M2000)
Operating Manual - IRC5 with FlexPendant (M2004)
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.
Limitation of liability
Related information
18
Type of information
Detailed in document
Section
Installation of safety
devices
Product manual for the robot
Changing operating
modes

(RobotWare 4.0)
Operating manual - IRC5 with
FlexPendant (RobotWare 5.0)
Start-up
Operating modes
Restricting the working

space
Product manual for the robot
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
are complied with.
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
1.2.2. Safety risks

Overview
This section includes information of general safety risks to be considered when performing
installation and service work on the robot.
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, are dismantled.
When dismantling/assembling mechanical units, watch out for falling objects.
Be aware of stored heat energy in the controller.
Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
19
1 Safety
Continued
Complete robot
Safety risk
Description
Hot components!
CAUTION!
Motors and gears are HOT after running the robot!
Touching the motors and gears may result in burns!
Removed parts may result in
collapse of robot!
WARNING!
Take any necessary measures to ensure that the robot
does not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.
Cabling
Safety risk
Description
Cable packs are sensitive to

mechanical damage!
CAUTION!
The cable packs are sensitive to mechanical damage!
They must be handled with care, especially the
connectors, in order to avoid damaging them!
Gearboxes and motors

Safety risk
Description
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!
20
Gears may be damaged if

excessive force is used!
1 Safety
1.2.2.2. Safety risks related to tools/workpieces
1.2.2.2. Safety risks related to tools/workpieces

Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. 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.
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
21
1 Safety
1.2.2.3. Safety risks related to pneumatic/hydraulic systems
1.2.2.3. 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. 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
1.2.2.4. Safety risks during operational disturbances
1.2.2.4. 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.
Corrective maintenance 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
1.2.2.5. 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 robots working space.
Voltage related risks, controller S4Cplus

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

24
1 Safety
Continued
Voltage related risks, IRC5 controller
A danger of high voltage is associated with for example the following parts:
Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the
controller.
Units such as I/O modules, can be supplied with power from an external source.
The mains supply/mains switch
The transformers
The power unit
The control power supply (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The drive unit (700 VDC)
The drive system power supply (230 VAC)
The service outlets (115/230 VAC)
The customer power supply (230 VAC)
The power supply unit for additional tools, or special power supply units for the
machining process.
The external voltage connected to the controller 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
chapter Installation and commissioning in the Product 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
1.2.3.1. Safety fence dimensions
1.2.3. Safety actions

1.2.3.1. 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
1.2.3.2. Fire extinguishing
1.2.3.2. Fire extinguishing

NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system
(manipulator or controller)!
27
1 Safety
1.2.3.3. Emergency release of the robots arm
1.2.3.3. Emergency release of the robots arm

Description
In an emergency situation, any of the robot's axes may be released manually by pushing the
brake release buttons on the robot.
How to release the brakes is detailed in section:
Manually releasing the brakes on page 71.
Manually releasing the brakes in the product manual for the robot.
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
1.2.3.4. Brake testing
1.2.3.4. Brake testing

When to test
During operation the holding brake 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 the holding brake of each axis motor 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
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!
Do not change "Transm gear ratio" or other kinematic system parameters from the
FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".
30
1 Safety
1.2.3.6. Safe use of the FlexPendant
1.2.3.6. Safe use of the FlexPendant

NOTE!
The enabling device is a push button located on the side of the FlexPendant 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 FlexPendant, 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 FlexPendant with him/her, when entering the
robot's working space. This is to prevent anyone else taking control of the robot
without the programmer knowing.
31
1 Safety
1.2.3.7. Work inside the manipulator's working range
1.2.3.7. Work inside the manipulator's working range

WARNING!
If work must be carried out within the robots work envelope, the following points must be
observed:
The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
The robots speed is limited to max. 250 mm/s when the operating mode selector is in
position "manual mode with reduced speed". This should be the normal position when
entering the working space. The position "manual mode with full speed (100%)" 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.
32
1 Safety
1.2.3.8. Signal lamp (optional)
1.2.3.8. Signal lamp (optional)

Description
A signal lamp with an yellow fixed light can be mounted on the manipulator, as a safety
device.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in the
controller documentation.
33
1 Safety
1.2.3.9. Translate the information on safety and information labels
1.2.3.9. Translate the information on safety and information labels

Labels on the product
Both the robot and the controller are marked with several safety and information labels,
containing important information about the product. The information is useful for all
personnel handling the robot system, eg. during installation, service or operation.
The labels are identified and located on the product as shown in section:
Inspection, information labels on page 162
Translation possibilities
The labels fitted to the product contain space for adding a fourth language underneath the
three standard languages (English, German and French).
Add a local language to the label by:
Using a transparent sticker over the standard label with text added in a fourth
language. Drawings detailing the design (text, figure, dimensions) of the standard
labels can be ordered from ABB. Notice that each label is identified according to the
article number located in the lower corner of the label.
Example of transparent sticker
The figure below shows the location of the free space on one of the labels on the robot, where
the fourth language can be added. The figure also shows a transparent sticker, containing the
text in Swedish.
xx0500002517
34
Free space for adding a fourth language
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 do 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

35
1 Safety
Continued
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
36
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
Action
Note
1. Before attempting to run the manipulator,

make sure all emergency stop equipment
is correctly installed and connected.
Emergency stop equipment such as gates,

tread mats, light curtains, etc.
2. If possible, use the hold-to-run function

whenever possible.
The hold-to-run function is used in manual
mode, not in automatic mode.
How to use the hold-to-run function in

RobotWare 5.0 is detailed in section How
to use the hold-to-run function in the
Operating manual - IRC5 with FlexPendant.
How to use the hold-to-run control in
RobotWare 4.0 is detailed in section The
Teach Pendant unit in the Users guide S4Cplus.
3. Make sure no personnel are present within

the manipulator working range before
pressing the start button.
37
1 Safety
1.3.3. DANGER - First test run may cause injury or damage!
1.3.3. DANGER - First test run may cause injury or damage!

Description
Since performing a service activity often requires disassembly of the robot there are several
safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service activity (repair,
installation or maintenance):
Action
1. Remove all service tools and foreign objects from the robot and its working area!
2. Install all safety equipment properly!
3. Make sure all personnel are standing at a safe distance from the robot, i.e. out of its
reach behind safety fences, etc!
4. Pay special attention to the function of the part previously serviced!
38
1 Safety
1.3.4. WARNING - The brake release buttons may be jammed after service work
1.3.4. 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:
Action
1. Make sure the power is turned off.
2. Remove the push button guard, if necessary.
3. Check the push buttons of the brake release unit by pressing them down, one by one.
Make sure none of the buttons are jammed in the tube.
4. If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes!
39
1 Safety
1.3.5. WARNING - The unit is sensitive to ESD!
1.3.5. 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 grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.
Elimination
Action
Note
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.
Location of wrist strap button
The wrist strap button is located in the top right corner as shown in the illustration below.
xx0500002171
40
Wrist strap button
1 Safety
1.3.6. 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!
Specified amount
depends on drained
volume!
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.
41
1 Safety
42

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.
43

2.2. Robot transportation precautions

General
This section details ABB approved transportation precautions for ABB robots.
CAUTION!
All transportation in or outside the plant, must be carried out according to description
in method 1.If transportation according to method 1 is not possible, use method 2.
Transportation in any other way than method 1 or 2 can seriously damage the robot.If
the robot is incorrectly transported and the instructions are not followed, the robot is
not covered by the warranty and ABB will not accept any compensation claim.
Method 1
xx0800000030
Always follow these instructions when transporting an ABB robot according to method 1:
Always remove the tool before transportation of the robot.
Always place the robot in the ABB recommended transport position, detailed in
section Risk of tipping/stability.
Always read and follow the instructions in section Pre-installation procedure.

44
Transportation according to method 1 is strongly recommended by ABB.

Continued
Method 2
Transportation according to method 2 is approved by ABB, if use of method 1 is not
possible.
Always follow these instructions when transporting an ABB robot according to method 2:
Always read and follow the instructions in section Securing the robot
Always place the robot in the ABB recommended transport position for robot with
tool, detailed in sub section Transport position with a transport support.
Always use the recommended transport support detailed in sub section Recommended
transport support.
IRB7600/IRB66XX
xx0800000037
Transport Support
Hexagon socket head cap screw M16x140
Threaded bar M10x200
Nut M10

45

Continued
IRB6620
xx0800000036
Transport Support
Hexagon socket head cap screw M10x50
Threaded bar M10x280
Nut M10

46

Continued
Transport position with a transport support
All transportation of the robot with tool must follow these instructions.
IRB 7600/IRB 66XX
xx0800000040

47

Continued
IRB 6620
xx0800000041

48

Continued
Recommended transport support
Always use the recommended transport support when transporting a robot with tool.
IRB 7600/IRB 66XX
xx0800000039

49

Continued
IRB 6620
xx0800000038
50

2.3. Securing the robot

General
This section describes how to secure the robot using the transport support.
DANGER!
Releasing the brakes is a hazardous action that may cause injury and damage property. It must
be done with great care and only when absolutely necessary.
Securing the robot
xx0800000062

51

Continued
Action
Note
1. Mount the transport support lower end to the Do not tightening the screw.
robot using the recommended screw joint, (A) See attachment point for the specific
in figure.
robot in section Transport position with
a transport support.
2. Jog the robot into a position as near above as
possible to the recommended transport
position for the specific robot. specified in
section Transport position with a transport
CAUTION!
support.
Do not try to jog the robot to the exact
position (max distance 1mm).
3. Use the brake release for axis 3 to reach the See attachment point for the specific
final resting position on the transport support, robot in section Transport position with
see section Manually releasing the brakes .
a transport support
4. Tightening all the attachment screws (A) and
(B) in figure with the brake release for axis 3
still activated starting with the lower end
attachment screw.
CAUTION!
Do not attempt to tightening any
attachment screw without first release
the brakes, this can seriously damage
the robot.
5. Use the brake release for axis 5 and 6 to

reach the final resting position for the tool, see
section Manually releasing the brakes
52

2.4.1. Pre-installation procedure
2.4 Unpacking
General
This section is intended for use when unpacking and installing the robot for the first time. It
also contains information useful during later re-installation of the robot.
Checking the pre-requisites for installation
The checklist below details what must be observed before proceeding with the actual
installation of the robot:
1. Make sure only qualified installation personnel conforming to all national and local codes
are allowed to perform the installation.
2. Visually inspect the robot to make sure it is not damaged.
3. Make sure the lifting device used is suitable to handle the weight of the robot as specified
in Weight, robot on page 53.
4. If the robot is not installed directly, it must be stored as described in Storage conditions,
robot on page 54.
5. Make sure the expected operating environment of the robot conforms to the specifications
as described in Operating conditions, robot on page 54.
6. Before taking the robot to its installation site, make sure the site conforms to Loads on
foundation, robot on page 54, Requirements, foundation on page 54 and Protection
classes, robot on page 55.
7. Before moving the robot, please observe Risk of tipping / stability on page 60 regarding
risk of tipping!
8. When these prerequisites are met, the robot may be taken to its installation site as
described in section On-site installation on page 61.
Weight, robot
The table below shows the weights of the different models:
Robot model
Weight
IRB 6600 - 225/2.55
1780 kg *
IRB 6600 - 175/2.8
1780 kg *
IRB 6650 - 125/3.2
1780 kg *
IRB 6650 - 200/2.75
1780 kg *
IRB 6600ID - 185/2.55
1880 kg
IRB 6650ID - 170/2.75
1880 kg
* Weight of robot excluding DressPack.

53

Continued
Loads on foundation, robot
The table below shows the various forces and torques working on the robot during different
kinds of operation, in relation to the base coordinate system.
Note! These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
Force
Endurance load (operation)
Max. load (emergency stop)
Force xy
10.1 kN
20.7 kN
Force z
18.0 13.8 kN
18.0 22.4 kN
11.0 3.7 kN
Torque xy
27.6 kNm
30.4 kNm*
50.6 kNm
55.7 kNm*
Torque z
7.4 kNm
14.4 kNm
* When using base spacers (option 571-1).

Requirements, foundation
The table below shows the requirements for the foundation where the weight of the installed
robot is included:
Requirement
Value
Min. levelity
0.5 mm
Max. tilt
Min. resonance frequency
22 Hz
Note
The limit for the maximum load on the robot
is reduced if the robot is tilted.
Contact ABB for further information about
acceptable loads.
Storage conditions, robot
Parameter
Value
Min. ambient temperature
-25 C
Max. ambient temperature
+55 C
Max. ambient temperature (less than 24 hrs)
+70 C
Max. ambient humidity
Max. 95% at constant temperature
Operating conditions, robot

The table below shows the allowed operating conditions for the robot:
Parameter
Value
Min. ambient temperature
+5 C
Max. ambient temperature
+50 C
Max. ambient humidity
Max. 95% at constant temperature
Max. ambient humidity (Foundry Prime)
100% if robot installed and maintained in

accordance with the the manual.

54
The table below shows the allowed storage conditions for the robot:

Continued
Protection classes, robot
The table below shows the protection class of the robot:
Protection class
Robot
IP 67
Cooling fans (option)
IP 54
Equipment
55

2.4.2. Working range and type of motion

Working range
Following figures show the working ranges of the robot models. The extreme positions of the
robot arm are specified at the wrist center (dimensions in mm).
IRB 6600 - 225/2.55, IRB 6600ID - 185/2.55
The illustration below shows the unrestricted working range:
xx0200000025

56

Continued
IRB 6600 - 175/2.8
xx0200000026

57

Continued
IRB 6650 - 125/3.2
xx0200000338

58

Continued
IRB 6650 - 200/2.75,IRB 6650ID - 170/2.75
xx0200000339
Type of motion
Axis
Type of motion
Range of movement
Note
Rotation motion
+180 to -180
Movement range of IRB 6600/

6650 can be set to:
+220 to -220 (option 561-1)
Arm motion
+85 to -65
Arm motion
+70 to -180
Wrist motion
+300 to -300
Bend motion
IRB 6600/6650:
+120 to -120
IRB 6600ID/6650ID:
+100 to -100
Turn motion
IRB 6600/6650:
+360 to -360 (default),
96 revolutions
IRB 6600ID/6650ID:
+300 to -300
300 max 1)
1)
IRB 6600ID/6650ID: the range

of movement is the combined
value for axis 4 and 6 together.
The minimum combination of axes 4 and 6.
59

2.4.3. Risk of tipping / stability
2.4.3. Risk of tipping / stability

Risk of tipping
When the robot is not fastened to the foundation and standing still, the robot is not stable in
the whole working area. Moving the arms will displace the center of gravity, which may cause
the robot to tip over.
Do not change the robot position before securing it to the foundation!
Stabililty
The figure below shows the robot in its shipping position, which also is its most stable
position.
xx0100000103
The robot is likely to be mechanically unstable while not secured to the foundation!
60
WARNING!

2.5.1. Lifting robot with fork lift
2.5 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.
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

61

Continued
Required equipment
Equipment, etc.
Art. no.
Note
Fork lift set, incl. all required 3HAC 0604-1

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

on page 62.
Standard toolkit
The contents are defined in section

Standard toolkit on page 436 in part 2 of
the Product manual.
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)
Securing screw, used for IRB 6650S

62

Continued
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!
Action
Note/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 the Release the brakes if required as
right!
detailed in section Manually releasing
the brakes on page 71.
xx0200000387
3. Fit the two spacers to the robot and secure.
Attachment points on the robot are

shown in the figure Attachment points
on page 61.
4.
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 61.
xx0400001068
A: horizontal attachment
screws, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
B: spacers, 2 pcs.

63

Continued
Action
Note/Illustration
6. 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
7. Secure the fork lift pocket to the robot with the

two vertical attachment screws and washers.
Note! The vertically and the horizontally
attached screws are identical, but tightened
with different torques!
xx0300000464
A: vertical attachment screws, 2

pcs, M16x60.
on page 61.
8.
CAUTION!
The fork lift pocket weighs 22 kg!
9. Secure the shorter fork lift pocket on the other 4 pcs, M16x60.
side of the robot with the four remaining
horizontal attachment screws.
on page 61.

64

Continued
Action
Note/Illustration
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!
11.
CAUTION!
The robot models weigh:
IRB 6600, IRB 6650: 1780 kg!
IRB 6600ID, IRB 6650ID: 1880 kg!
All lifting equipment used must be sized
accordingly!
12. Carefully lift the robot and move it to its installation site.
13.
WARNING!
Personnel must not, under any circumstances,

be present under the suspended load!
14. Refit the cooling fan to the motor, if any.
Detailed in section Installation of

cooling fan for motors, axes 1-3 (option)
on page 97.
65

2.5.2. Lifting robot with roundslings

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

66

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

2.5 m
Lifting with roundslings

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

the figure Attachment points on page 66.
2.
CAUTION!
IRB 6600, IRB 6650: 1780 kg!
IRB 6600ID, IRB 6650ID: 1880 kg!
All lifting equipment used must be sized accordingly!
3.
WARNING!
Personnel must not, under any circumstances,

be present under the suspended load!
67

2.5.3. Lifting robot with lifting slings

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

68

Continued
Required equipment
Equipment
Art. no.
Note
Lifting device, robot
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.
Action
Note/Illustration
1. Run the overhead crane to a position above

the robot.
2. Make sure the robot is positioned as shown in Release the brakes if required as
the figure on the right. If it is not, position it that detailed in section Manually releasing
way.
the brakes on page 71.
xx0100000103
3. Fit the lifting device, manipulator to the robot Art. no. is specified in Required
as described in the enclosed instruction!
equipment on page 69
4.
CAUTION!
IRB 6600, IRB 6650: 1780 kg!
IRB 6600ID, IRB 6650ID: 1880 kg!
accordingly!
5.
WARNING!
Personnel must not, under any circumstances, be present under the suspended
load!

69

Continued
Action
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.
6. Raise the overhead crane to lift the robot.
Note/Illustration
70

2.5.4. Manually releasing the brakes

General
This section details how to release the holding brakes of each axis motor.
Location of brake release unit
The internal brake release unit is located at the frame, as shown in the figure below.
xx0300000044
Internal brake release unit with push buttons. Open the protection cover to access
the buttons.
Releasing the brakes
The procedure below details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action
Note/Illustration
1. The internal brake release unit is equipped with six

The buttons are shown in
buttons for controlling the axes brakes. The buttons are the figure Location of brake
numbered according to the numbers of the axes.
release unit on page 71
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 72.
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. 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.

71

Continued
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.
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
72

2.5.5. Lifting the base plate
2.5.5. Lifting the base plate

Required equipment
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, base plate

Action
Note
1.
CAUTION!
The base plate weighs 353 kg! All lifting equipment
used must be sized accordingly!
2. Fit the lifting eyes in the three lifting holes.
Shown in the figure Hole configuration on page 73!
3. Fit the lifting slings to the eyes and to the lifting device.
73

2.5.6. Securing the base plate

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

74

Continued
xx0400000715
Note1
Four holes for alternative clamping

75

Continued
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)
Equipment
Art. no.
Note
Base plate
3HAC 12937-8
Includes
guide sleeves, 3HAC 12937-3
levelling screws, 9ADA 120-79
attachment screws and
washers for securing the
manipulator to the base plate.
A drawing of the base plate itself may
be ordered from ABB Robotics!
Standard toolkit

the Product manual.
Other tools and procedures may

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

to the tools required.

76
Required equipment

Continued
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.
Action
Note
1. Make sure the foundation is level.

2.
CAUTION!
The base plate weighs 353 kg! All lifting

equipment used must be sized accordingly!
3. 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 76.
4. Lift the base plate to its mounting position.
Detailed in section Lifting the base plate

on page 73.
5. Use the base plate as a template and drill 16 If possible, observe the recommendaattachment holes as required by the selected tions specified in section Recommendabolt dimension.
tions, quality on page 77. ABB does not
assume any responsibility for other
foundation qualities, due to great
variations in the foundation properties.
6. Fit the base plate and use the levelling bolts to Shown in the figure Base plate, grooves
level the base plate.
and holes on page 76.
7. If required, fit strips of sheet metal underneath
the base plate to fill any gaps.
8. Secure the base plate to the foundation with
screws and sleeves.
9. Recheck the four robot contact surfaces on
Max. allowed deviation: 0.5 mm
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.
77

2.5.7. Orienting and securing the robot

General
This section details how to orient and secure the robot to the base plate in order to run the
robot safely. The requirements made on the foundations are shown in the following tables and
figures.
Illustration, robot fitted to base plate
The illustration below shows the robot base fitted to the base plate.
Robot attachment bolts and washers, 8 pcs (M24 x 140)
Orienting grooves in the robot base and in the base plate
Levelling screws
Base plate attachment screws
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
robot to the base plate/foundation.
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

78
xx0300000566

Continued
Securing the robot
The procedure below details how to secure the robot to the base plate after fitting the plate to
the foundation.
Action
1. Lift the robot.
Note/Illustration
Detailed in section Lifting robot with
lifting slings on page 68.
2. Move the robot to the vicinity of its installation

location.
3. Fit two guide sleeves to the guide sleeve holes Shown in the figure Base plate,
in the base plate.
grooves and holes on page 76.
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 78.
Shown in the figure Illustration, robot
fitted to base plate on page 78!
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.
xx0600002628

79

Continued
Cross section, guide sleeve hole
The illustration below shows the cross section of the guide sleeve holes.
xx0600002629
80

2.5.8. Fitting equipment on robot

General
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional cabling,
equipment etc. fitted by the robot user. Make sure the required mounting holes are accessible
when planning the robot cell.
The robot IRB 6600ID and IRB 6650ID is delivered with DressPack/SpotPack and there may
not be any additional equipment fitted to the robot, except at the turning disk and the frame.
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 ofthe lower arm when fitting extra
equipment. Always use appropriate attachment screws!
Note! Extra equipment may not be mounted on the lower arm of IRB 6600ID or IRB 6650ID!
xx0200000195
Only valid for IRB 6600 and IRB 6650!

81

Continued
xx0300000571
xx0300000572

82

Continued
Illustration, fitting of extra equipment on upper arm
upper arm.
Note! Extra equipment may not be mounted on the upper arm of IRB 6600ID or IRB 6650ID!
xx0300000573
Only valid for IRB 6600 and IRB 6650
xx0200000196
Only valid for IRB 6600 and IRB 6650

83

Continued
Illustration, fitting of extra equipment on frame
frame.
xx0500001568
*1
Early version of the frame
*2
Later version of the frame

84

Continued
Illustration, fitting on turning disk
The illustration below shows the mounting holes available for fitting equipment on the
turning disk.
xx0200000197
Turning disk for robot version IRB 6600 - 225/2.55 and - 175/2.8, IRB 6650 - 125/3.2
and - 200/2.75

85

Continued
xx0500001580
Turning disk unit for robot versions IRB 6600ID and IRB 6650ID.
When fitting tools on the turning disk (see the figures above), use only screws with quality
12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
86
Fastener quality

2.5.9. Installation of chip and dust protection (option)

General
This section details how to install the optional chip and dust protection. It also details how to
remove the proctection, when necessary.
Illustration, equipment mounted on robot
The illustration below shows the chip and dust protection mounted on the robot.
xx0400001071
Bearing unit, lower arm shaft
Bearing unit, axis 2 motor
Stop
Shield (4 pcs)
Cover, balancing device
Sliding cover
Cover, lower arm
Required equipment
Equipment
Art. no.
Note
Chip and dust protection
3HAC 020529-008
Includes mounting set with

attachment screws and mounting
instruction.

87

Continued
Equipment
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
The contents are defined in

section Standard toolkit on page
436, in part 2 of the Product
manual.
Installation, chip and dust protection

The procedure below details how to install the chip and dust protection to the robot.
Action
Note/Illustration
xx0400001077
A: Bearing unit
B: Lower arm shaft
C: Washer and nut
Also shown in the figure Illustration, equipment
mounted on robot on page 87

88
1. Fit the bearing unit, lower arm shaft to

the robot by inserting it through the shaft
and securing with the washer and nut.

Continued
Action
Note/Illustration
2. Remove the four attachment screws (A)

from the cover, axis 2.
Use the holes to attach the bearing as
described in next step.
xx0400001103
3. Attach the bearing unit, axis 2 motor to

the robot with the enclosed attachment
screws.
Make sure the bearing unit is orientated
correctly. The opening must be
orientated approximately as shown in
the figure to the right (B).
xx0400001079
Attachment screws: 4 pcs, M8 x 40.

Also shown in the figure Illustration, equipment
mounted on robot on page 87
4. Remove the securing screws that are
fitted to the bearing unit during transport
and installation.
The separate rings are now movable.
xx0400001098

89

Continued
Action
Note/Illustration
5. Fit the stop to the robot. Use the

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

shield.
xx0400001099

90

Continued
Action
Note/Illustration
7. Fit the four shields to the robot with

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

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

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

91

Continued
Action
Note/Illustration
9. 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
10. Fit the sliding cover to the robot.
xx0400001087
J: Bushing
K: Hub

92

Continued
Action
Note/Illustration
11. 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
L: Rubber cloth
M: Upper shield
N: Rear bracket
12. Fit the cover, lower arm to the robot,

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

2. Remove the bearing unit.

93

Continued
Part to be removed
1. Remove all the shields.

2. Remove the bearing unit.
3. Refit the original attachment screws to the cover,
axis 2.
Bearing unit, axis 2 motor
Action
94

2.5.10. Installation of base spacers (option)
Illustration, installation of base spacers
xx0500001570
Base spacer (4 pcs)
Guide sleeve (4 pcs)
Attachment screws and washers (8 pcs)
Required equipment
Equipment
Art. no.
Note
Base spacers
3HAC 021899-002
Includes mounting set with

attachment screws and
mounting instruction.
Base plate
3HAC 12937-8
Standard toolkit

section Standard toolkit on
page 436, in part 2 of the
Product manual.

95

Continued
Equipment
Art. no.
Note
Other tools and procedures

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

references to the tools
required.
Installation, base spacers

The procedure below details how to fit the base spacers between the robot and the base plate.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Unfasten the robot from the foundation, if
fastened, and lift it away with lifting slings.
Make sure the robot is positioned in the most
stable position; the transport position!
Detailed in section Lifting robot with

lifting slings on page 68.
3. Install the base plate to the foundation, if not

used previously.
Detailed in section Securing the base

plate on page 74.
4. Fit the four base spacers and guiding sleeves to Shown in the figure Illustration, instalthe base plate.
lation of base spacers on page 95.
5. Lift the robot with lifting slings and move it to the
prepared base plate.
6. Guide the robot with the guiding sleeves as
lowering it towards the base plate and spacers.
M24 x 240, tightening torque: 775 Nm.
7. Fasten the robot base to the spacers with

enclosed attachment screws and washers.
8.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
96

2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

General
A cooling fan can be installed on the motors of axes 1, 2 and 3. However, cooling fans for
axes 1 and 2 can not be combined!
The cabling for the fans is available in different designs:
complete cabling, including connections for both cooling fans and position switches,
at axes 1, 2 and 3. Installation of this complete cabling is detailed in section
Installation of cable harness for position switches and fans on page 118.
separate cabling for axis 1 or 2, including only connections for the cooling fans on
axes 1 or 2. Installation of this cabling is detailed in section Installation, separate fan
cabling axis 1 or 2 on page 101.
If both cooling fans and position switches are installed on the robot, the complete cabling
must be used! It can not be combined with the separate cabling.
Location of cooling fans
The fans are installed on the motors, axes 1-3, as shown in the figure below.
xx0500002157
Cooling fan, axis 1
Cooling fan, axis 2
Cooling fan, axis 3
Rear cover plate

97

Continued
Cooling fan
The details of the cooling fan are shown in the figure below.
Fanbox
Attachment screws, fanbox plates (9 pcs)
Groove in the connector
Tightening screws, fanbox (3 pcs)
Required equipment
Equipment
Art. no.
Note
Cooling fan
3HAC15374-1
Cabling, position switches

and cooling fans, axes 1, 2
and 3
3HAC15390-1
Choose this cabling if equipping the robot
(IRB 6600/6600ID) with both position switches and cooling
fans or with cooling fans on axis 3.
3HAC16659-1
(IRB 6650/6650ID)
Cabling, cooling fans, axes

1 or 2
3HAC023599-001
Choose this cabling if only equipping the

robot with cooling fans on axis 1 or 2 (not
on axis 3 and not with position switches).

98
xx0500002158

Continued
Equipment
Art. no.
Note
Plate for customer

connections
3HAC025778-001
An additional connection plate must be

fitted to the robot base, if not already
installed. The plate is shown in the figure
Plate for customer connections, at base
on page 99.
Additional cabling to and

inside the controller
Specified in section Position switch and

fan cables, robot base to controller
(option) on page 123.
Locking liquid
Loctite. Used for the three tightening

screws.
Standard toolkit

Standard toolkit on page 436, in part 2 of
the Product manual.
Circuit diagram
See chapter Circuit diagram in the

Product manual, reference information.

references to these
These procedures include references to

the tools required.
xx0500002301
Plate for customer connections
Attachment screws, 3 pcs, M6x16

99

Continued
Installation, fan
The procedure below details how to install the cooling fan on any of the motors, axes 1-3.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure
supplies to the robot!
For Foundry Prime robots: Do not turn off the air pressure to
motors and SMB.
2. Prepare the fanbox for installation:
Shown in the figure
disassemble the two parts of the box by removing the Cooling fan on page 98.
nine attachment screws
loosen the three tightening screws, to avoid damaging
the surfaces of the motor when fitting the fanbox
turn the connector to the correct position; axis 1:
groove pointing inwards, as shown in the figure
Cooling fan on page 98. Positions for axis 2 and 3 are
shown in the figure Location of cooling fans on page
97.
3. Temporarily lift the motor cabling out of the way of the current
motor to make room for the fanbox.
4. Fit the parts of the fanbox to the motor and reassemble with
the nine attachment screws.
5. Lift the box (axis 1) so that it does not rest directly on the robot
and secure the box with the three tightening screws, using
locking liquid. Tighten them properly so that the box is firmly
attached to the motor.
Separate cabling for axis 1 or 2

The figure below shows the cabling used only for the fan on axis 1 or 2.
xx0500002173
Cable bracket
Connector R1.SW2/3, connected to the robot base
Connector R3.FAN2, connected to the fan of axis 1 or 2

100
6. Install the cabling and make adjustments in RobotWare, as

described in the following procedures.

Continued
Installation, separate fan cabling axis 1 or 2
The procedure below details how to install the separate cabling for the cooling fan of axis 1
or 2.
Action
1. Move the robot to its calibration position.
Note/Illustration
Shown in section Calibration
scales and correct axis position on
page 412.
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Remove the rear cover plate from the robot base. Shown in the figure Location of
cooling fans on page 97.
4. Fit the plate for customer connections, if not
Shown in the figure Plate for
already fitted, to the connection plate of the robot customer connections, at base on
base.
page 99.
equipment on page 98.
5. Run the cabling through the base and frame, up

beneath the balancing device.
6. Secure the cable bracket to the bracket of the
robot cabling inside the frame.
Run the cable underneath the robot cabling and
out through the side of the frame, at motor, axis 1.
The correct cable run is shown in the figure to the
right!
Note! There is a risk of the balancing device
damaging the cable if it is not protected by the
robot cabling!
xx0500002174
A. Cable bracket. Also shown

in the figure Separate
cabling for axis 1 or 2 on
page 100.

101

Continued
Action
Note/Illustration
7. Connect the connector R3.FAN2 to the fan of axis Note! Fans on both axis 1 and 2
1 or 2.
can not be used at the same time!
8. Connect the connector R1.SW2/3 to the base of
the robot. Make sure that the cabling, run through
the frame and base, is not twisted and runs freely
from the robot cabling.
9. Refit the rear cover plate to the robot base.
10. Install additional cabling to and inside the
controller.
Also make adjustments in RobotWare, as
described in the following procedure.
Cabling is specified in section

Position switch and fan cables,
robot base to controller (option) on
page 123.
Adjustments in RobotWare
Action
RobotWare 4.0: modify the settings in

RobInstall. RobotWare 4.063 and older must
be updated with a newer release.
RobotWare 5.0: change the settings in the
Modifying options dialogue, by using the
Modify Controller System Wizard in the
System Builder of RobotStudio. Read more
about modifying the system in Operating
manual - RobotStudio.
1. Modify the settings in RobotWare to

include the cooling fans.
Note
102

2.5.12. Loads
2.5.12. Loads
General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and mass moments of inertia) in order to avoid jolting
movements and overloading the motors.
CAUTION!
Incorrect defined loads may result in operational stops or major damage in bearings.
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 User's
Guide(RobotWare 4.0)Operating 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.
103

2.6.1. Introduction
2.6 Restricting the working range

2.6.1. 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 the 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 also be made in the software. References to software manuals
are given in the following installation procedures.
104

2.6.2. 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, between 22.5 and 135 in
both directions.
Mechanical stops, axis 1
The illustration below shows the mounting position of the stop pin and one of the additional
mechanical stops available for axis 1.
xx0300000049
Additional mechanical stop
Stop pin
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop for axis 1, 7.5
3HAC 11076-1
Includes attachment screws

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

and an assembly drawing.
Standard toolkit

page 436 in part 2 of the
Product manual.

105

Continued
Equipment, etc.
Art. no.
Note
Users guide - S4Cplus (RobotWare 4.0)

Technical reference manual - System
parameters (RobotWare 5.0)
Art. no. is specified in section

Installation, mechanical stops axis 1

The procedure below details how to fit the mechanical stops of axis 1 to the robot. An
assembly drawing is also enclosed with the product.
Action
Note
1.
DANGER!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Fit the additional mechanical stop to the
frame according to the figure Mechanical
stops, axis 1 on page 105.
3. Note! 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 Users
guide - S4Cplus, chapter System
Parameters - topic Manipulator.
The system parameters that must be
changed in RobotWare 5.0 (Upper joint
bound and Lower joint bound) are further
detailed in Technical reference manual System parameters.
4.
WARNING!
If the mechanical stop is deformed after a
hard collision, it must be replaced!
106


General
adding up to six additional mechanical stops with 15 graduation in respective direction.
The illustration below shows the mounting position of the mechanical stops on axis 2.
xx0300000047
Additional mechanical stops
Fixed mechanical stop
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop set, axis 2
3HAC 020885- Includes six stops, attachment screws,

001
washers and assembly drawings.
Standard toolkit

Standard toolkit on page 436 in part 2 of the
Product manual.

(RobotWare 4.0)
Technical reference manual System parameters
(RobotWare 5.0)
Art. no. is specified in section References

on page 10.

107

Continued
The procedure below details how to fit the mechanical stops for axis 2 to the robot. An
Action
Note
1.
DANGER!
2. Fit and tighten the additional stops in a row,
starting from the fixed stop.

Shown in the figure Mechanical stops,
axis 2 on page 107.
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 Users guide
- S4Cplus, chapter System Parameters topic Manipulator.
4.
WARNING!

108


General
adding additional mechanical stops with 20 graduation in respective direction.
The illustration below shows the mounting position of the mechanical stops on axis 3.
xx0300000048
Additional mechanical stops
Fixed mechanical stop
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop set, axis 3
3HAC 13128-1
Includes:
six stops, one with 80
restriction, 3HAC 12708-3
(use when limitation angle
>=80), and five with 20,
3HAC 12708-1.
attachment screws.
Standard toolkit

Standard toolkit on page 436 in part
2 of the Product manual.

(RobotWare 4.0)
Technical reference manual System parameters
(RobotWare 5.0)
Art. no. is specified in section


109

Continued
The procedure below details how to fit the mechanical stops for axis 3 to the robot. An
Action
Note
1.
DANGER!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
2. Mount and tighten the additional stops in a
row, starting from the fixed stop.
Shown in the figure Mechanical stops,

axis 3 on page 109
3. Note! 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 Users guide
- S4Cplus, chapter System Parameters topic Manipulator.
4.
WARNING!

110

2.6.5. Installation of position switches (option)

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
Art. no.
Note
Position switch, axis 1
3HAC 15715-1
Includes position swtich and plate for

customer connections.
3HAC 021885-001
Includes only the position switch.
3HAC 16417-2
Includes only the position switch.
Cabling, position switches and

cooling fans, axes 1, 2 and 3
3HAC 15390-1
IRB 6600, IRB 6600ID

Cabling to be installed on the robot.
Cabling, position switches and

cooling fans, axes 1, 2 and 3
3HAC 16659-1
IRB 6650, IRB 6650ID

Cabling to be installed on the robot.
3HAC 025778-001
An additional connection plate must

be fitted to the robot base, if not
already installed. The plate is shown
in the figure Plate for customer connections, at base on page 117.
Additional cabling to and inside

the controller
Specified in section Robot cabling

and connection points on page 122.
Connector kit R1.SW1
3HAC 17252-1
Connector kit R1.SW2/3
3HAC 17253-1
Description

111

Continued
Axis 1
The illustration below shows the position switch for axis 1. There is no extra cabling installed
on the robot, as for axes 2 and 3. Instead the switch is connected directly to the connector in
the base, R1.SW1.
xx0100000158
Cam
Set screw, cam (cam stop)
Protection sheet
Rail
Rail attachment

112

Continued
Axis 2
The illustration below shows the position switch for axis 2. In addition to the shown
components, cabling must also be installed from the switch to the robot base.
xx0100000159
Cam
Rail
Rail Attachment

113

Continued
Axis 3
The illustration below shows the position switch for axis 3. In addition to the shown
components, cabling must also be installed from the switch to the robot base.
xx0100000160
Cam
Rail
Rail attachment
Specifications
Maximum voltage/current for the position switches:
Parameter
Value
Voltage
Max. 50 VDC
Current
Max. 1 A

114

Continued
Connections
The position switches are 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 111!
R1.SW2/3 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 111!
Further information about the cables and connection points, see section Robot cabling and
connection points on page 122.
Installation of position switch, axis 2
In The robot is equipped with a cable protection at the lower arm that must be removed before
fitting the positions switch for axis 2:
Action
1. Remove the cable protection from the lower arm.
2. Fit the rail by pushing it against the support surface on the lower arm and tightening
the two screws.
3. Fit the cam and the position switch unit.
4. Refit the cable protection to the lower arm with two screws.
Fitting and adjusting cams and stops

The instruction below details how to fit and adjust the parts of the position switches:
Action
Note
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 116.
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 116
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
116.
6. Install the cabling for axes 2 and/or 3.
Detailed in section Installation

of cable harness for position
switches and fans on page
118.

115

Continued
Illustration, adjust and secure cams
The illustration below show how to adjust and secure the position switch cams and profiles.
xx0100000113
Cam stop, M5 nut and M5 x 6 set screw
Adjustable cam
Profile
Illustration, cutting the cam
The illustration below show how to cut the position switch cam.
xx0100000114
Remove the gray section

116

Continued
xx0500002301
Attachment screws, 3 pcs, M6x16
Cable harness for position switches and fans, axes 1-3
xx0500002305
Cable bracket, frame
Cable bracket, lower arm
Cable bracket, upper arm
R1.SW2/3
Connected to the robot base
R3.FAN2
Connected to the fan of axis 1 or 2

117

Continued
R3.FAN3
Connected to the fan of axis 3
R2.SW2
Connected to the position switch of axis 2
R2.SW3
Connected to the position switch of axis 3
Installation of cable harness for position switches and fans

The procedure below details how to fit the complete cable harness for position switches and
cooling fans to the robot.
Action
Note/Illustration

2.
DANGER!
3. Remove the rear cover (A) from the robot
base and replace the protection (B) with a
plate for customer connections (if not
already mounted).
xx0500002306
Art. no. for the plate is specified in

Required equipment on page 111.
4. Run the cabling through the base and

frame of the robot, up beneath the
balancing device.

118

Continued
Action
Note/Illustration
5. Run and secure the cabling inside the

frame as detailed below and as shown in
the figure to the right:
Secure the cable bracket (A) to the
bracket of the robot cabling.
Run the cable for the fan of axis 1
or 2 under the robot cabling and
through the side of the frame at
motor axis 1.
Secure the cabling going up to the
axis 3 fan and position switch with
existing velcro strap (B), attached
around the robot cabling.
Connect the connector R2.SW2 to
the position switch of axis 2.
Note! There is a risk of the balancing
device damaging the fan cable if it is not
protected by correct routing underneath
the robot cabling!
xx0500002309
A. Cable bracket, frame. Also shown

in the figure Cable harness for
position switches and fans, axes 13 on page 117.
B. Velcro strap
C. Connector R2.SW2
6. Connect the connector R3.FAN2 to the
fan of either axis 1 or axis 2.
If no fan is used, strap the cabling together
with the motor cabling so that the
connector stays close to the frame, as
xx0500002312

119

Continued
Action
Note/Illustration
7. Run the remaining cable harness up

through the lower arm and:
secure with the bracket, lower arm,
as shown in the figure to the right.
connect the connector R2.SW3 to
the position switch of axis 3.
secure the cable going to the fan of
axis 3, together with the robot
cabling with a velcro strap.
xx0500002313
8. Secure the axis 3 fan cable with the

bracket, upper arm.
Shown in the figure Cable harness for

position switches and fans, axes 1-3 on
page 117.
9. Connect the connector R3.FAN3 to the

fan of axis 3. If no fan is used, strap the
cable together with the robot cabling.
xx0500002314

120
A. Bracket, lower arm. Also shown in

the figure Cable harness for
position switches and fans, axes 13 on page 117.
B. Bracket for robot cabling
C. Connector R2.SW3
D. Velcro strap

Continued
Action
Note/Illustration
10. Connect the connector R1.SW2/3 to the

base of the robot. Make sure that the
cabling, run through the base, frame and
lower arm, is not twisted and is running
free from the robot cabling.
11. Refit the rear cover to the robot base.
12. Install additional cabling to and inside the Cabling is specified in section:
control cabinet.
Position switch and fan cables,
robot base to controller (option) on
page 123
121

2.7.1. Robot cabling and connection points
2.7 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 controller are divided into the following categories:
Cable category
Description
Robot cables
Handles power supply to and control of the robot's motors as

well as feedback from the serial measurement board.
Specified in the table Robot cables on page 122.
Position switch and fan cables Handles supply to and feedback from any position switches
(option)
and cooling fans on the robot.
Specified in the table Position switch and fan cables, robot
base to controller (option) on page 123.
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
ground.
See the product manual for the controller 1).
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 Application manual - Additional axes and stand
alone controller (M2004)orApplication manual - External
axes (M2000) 1).
1)
Art. no. is specified in section References on page 10.
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

and power supply to the serial
measurement board.
R1.SMB
XS2
Robot cable, power

Cable
Art. no.
Robot cable, power, 7 m
3HAC 11818-1

122
The cable categories are divided into sub-categories, specified below:

Continued
Cable
Art. no.
3HAC 11818-2
3HAC 11818-3
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 and fan cables, robot base to controller (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 and fans can also be ordered without
cables. The cables are completely pre-manufactured and ready to plug in.
Cabling to be installed on the robot is specified in sections Installation of cooling fan for
motors, axes 1-3 (option) on page 97 and Installation of position switches (option) on page
111.
Cabling between robot base and controller
In a M2000 and M2000A robot system, the cables specified below are used for both position
switches and cooling fans.
In a M2004 robot system, however, the cables below are only used for position switches.
Cabling for the cooling fans is specified in the table Cabling between robot base and
controller, cooling fans, M2004 on page 124.
Connection point,
robot
Connection
point,
cabinet
Cable
Art. no.
Position switch cable, axis 1, 7 m
3HAC 13175-1 R1.SW
XS8
3HAC 13175-2 R1.SW
XS8
3HAC 13175-3 R1.SW
XS8
3HAC 13175-4 R1.SW
XS8
Position switch cable, axes 2 and 3, 7 m
3HAC 13176-1 R1.SW2/3
XS58
Position switch cable, axes 2 and 3, 15 m 3HAC 13176-2 R1.SW2/3
XS58
XS58
XS58

123

Continued
Cabling between robot base and controller, cooling fans, M2004
The cables specified below are specific for the IRC5 controller and used when the robot is
equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot
base to the inside of the cabinet.
If equipping the robot with only cooling fans, use the cabling specified below. In case both
cooling fans and position switches are used, the cabling for position switches listed in the
previous table and the cabling for cooling fans listed below are used together with a
distributing cable, also specified below.
Cable
Art. no.
Connection point
Distributing cable
3HAC 022708-001
Robot base: R1.SW2/3
Harness - cooling, 7 m
3HAC 022723-001
Distributing cable: R1.FAN.SW2/3

Inside cabinet: A43.X10 and A43.X11
3HAC 022723-004

3HAC 022723-005

3HAC 022723-006

Cabling inside control cabinet

Additional cabling must be connected inside the control cabinet when installing position
switchesor when installing fans for robot systems M2000 and M2000A (fan cabling for
M2004 runs all the way from the robot base to the inside of the cabinet and the additional
cabling specified below is therefor not needed).
Art. no.
Bracket in the cabinet wall (M2000 3HAB 7286-5

and M2000A)
Bracket in the cabinet wall (M2004) 3HAC 020813-082 -
Harness position switch (M2000)
3HAC 15899-1
XS58
XP57
Harness position switch (M2000A) 3HAC 14617-1
XS58
XP57
Harness position switch axis 1

(M2004)
124
Connection
Connection
point 1 inside point 2 inside
cabinet
cabinet
3HAC 021117-001 XS8
XT8.1 and
XT8.2
Harness position switch axes 2 and 3HAC 021116-001 XS58

3 (M2004)
XT58.1 and
XT58.2
Cable harness fans (M2000)
3HAC 15666-1
XS57
XT31
Cable harness fans (M2000A)
3HAC 17832-1
XS57
XT31:10
XT31:12
Cable

2.8.1. Additional installation procedure
2.8 Making robot ready for operation (Foundry Prime)

General
Robots delivered with the Foundry Prime protection are specially designed to work in water
jet cleaning cells with 100% humidity and alkaline detergent. To ensure that the protection
offers the best reliability, some measures are needed during installation of the robot according
to the procedures below.
NOTE!
For best reliability, it is also of highest importance that the special maintenance instructions
for the Foundry Prime robot are followed and documented.
Commissioning
Never switch off the overpressure in motors and serial measurement compartment
during cooling down of robot after it has been switched off.
When turning off an cleaning cell we recommend that the humid air inside a cell is
ventilated out, to avoid that the humid air is sucked into e.g. gearboxes due to the
raised vacuum when cooled down.
Environmental conditions
Humidity
100%
Washing detergent must contain rust inhibitor and be

approved by ABB
Cleaning bath temperature
<60C, used in a typical waterjet

cleaning application at suitable
speed.
Washing detergent with pH
<9.0
Air specification for pressurizing of robot

The air must be dry and clean, such as instrument air. Following table details the air
specification.
Dew point
<+2C at 6 bar
Solid particle size
<5 microns
Oil content
<1 ppm (1 mg/m3)
Pressure to robot
0.2-0.3 bar

125

Continued
WARNING!
If the pressurized air contains oil, it could result in a brake failure in the motors and cause the
robot arms to fall down, leding to personal injure or physical damage.
WARNING!
If the air pressure exceeds the specified, it could result in a brake failure in the motors and
cause the robot arms to fall down, leding to personal injure or physical damage.
NOTE!
To secure sufficient air pressure, it is recommended to use a pressure sensor.
Pressurize the motors and serial measurement board cavity
The robots are prepared with hoses to the motors and the serial measurement board cavity to
enable pressurizing of them.
WARNING!
The robot must be pressurized also when it is switch off, to avoid that the humid
environmental air is sucked into the motors when cooling down.
Action
Note/Illustration
1. Connect a compressed air hose to air

connector on robot base, see illustration.
xx0600002794
A: air connection for air hose,

outside diameter = 6mm.
2. Protect the screws on the Harting

connectosr on the robot base from
corrosion with Mercasol 3106.
Do this when the controller cables are

connected.
3. Pressurize the robot.
See Air specification for pressurizing of

robot on page 125 for correct pressure.
4. Inspect the air system.
See Inspection of air hoses (Foundry

Prime) on page 176.

126

Continued
Protecting from high pressure water
WARNING!
No part of the robot should be exposed to direct high pressure jet of water. The sealings
between the moving parts on the wrist should not be exposed to direct or rebounding highpressure jet of water.
Protecting point at the wrist joints
The illustration below show points that are particular sensitive to water spray.
C
xx0600002792
Axis 5, bearing support side
Axis 5, bearing gear side
Axis 6, mounting flange - gear house
Recommendations
NOTE!
To reduce the risk for corrosion due to condensation in gearboxes, it is recommendable that
the robot is running with high speed on each axes at least on one occasion each hour. This is
to lubricate the gearbox cavities.
WARNING!
Never switch off the overpressure in motors and serial measurement compartment during
cooling down of robot after it has been switched off.
NOTE!
When turning off an cleaning cell we recommend that the humid air is ventilated out from the
cell, to avoid that the humid air is sucked into e.g gearboxes due to the arised vacuum when
cooled down.
127
128
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 intervals 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. Read the
chapter Safety on page 17 before performing any service work.
129
3 Maintenance
3.2.1. Specification of maintenance intervals
3.2 Maintenance schedule and expected component life

3.2.1. Specification of maintenance intervals
Description
The intervals may be specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the robot:
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, M2000
on page 214
130
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 136.
Activities and intervals, standard equipment
The table below specifies the required maintenance activities and intervals:
Maintenance
activity
Equipment
Interval
Cleaning
Robot
Inspection
Axis 1 gear, oil level
12 mths
1)
Inspection, oil level gearbox

axis 1 on page 137
Inspection
12 mths
1)

axis 2 on page 139
Inspection
12 mths
1)

axis 3 on page 141
Inspection
12 mths

axis 4 on page 143
Inspection
12 mths
Inspection, oil level, gearbox

axis 5 on page 146
Inspection
12 mths
Inspection
Balancing device
12 mths
Inspection, balancing device

on page 153
Inspection
Robot harness
12 mths
Inspection, cable harness on

page 158
Inspection
Information labels
12 mths
Inspection, information
labels on page 162
Inspection
Damper axes 2-5
12 mths
Inspection, damper axes 2-5

on page 169
Inspection
Mechanical stop, axis 1 12 mths
Inspection, mechanical stop,

axis 1 on page 164
Changing
Axis 1 gear oil:

Kyodo Yushi TMO 150
First change after: Do not mix with other oils!

6 000 h
Oil change, gearbox axis 1
Second change
on page 182
after: 24 000 h 9)
Changing
Axis 2 gear oil:

Kyodo Yushi TMO 150

6 000 h
Second change
on page 185
after: 24 000 h 9)
Detailed in section
Cleaning, robot on page 212
1)

axis 6 on page 149

131
3 Maintenance
Continued
Equipment
Interval
Detailed in section
Changing
Axis 3 gear oil:

Kyodo Yushi TMO 150

6 000 h
Oil change, gearbox, axis 3
Second change
on page 188
after: 24 000 h 9)
Changing
Axis 4 gear, oil:

Mobilgear 600 XP320
24 000 h
1)

on page 191
Changing
Axis 5 gear, oil:

Mobilgear 600 XP320
24 000 h
1)

on page 194
Changing
Axis 6 gear oil:

Kyodo Yushi TMO 150

6 000 h
Second change
on page 197
after: 24 000 h 9)
Changing
Axis 6 gear oil:

Mobilgear 600 XP320
(IRB 6600ID/6650ID)
12 000 h 1)

on page 197
Replacement
Axis 1 gearbox
As specified by
the SIS, or
typically 96 mths
Replacement of gearbox,
axis 1 on page 383
Replacement
Axis 2 gearbox
As specified by
the SIS, or
typically 96 mths
Replacement of gearbox
axis 2 on page 391
Replacement
Axis 3 gearbox
As specified by
the SIS, or
typically 96 mths
axis 3 on page 399
Replacement
Axis 4 gearbox 5)
96 mths
2)
Replacement of upper arm

on page 286
Replacement
Axis 5 gearbox 6)
96 mths
2)
Replacement of complete
wrist unit, IRB 6600 and IRB
6650 on page 277
Replacement
Axis 6 gearbox
96 mths1
Replacement
Robot harness
See note below 3) Replacement of cable

harness, axes 1-6 on page
228
Replacement
SMB Battery pack
36 mths
Lubrication
Balancing device
bearing
12 000 h
axis 6 on page 405
Replacement of SMB battery

on page 200
4)
Lubrication of spherical roller

bearing, balancing device on
page 203

132
Maintenance
activity
3 Maintenance
Continued
1)
2)
3)
4)
5)
6)
It is recommended to replace the complete wrist unit, instead of only replacing the
gearbox.
9)
If the robot is run at ambient temperatures higher than 50C, the equipment may
require maintenance more frequently.
The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see
expected life in section Expected component life on page 136.
Replace when damage is detected or when approaching life limit as specified in
Expected component life on page 136.
The interval is the same as the interval for changing axis 2 gear oil because of the
similarity of the type and degree of operation. Always lubricate the front eye bearing
after refitting the balancing device shaft!
It is recommended to replace the complete upper arm house, instead of only

replacing the gearbox.
"24 000 h" = 6000 h + 18000 h.
Activities and intervals, optional equipment
The table below specifies the required maintenance activities and intervals for common
optional equipment. Maintenance of other external equipment for the robot is detailed in
separate documentation.
Maintenance
activity
Equipment
Inspection
Signal lamp
Inspection
Mechanical stop axes 1-2-3
Inspection
Position switches, axes 1-2-3 12 mths
Interval
Detailed in section
Inspection, signal lamp on
page 173
12 mths
Inspection, additional
mechanical stops on page
166
Inspection, position switch
axes 1, 2 and 3 on page 171
Activities and intervals, Foundry Prime

The table below specifies the required maintenance activities and intervals for Foundry
Prime.
Maintenance
Equipment
activity
Interval
Detailed in section
Inspection
Cable harness
6 mths
Inspection, cable harness on

page 158
Inspection
Air hoses
6 mths
Inspection of air hoses (Foundry

Prime) on page 176
Inspection
Balancing device
12 mths
Inspection, balancing device on

page 153
Inspection
Information labels
12 mths
Inspection, information labels

on page 162
Inspection
Damper axes 2-5
12 mths
Inspection, damper axes 2-5 on

page 169
Inspection
Mechanical stop, axis 1
12 mths
Inspection, mechanical stop,

axis 1 on page 164

133
3 Maintenance
Continued
Interval
Detailed in section
Analysis
Oil gearbox axis 6
3000h or
6 mths 2)
Inspection, oil level gearbox axis

6 on page 149
Changing
Axis 1 gear, oil:

Kyodo Yushi TMO 150
6000h
Oil change, gearbox axis 1 on

page 182
Changing
Axis 2 gear, oil:

Kyodo Yushi TMO 150
6000h

page 185
Changing
Axis 3 gear, oil:

Kyodo Yushi TMO 150
6000h
Oil change, gearbox, axis 3 on

page 188
Changing
Axis 4 gear, oil :

Mobilgear 600 XP320
12000h

page 191
Changing
Axis 5 gear, oil :

Mobilgear 600 XP320
12000h

page 194
Changing
Axis 6 gear, oil:

Kyodo Yushi TMO 150
3000h or
6 mths1)

page 197
Replacement
Cable harness
If required 6) Replacement of cable harness,

axes 1-6 on page 228
Replacement
SMB Battery pack
36 mths
Replacement
Axis 1 gearbox
As specified Replacement of gearbox, axis 1

by the SIS, on page 383
or typically
96 mths
Replacement
Axis 2 gearbox
As specified Replacement of gearbox axis 2

or typically
96 mths
Replacement
Axis 3 gearbox
As specified Replacement of gearbox, axis 3

or typically
96 mths
Replacement
Axis 4 gearbox 4)
96 mths
Replacement
Axis 5 gearbox 5)
96 mths 3)
Replacement
Axis 6 gearbox
24 mths 1), 6) Replacement of gearbox, axis 6

on page 405
Replacement of SMB battery on

page 200
3)
Replacement of upper arm on

page 286
Replacement of complete wrist
unit, IRB 6600 and IRB 6650 on
page 277
Rust preventing Wrist bearing
6 mths
Rust preventive, support

bearing in wrist (Foundry Prime)
on page 210
Rust preventing Axis 1 sealing
6 mths
Rust preventive, bearing axis 1

(Foundry Prime) on page 205

134
Maintenance
Equipment
activity
3 Maintenance
Continued
1. If the robot is working in cleanings cells that are not emptied when the robot is
switched off, the oil may be replaced more frequently.
2. Analyse water content in oil in gearbox axis 6 first time after 3000H or 6 mounths.
If the working conditions changes, analyse again after 3000h or 6 mounths.
3.The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see
expected life in section Expected component life on page 136.
4. It is recommended to replace the complete upper arm house, instead of only

replacing the gearbox.
5. It is recommended to replace the complete wrist unit, instead of only replacing the
gearbox.
6. The guarantee does not apply to effects or wear caused by environmental factors.
135
3 Maintenance
3.2.3. Expected component life
3.2.3. Expected component life

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

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

2,000,000 cycles axis 1 220
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000h
See note 3)
1)
The expected life can also be affected by assemblage of cabling other than standard options.
The given life is based on a test cycle that for every axis starts from the calibration position
to minimum angle to maximum angle and back to the calibration position. Deviations from
this cycle will result in differences in expected life! The life may also be affected by acid or
alkaline environment.
2)
The given life for the balancing device is based on a test cycle that starts from the initial
position and goes to maximum extension, and back. Deviations from this cycle will result in
differences in expected life!
3)
The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spot
welding application. Depending on the actual application, the life of individual gearboxes
may vary greatly from this specification. The Service Information System (SIS), integrated
in the robot software, keeps track of the gearbox life in each individual case and will notify
the user when a service is due. For Foundry Prime robots, working in 100% humidity, other
service intervalls may be required.
For an M2000 system, the SIS is described in section Service Information System, M2000 on
page 214.
136
The SIS is for an M2004 system described in the Operating manual - Service Information
System. Document number can be found in section References on page 10.
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
3.3 Inspection activities

Location of gearbox
The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the
figure below.
xx0200000228
Gearbox axis 1
Oil plug, inspection
Motor, axis 1
Oil plug, filling
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC032140-001
Kyodo Yushi TMO 150

Do not mix with other oils!
Check which oil is currently filled
in the gearbox, as detailed in
section Which type of oil does the
gearbox contain? on page 177!
Standard toolkit

436.

137
3 Maintenance
Continued
Equipment
Art. no.

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

The procedure below details how to inspect the oil level in gearbox axis 1.
Action
Note
1.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 41.
2.
DANGER!
3. Open the oil plug, inspection.

gearbox on page 137!
5. Add oil if required.

equipment on page 137!
Further information about how to fill
the oil may be found in section Filling
oil, axis 1 on page 184.
6. Refit the oil plug, inspection.
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 42!
138
4. Required oil level: max.10 mm below the oil plug

hole!
3 Maintenance

Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor
attachment.
xx0400001066
Gearbox axis 2
Oil plug, filling
Oil plug, draining
Vent hole, gearbox axis 2
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
3HAC032140-001
Kyodo Yushi TMO 150

Standard toolkit

436.
Other tools and procedures may be

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


139
3 Maintenance
Continued
Inspection, oil level gearbox 2
Action
Note
1.
WARNING!
2.
DANGER!
3. Open the oil plug, filling.

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

Required oil level: max. 5 mm below the oil plug gearbox on page 139!
hole.

Filling of oil is detailed further in
section Filling, oil on page 186.
6. Refit the oil plug, filling.
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 42!
140
3 Maintenance

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
xx0200000230
Gearbox axis 3
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
3HAC032140-001
Kyodo Yushi TMO 150

section Which type of oil does
the gearbox contain? on page
177!
Standard toolkit

436.

141
3 Maintenance
Continued
Equipment, etc.
Art. no.

Note

The procedure below details how to inspect the oil level in the gearbox axis 3.
Action
Note
1.
WARNING!
2. Move the robot to the calibration position.
Detailed in section Calibration scales

and correct axis position on page
412.
3.
DANGER!


the oil may be found in section Filling,
oil on page 190.
8.
WARNING!
142
5. Required oil level: max. 5 mm below the oil plug

hole.
3 Maintenance

Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
xx0200000231
Oil plug, filling
Oil plug, draining
xx0600002962
Oil plug, filling / inspection
Oil plug, draining

143
3 Maintenance
Continued
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
11712016-604
Mobilgear 600 XP320

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

Standard toolkit on page 436.



Action
Note
1.
WARNING!
safety information in section WARNING Safety risks during work with gearbox oil on
page 41.
Shown in section Calibration scales

and correct axis position on page 412.
3.


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

plug hole.

Further information about how to fill the
oil may be found in section Filling, oil on
page 192.
7. Refit the oil plug.

144
DANGER!
3 Maintenance
Continued
Action
Note
8.
WARNING!

145
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.
The figure above shows the wrist unit of IRB 6600 and IRB 6650
Oil plug, filling
Oil plug, draining
xx0500002013
The figure above shows the wrist unit of IRB 6600ID and IRB 6650ID
Wrist unit, axis 5
Oil plug, filling
Oil plugs, draining

146
xx0200000232
3 Maintenance
Continued
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
11712016-604
Mobilgear 600 XP320

This is a common oil that can be
replaced with an equivalent oil from
Standard toolkit




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

5. Measure the oil level.

Required oil level to the upper edge of the oil plug
hole (a):30mm.
xx0500002222

the oil may be found in section
Filling, oil, axis 5 on page 196.

147
3 Maintenance
Continued
Action
Note
8.
WARNING!

148
3 Maintenance

Location of gearbox
xx0400001092
Gearbox, axis 6
Oil plug, filling
Oil plug, draining
xx0500002017
Gearbox, axis 6
Oil plugs, draining
Oil plug, filling

149
3 Maintenance
Continued
Required equipment
Equipment
Art. no.
Note
Lubricating oil,
IRB 6600/6650
3HAC032140-001
Kyodo Yushi TMO 150

Check which oil is currently filled in
the gearbox, as detailed in section
Which type of oil does the gearbox
contain? on page 177!
Lubricating oil,
IRB 6600ID/6650ID
11712016-604
Mobilgear 600 XP320
Standard toolkit




Action
Note
1.
WARNING!
DANGER!
3. Make sure the oil plug, filling is facing upwards Shown in the figure Location of
and open it.
4. Measure the oil level.
Required oil level to the upper edge of the oil
plug hole for filling (a):
55 mm 5 mm (IRB6600/6650)
15 mm (IRB 6600ID/6650ID)
xx0500002222

150
2.
3 Maintenance
Continued
Action
Note

the oil may be found in section Filling,
oil, axis 6 on page 199.
7.
WARNING!
Analysis of water content in oil, gearbox axis 6 (Foundry Prime)

When changing oil, check for water content in oil an analysis can be ordered from the oil
manufacturer Shell.
If:
Then....
1. More than 2% water in oil,

replacement of gearbox axis 6 is required
With more than 2% water content every second year
there is a risk for corrosion in the
A
gearbox and reduced viscosity in
the oil.
2%
18
6
24
12
30
3000 6000 9000 12000 15000
C
xx0600003155
A: Water content in oil from gearbox

axis 6
B: Months or hours in operation
C: Replacement of gearbox axis 6

151
3 Maintenance
Continued
If:
2. Less than 2% water in oil,
Then....
normal replacement interval as specified by
SIS or typically 96 months for gearbox axis 6
is required
2%
B
6
12
18
24
30
3000 6000 9000 12000 15000
xx0600003156
A: Water content in oil from gearbox

axis 6
B: Months or hours in operation
152
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.
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

153
3 Maintenance
Continued
Required equipment
Equipment, etc.
Spare part no.
Art. no.
Maintenance kit,
complete
3HAC 021592-001
Includes:
complete kit including the
kit with bearings and
seals
instructions for maintenance.
Maintenance kit,
bearings and seals
3HAC 021593-001
Includes:
kit with bearings, o-rings
and seals only
instructions for maintenance.
Securing screw
Note
Securing screw in the shaft.

M16 x 180
Locking liquid must be used
when fitting the screw (Loctite
245)!
Toolkit for
maintenance
3HAC 021984001
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

436.
Check for dissonance

The check points are shown in the figure Inspection points, balancing device on page 153.
Check for dissonance from...
1.
bearing at the ear

bearings at the balancing
devices attachments.
If dissonance is detected...
... perform maintenance according to given
instructions in Maintenance kit, bearings and
seals. The replacement of the bearing at the
ear is also detailed in section Replacement
of spherical roller bearing, balancing device
on page 317.
Art. no. for the kit and the documentation are
specified in section Required equipment on
page 154.

154
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
3 Maintenance
Continued
Check for dissonance from...
If dissonance is detected...
2.
cylinder (a tapping sound,

...replace the balancing device or consult
caused by the springs inside the ABB Robotics.
cylinder).
How to replace the device is detailed in
section Replacement of balancing device on
page 322. This section also specifies the
spare part number!
3.
piston rod (squeaking may

indicate worn plain bearings,
internal contamination or insufficient lubrication).

instructions in Maintenance kit, complete.
Art. no. for the kit and the documentation are
specified in section Required equipment on
page 154.
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 153.
Check for damage on...
1.
2.
If damage is detected...
the piston rod (part of the piston

rod that is visible at the front of the instructions in Maintenance kit, complete.
balancing device).
Art. no. for the kit and the documentation
are specified in section Required
the securing screw in the front ear ...replace.

shaft.
Dimension is specified in section Required
Also check the tightening torque (50 Nm). equipment on page 154.

155
3 Maintenance
Continued
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 ring in 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!
xx0500002506
Shaft
O-ring
Sealing spacer
Sealing ring in sealing spacer
Correct way out for excessive grease from inside the front ear
Incorrect leakage from the front ear
Action
Note
1. Clean the area at the front ear from old grease.

2. Run the robot for some minutes, in order to
move the balancing device piston.

156
Check the o-rings in the front ear of the balancing device for leaks, as shown and detailed
below.
3 Maintenance
Continued
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 ring 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 154!
The replacement of the complete
bearing is also detailed in section
Replacement of spherical roller
bearing, balancing device on page
317.
Incorrect leakage is shown in the
previous figure.
Check for contamination / lack of free space

Action
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
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
153.
Keep the areas around the balancing device clean and free from objects, such as service
tools.
157
3 Maintenance
3.3.8. Inspection, cable harness

Location of cable harness, axes 1-6
The robot cable harness, axes 1-6, 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
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1



the tools required.
Circuit diagram


158
Note! The cable harness is also available without the division point R2.M5/6. Except for the
connectors at the division point, the rest of the inspection points are the same for the harness
that runs undivided from axis 1 to axis 6.
3 Maintenance
Continued
Inspection, cable harness 1-6
The procedure below details how to inspect the cable harness of axes 1-4.
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 Shown in the figure Location of cable
at the base.
harness, axes 1-6 on page 158.
4.
note
If the manipulator is used in a Foundry Prime

application, check the cables for cracks in
insulation.
Location is shown in the figure Location
of cable harness, axes 1-6 on page 158.
A certain wear of the hose at the
entrance to the lower arm is natural.
6. Replace the cable harness if wear, cracks or

damage is detected.
Detailed in section Location of cable

5. 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.

159
3 Maintenance
Continued
Location of cabling axes 5-6
The robot cable harness, axes 5-6, is located as shown in the figure below.
Note! The cable harness is also available without the division point R2.M5/6. Except for the
connectors at the division point, the rest of the inspection points are the same for the harness
that runs undivided from axis 1 to axis 6.
Connectors at cable harness division point, R2.M5/6
Cable attachment, rear of upper arm
Cable attachment, upper arm tube
xx0200000234

160
3 Maintenance
Continued
Inspection, cable harness, axes 5-6
The procedure below details how to inspect the cable harness of axes 5-6.
Action
Note
1.
DANGER!
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.
Shown in the figure Location of cabling

axes 5-6 on page 160.
4.
Shown in the figure Location of cable

note
If the manipulator is used in a Foundry Prime

application, check the cables for cracks in
insulation.
5. Replace the cable harness if wear, cracks or Detailed in section:

damage is detected.
Replacement of cable harness,
axes 5-6 on page 249
Replacement of cable harness,
axes 5-6, IRB 6600ID and IRB
6650ID on page 253
161
3 Maintenance
3.3.9. Inspection, information labels

Location of labels
The figures below show the location of the information labels to be inspected.
Warning label "High temperature", 3HAC4431-1 (4 pcs)
Warning sign, symbol of a flash (located on motor cover), 3HAC1589-1 (5 pcs)
Instruction label "Safety instructions", 3HAC4591-1
Warning label "Brake release", 3HAC9508-1
Warning label, tools are not allowed around the balancing device during operation,
3HAC020611-001
Warning label, "Shut off power", 3HAC17804-1
Information labels at gearboxes and at robot base, if gearboxes are filled with
Kyodo Yushi TMO 150

162
xx0200000236
3 Maintenance
Continued
xx0400000786
Instruction label "Lifting the robot", 3HAC16487-1
Warning label "Robot can tip forward...", 3HAC9191-1
Foundry logotype, 3HAC8256-1
Warning label "Stored energy", 3HAC9526-1
Required equipment
Equipment
Art. no.
Note
Labels and plate set
3HAC8711-1
Includes all labels specified in the two

previous figures! The labels are in english.
Label set, oil labels
3HAC021670-002
Includes only the oil labels at the

gearboxes and at the robot base.
Are fitted to the robot if the gearboxes
include Kyodo Yushi TMO 150.
Inspection, labels
Action
Note
1.
DANGER!
2. Check the labels, located as shown in the figures
Location of labels on page 162.
3. Replace any missing or damaged labels.

163
3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1

Location of mechanical stop
The mechanical stop axis 1 is located at the base as shown in the figure below.
xx0200000151
Mechanical stop (stop pin)
Required equipment
Art. no.
Note
Mechanical stop ax 1
3HAC12812-2
To be replaced when damaged.
Standard toolkit
The contents are defined in section Standard

toolkit on page 436.
Equipment, etc.

164
3 Maintenance
Continued
Inspection, mechanical stop
The procedure below details how to inspect the mechanical stop axis 1.
Action
Note
1.
DANGER!
2. Inspect the mechanical stop, axis 1.

mechanical stop on page 164!
3. Make sure the mechanical stop can move in both

directions.
4. If the stop pin is bent or damaged, it must be

replaced!
Note! The expected life of gearboxes can be
reduced as a result of collissions with the
mechanical stop.
165
3 Maintenance
3.3.11. Inspection, additional mechanical stops

Location of mechanical stops
The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3
(IRB 7600 shown).
Additional stop
Fixed stop
xx0200000150

166
3 Maintenance
Continued
xx0200000150
Mechanical stop, axis 1
Required equipment
Equipment etc.
Art. no.
Note
Mechanical stop axis 1
3HAC11076-1
Limits the robot working range by 7,5.
3HAC11076-2
Limits the robot working range by 15.
3HAC020885-1
3HAC13128-1
Standard toolkit


167
3 Maintenance
Continued
Inspection, mechanical stops
The procedure below details how to inspect the additional mechanical stops on axes 1,2 and 3.
Action
Note
1.
DANGER!
2. Check the additional stops on axes 1, 2 and 3for
damage.

mechanical stops on page 166!
3. Make sure the stops are properly attached.

Correct tightening torque, mechanical stop axis 1:
120 Nm.
4. If any damage is detected, the mechanical stops

must be replaced!
Correct attachment screws (lubricated with Molycote
1000):
Axis 1: M16 x 35
Axis 2: M16 x 50
Axis 3: M16 x 60
168
3 Maintenance
3.3.12. Inspection, damper axes 2-5

Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0300000040
Damper, axis 2 (2 pcs)
Damper, axis 3 (2 pcs)
Damper, axis 4 (1 pc)
Damper, axis 5 (IRB 6600, IRB 6650: 2 pcs, IRB 6600ID, IRB 6650ID: 4 pcs)
Required equipment
A damper must be replaced if damaged!
Equipment
Spare part/ art. no. Note
Damper axis 2
3HAC12991-1
Damper axis 3
3HAC12320-1
Damper axis 4
3HAC13564-1
Damper axis 5
3HAB4337-2
IRB 6600 and IRB 6650
Damper 1, axis 5 (2 pcs)
3HAC021325-001
IRB 6600ID and IRB 6650ID

169
3 Maintenance
Continued
Equipment
Spare part/ art. no. Note
3HAC021675-001
IRB 6600ID and IRB 6650ID
Standard toolkit
3HAC15571-1

Standard toolkit on page 436 .
Inspection, dampers
The procedure below details how to inspect the dampers, axes 2-5
Action
Note
1.
DANGER!
2. Check all dampers for damage, and for cracks or
existing impressions larger than 1 mm.
dampers on page 169!
To inspect the damper, axis 4, remove the two covers
on top of the upper arm!
3. Check attachment screws for deformation.
4. If any damage is detected, the damper must be

replaced with a new one!
170
3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3

Position switches, axes 1-3
The position switches are shown, fitted to the robot, in section Installation of position
switches (option) on page 111.
Required equipment
Equipment, etc.
Art. no.
Note
Position switch, axes 1-3
The article numbers of the position

switches are specified in section Installation of position switches (option) on
page 111.
Standard toolkit



the tools required.
Inspection, position switches

The procedure below details how to inspect the position switch, axes 1, 2 and 3.
See the figures in section Installation of position switches (option) on page 111 to locate the
different components to be inspected.
Action
Note
1.
DANGER!
2. Check the position switch!
Check that the rollers are easy to push in and
that they roll freely.
3. Check the rail!
Check that the rail is firmly attached with the
attachment screws.
4. Check the cams!
Check that the rollers have not caused any
impressions on the cams.
Check that the cams are clean. Wipe them if
necessary!
Check that the set screws holding the cams in
position are firmly attached.

171
3 Maintenance
Continued
Action
Note
5. Check the protection sheets on axis 1!

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

be replaced!
172
3 Maintenance
3.3.14. Inspection, signal lamp

Location of signal lamp
The signal lamp is located as shown in the figure below. Note that the position can differ
depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on
the current harness for alternative positioning.
xx0200000240
Signal lamp
Clamp
Position for cable gland
Warning label on motor cover
Warning sign on motor cover

173
3 Maintenance
Continued
xx0600003071
UL signal lamp
Clamp
Cable strap, outdoor
Motor, axis 3
Attachment screw, M6x8 quality 8-A2F(2 pcs)
Equipment, etc.
Art. no.
Note
Signal lamp
3HAC10830-1
To be replaced in case of detected

damage.
Standard toolkit




174
Required equipment
3 Maintenance
Continued
Inspection, signal lamp
The procedure below details how to inspect the function of the signal lamp.
Action
Note
1. Check that the signal lamp is lit, when the motors are
put in operation ("MOTORS ON").
2.
DANGER!
3. If the lamp is not lit, trace the fault by:

Checking whether the signal lamp is broken. equipment on page 174!
If so, replace it.
Checking the cable connections.
Measuring the voltage in connectors motor
axis 3 (=24V).
Checking the cabling. Replace cabling if a
fault is detected.
175
3 Maintenance
3.3.15. Inspection of air hoses (Foundry Prime)
3.3.15. Inspection of air hoses (Foundry Prime)

General
The air hoses on Foundry Prime robots must be inspected for leakage every six month.
Required equipment
Equipment, etc.
Art. no.
Leak detection spray
Pressure gauge
Cut off valve
Note
Procedure
For this test it is recommended that the air supply to the robot has a pressure gauge and a cutoff valve connected.
Action
1. Apply compressed air to the air
connector on robot base, and raise the
pressure with the knob until the correct
value is shown on the pressure gauge.
Note/Illustration
Recommended pressure:
0.2+0.1/0 bar
xx0600002794
A: Air connection
2. Close the shut-off valve.
It should take at least 5 sec. for the pressure

to reach 0 bar.
3. If the time is shorter that 5 sec.

IF Yes: Localize the leak as detailed
below.
IF No: Remove the leakdown tester and
the test if complete.
4. Remove the leakdown tester
5. Spray suspected leak areas with leak
detection spray.
Bubbles indicate a leak.
6. When the leak has been localized: take
the necessary measures to correct the
leak.
176
3 Maintenance
3.4.1. Type of oil in gearboxes
3.4 Replacement/changing activities

Location of gearboxes
The figure show the location of the gearboxes on the robot.
F
C
D
xx0800000247
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 4 gearbox
Axis 5 gearbox
Axis 6 gearbox
xx0500002226
Axis 5 gearbox, IRB 6600ID/6650ID
Axis 6 gearbox, IRB 6600ID/6650ID

177
3 Maintenance
Continued
Type of oil - historically used
The six gearboxes of the robot have historically been filled with different types of oils. Today
only the types of oil specified in the table is recommended.
NOTE!
When there is a change of oil types in the gearbox, it need to be rinsed. See Rinsing gearbox.
CAUTION!
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 in the table!
If oils are mixed, the gearbox must be thoroughly rinsed! See Rinsing gearbox.
Type of oil - currently used
The table show which types of oil is used in gearboxes.
Gearbox
Type of oil
Art. no.
Amount
Axis 1
Kyodo Yushi TMO 150
3HAC032140-001
7,300 ml
Axis 2
Kyodo Yushi TMO 150
3HAC032140-001
5,800 ml
Axis 3
Kyodo Yushi TMO 150
3HAC032140-001
2,500 ml
Axis 4
Mobilgear 600 XP320
11712016-604
8,100 ml
Axis 5
Mobilgear 600 XP320
11712016-604
IRB 6600/6650:
6,700 ml
IRB 6600ID/
6650ID:
5,000 ml
Axis 6, IRB 6600/

6650
Kyodo Yushi TMO 150
3HAC032140-001
450 ml
Axis 6, IRB
6600ID/6650ID
Mobilgear 600 XP320
11712016-604
6,000 ml
Labels located next to oil plugs of each gearbox show which type of oil it contains. All
gearboxes must have the correct label clearly visible.
Kyodo Yushi
TMO 150
3HAC032140-001
3HAC032726-001
xx0800000230
Labels located next to oil plugs
Currently used types of oils
Mobil
Gearlube X320
Shell
Tivela S 150
3HAC021469-001
Optimol, Optigear
RMO 150
11712016-604
3HAC021480-001
3HAC021485-001
3HAC16843-1
xx0800000234
Historically used types of oil
Need to be replaced, if currently used.

178
Labels next to oil plugs
3 Maintenance
Continued
Labels at robot base
Label located at robot base show the types of oil in all gearboxes.
Lifting of robot
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Kyodo Yushi TMO 150

Kyodo Yushi TMO 150
Kyodo Yushi TMO 150
Mobilgear 600 XP320
Mobilgear 600 XP320
Kyodo Yushi TMO 150
Warning
Bal. device. Optimol longtime PD 0
UL
3HAC021505-002
xx0500001396
IRB 66X0
Label at robot base. Currently used types of oil.
Lifting of robot
Warning
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Kyodo Yushi TMO 150

Kyodo Yushi TMO 150
Kyodo Yushi TMO 150
Mobilgear 600 XP320
Mobilgear 600 XP320
Mobilgear 600 XP320
Bal. device. Optimol longtime PD 0
UL
3HAC025378-001
xx0500002012
IRB 66X0ID
-
Label at robot base. Currently used types of oil.

179
3 Maintenance
Continued
Mixed types of oil may cause may cause severe damage!
When refilling or replacing oil in a gearbox it is important to first check which type of oil is
recommended to use in the gearbox. See Type of oil - currently used. If the oil used is other
than the one in the list of currently used types of oil, it is recommended to replace the oil.
As Kyodo Yushi TMO 150 (as well as Shell Tivela S 150) is not compatible with mineral oil,
contamination with other types of oil in the gearboxes is not accepted! Equipment used in
handling of Kyodo Yushi (as well as Shell Tivela S 150) must be carefully cleaned before use!
In case of changing the type of oil, the gearbox therefor must be thoroughly rinsed! See
Rinsing gearbox.
NOTE!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the oil recommended by the manufacturer!
Rinsing gearbox
Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox
after rinsing, use the appropiate procedure.
The same applies if the type of oil shall be changed in the gearbox.
NOTE!
What is said about Kyodo Yushi TMO 150, also applies to Shell Tivela S 150.
What is said about Mobilgear 600 XP320, also applies to Mobil Gearlube X320.
Kyodo Yushi TMO 150 mixed with Optimol Optigear RMO 150
Flush the gearbox properly three times with the correct type of oil. Use a service
program when flushing.
Refill the gearbox with the correct type of oil.
Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320

Use this procedure to rinse the contaminated gearbox if the gearbox shall contain Kyodo
Yushi TMO 150 and it is mixed with Mobilgear 600 XP320.
Flush the gearbox properly three times with Kyodo Yushi TMO 150. Use a service
program when flushing.
Refill the gearbox with Kyodo Yushi TMO 150.

180
Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150
and Optimol Optigear RMO 150 are mixed.
3 Maintenance
Continued
Equipment
Art. no.
Note
Label set
See Spare Parts.
Includes small labels to each gearbox

and the complete label to be fitted at the
robot base.
NOTE!
The correct labels must be fitted to the
robot in case of changing of oil types!
Oil change equipment
3HAC021745-001
Includes pump with outlet pipe.
Equipment
181
3 Maintenance
3.4.2. Oil change, gearbox axis 1

Location of oil plugs
The axis 1 gearbox is located between the frame and base. The oil plugs for filling and
inspection are shown in the figure below. The oil is drained through a hose, available in the
rear of the robot base, not shown in the figure.
Gearbox axis 1
Oil plug, inspection
Motor axis 1
Oil plug, filling
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC032140-001
7,300 ml
Kyodo Yushi TMO 150

Oil collecting vessel

Oil exchange
equipment
Capacity: 8,000 ml.

3HAC 021745-001

section Special tools on page
437.

182
xx0200000228
3 Maintenance
Continued
Equipment, etc.
Art. no.
Standard toolkit
Amount
Note
436.
Draining oil, 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 182.
Action
Note
1.
DANGER!
2.
WARNING!
page 41.
3. Remove the rear cover on the base by
unscrewing its attachment screws.
4. Pull the oil draining hose out of the rear of the

base.
xx0200000237
The hose is located beneath the base,

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

6. Remove the oil plug, filling, in order to drain the Shown in the figure Location of oil
oil quicker!
plugs on page 182.
7. Open the hose endoil plug, draining and drain Notice! The draining is timethe oil into the vessel.
consuming. Elapsed time depends on
the temperature of the oil.

183
3 Maintenance
Continued
Action
Note
8. Close the oil drain hose, and put it back inside

the base.
9. Refit the rear cover by securing it with its
attachment screws.
Filling oil, axis 1

The procedure below details how to fill the oil in gearbox axis 1.
Action
Note
1.
DANGER!
2.
WARNING!
information in section WARNING - Safety risks during
work with gearbox oil on page 41.

oil plugs on page 182!
5.
WARNING!
WARNING - Mixed oils may cause severe damage to
gearbox! on page 42!
184
4. Refill the gearbox with lubricating oil.

Art. no. and the total amount are
specified in Required equipment
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil level on page 182!
is detailed in section Inspection, oil level gearbox axis
1 on page 137.
3 Maintenance

Location of oil plugs
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor
attachment.
xx0400001066
Gearbox axis 2
Oil plug, filling
Oil plug, draining
Vent hole, gearbox axis 2
Required equipment
Equipment, etc. Art. no.
Amount
Note
Lubricating oil
5,800 ml
Kyodo Yushi TMO 150

Check which oil is currently
filled in the gearbox, as
detailed in section Which type
of oil does the gearbox
3HAC032140-001
Oil collecting vessel -
Capacity: 6,000 ml.
Oil exchange
equipment
3HAC021745-001

437.
Standard toolkit

page 436.

185
3 Maintenance
Continued
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
Action
Note
1.
DANGER!
2.
WARNING!
3. Remove the plug of the vent hole .
Shown in the figure Location of oil plugs

on page 185!
4. Remove the oil plug, draining, and drain the

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

on page 185!
Vessel capacity is specified in Required
Draining is time-consuming. Elapsed
time varies depending on the
temperature of the oil.
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
Action
Note
1.
DANGER!

186

page 41.
3 Maintenance
Continued
Action
Note
2.
WARNING!
3. Remove the oil plug, filling and the plug from the
vent hole.
Shown in the figure Location of oil

plugs on page 185!

amount previously being drained. The correct oil
level is detailed in section Inspection, oil level
gearbox axis 2 on page 139.
Art. no. and total amount are

specified in Required equipment on
page 185!
5.
WARNING!
WARNING - Mixed oils may cause severe damage
to gearbox! on page 42!
6. Refit the oil plugand the plug in the vent hole.
187
3 Maintenance
3.4.4. Oil change, gearbox, axis 3

Location of gearbox
Gearbox axis 3
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC032140-001
2,500 ml
Kyodo Yushi TMO 150

Oil exchange
equipment
3HAC021745-001

437.
Capacity: 3,000 ml.

188
xx0200000230
3 Maintenance
Continued
Equipment, etc.
Art. no.
Standard toolkit
Amount
Note
436.
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
Action
Note
1.
DANGER!
2.
WARNING!

page 41.
3. Remove the oil plug, draining, and drain the
gearbox oil using a hose with nipple and an
oil collecting vessel.
Remove the oil plug, filling in order to drain
the oil quicker!
Shown in the figure Location of gearbox

on page 188!
Vessel capacity is specified in Required
Draining is time-consuming. Elapsed
time varies depending on the
temperature of the oil.

189
3 Maintenance
Continued
Filling, oil
The procedure below details how to fill oil to the gearbox, axis 3.
Action
Note
1.
DANGER!
2.
WARNING!
information in section WARNING - Safety risks during
work with gearbox oil on page 41.
3. Remove the oil plug, filling.


The amount of oil to be refilled depends on the amount specified in Required
previously being drained. The correct oil level is
detailed in section Inspection, oil level gearbox axis 3
on page 141.
5.

WARNING - Mixed oils may cause severe damage to
gearbox! on page 42!
6. Note! Dont mix Kyodo Yushi TMO 150 with other oil Detailed in section Oil in
types!
gearboxes on page 176.
190
WARNING!
3 Maintenance

Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
xx0200000231
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
11712016-604
8,100 ml
Mobilgear 600 XP320

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

437.
Capacity: 9,000 ml.
Standard toolkit

page 436.

191
3 Maintenance
Continued
Draining, oil
The procedure below details how to drain the oil in the gearbox, axis 4.
Action
Note
1. Run the upper arm -45 from the calibration

position.
2.
DANGER!
3.
WARNING!
4. Drain the oil from the gearbox into an vessel by

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

5. Run the upper arm back to its calibration

position (horizontal position).
Shown in section Calibration scales

and correct axis position on page 412.
6. Refit the oil plug, draining.
Filling, oil
The procedure below details how to fill the oil in the gearbox, axis 4.
Action
Note
1.
DANGER!

192

3 Maintenance
Continued
Action
Note
2.
WARNING!
3. Refill the gearbox with lubricating oil through the oil
plug, filling.

on page 191.
4.
WARNING!
193
3 Maintenance

Location of gearbox
Wrist unit of IRB 6600 and IRB 6650
Oil plug, filling
Oil plug, draining
xx0200000232
xx0500002013
Wrist unit of IRB 6600ID and IRB 6650ID
Oil plug, filling
Oil plug, draining

194
3 Maintenance
Continued
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
11712016-604
IRB 6600/6650:
6,700 ml
IRB 6600ID/6650ID:
5,000 ml
Mobilgear 600 XP320

This is a common oil that
can be replaced with an
equivalent oil from
Oil exchange
equipment
3HAC021745-001
The contents are defined

in section Special tools
on page 437.
Capacity: 7,000 ml.
Standard toolkit

in section Standard toolkit
on page 436.
Draining, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.
Action
Note
1. Run axis 5 to a position where the oil plug,

draining, is facing downwards.
2.
DANGER!

3.
WARNING!
4. Drain the oil from the gearbox by opening the oil
plug, draining.
Remove the oil plug, filling in order to drain the oil
quicker!


195
3 Maintenance
Continued
Filling, oil, axis 5
The procedure below details how to change the oil in gearbox, axis 5.
Action
Note
1. Run axis 5 to a position where the oil plug, filling,

is facing upwards.
2.
WARNING!
3.
DANGER!
4. Refill the gearbox with lubricating oil through the
oil plug, filling.
level is detailed in section Inspection, oil level,

on page 195.
WARNING!
196
5.
3 Maintenance

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
xx0400001092
Gearbox, axis 6
Oil plug, filling
Oil plug, draining
xx0500002017
Gearbox, axis 6
Oil plug, draining
Oil plug, filling

197
3 Maintenance
Continued
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil,
IRB 6600/6650
3HAC032140-001
450 ml
Kyodo Yushi TMO 150

Check which oil is currently
filled in the gearbox, as
detailed in section Which type
of oil does the gearbox
6,000 ml
Mobilgear 600 XP320
Lubricating oil,
11712016-604
IRB 6600ID/6650ID
Oil exchange
equipment
3HAC021745-001

437.
Vessel capacity:
500 ml (IRB 6600/6650)
7,000 ml (IRB 6600ID/6650ID)
Standard toolkit

page 436.
Draining, oil, axis 6

The procedure below details how to drain oil from the gearbox, axis 6.
Note
1. IRB 6600/6650:Run the robot to a position where Shown in the figure Location of
the oil plug, draining of axis 6 gearbox is facing
downwards and the oil plug, filling, is facing
upwards.
IRB 6600ID/6650ID: Run the robot to a position
where the oil plug, draining is facing downwards.
2.
DANGER!
3.
WARNING!
4. Drain the oil from the gearbox into a vessel by
removing the oil plug.


198
Action
3 Maintenance
Continued
Action
Note
Filling, oil, axis 6

The procedure below details how to fil oil in the gearbox, axis 6.
Action
Note
1.
DANGER!
2.
WARNING!

3. Remove the oil plug, filling.


Art. no. and the total amount

are specified in Required
5.
WARNING!
6. Note! Dont mix Kyodo Yushi TMO 150 with other oil Detailed in section Oil in
types!
gearboxes on page 176.
199
3 Maintenance
3.4.8. Replacement of SMB battery

Location of SMB battery
The SMB battery (SMB = serial measurement board) is located on the left hand side of the
frame as shown in the figure below.
Note that the robot is shown with the SMB cover already removed!
SMB battery cover
SMB battery pack
Battery cable
Required equipment
Equipment, etc.
Spare part no.
Note
Battery pack
3HAC 16831-1
Battery includes protection circuits. Replace it

only with given spare part no. or an ABB
approved eqvivalent.
Standard toolkit
The contents are defined in section Standard

toolkit on page 436 in part 2 of the Product
manual.
Circuit Diagram
See chapter Circuit diagram in the Product

manual, reference information.
Removal, battery
The procedure below details how to remove the SMB battery.
Action
Note
This is done in order to facilitate the
updating of the revolution counter.

200
xx0200000238
3 Maintenance
Continued
Action
Note
2.
DANGER!
3.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
4. Remove the SMB battery cover by unscrewing its Shown in the figure Location of SMB
attachment screws.
battery on page 200.
5. Pull out the battery and disconnect the battery
cable.
Shown in the figure Location of SMB

6. Remove the SMB battery.

Battery includes protection circuits. Replace it
only with the specified spare part or with an ABB
approved eqvivalent.
Refitting, battery
The procedure below details how to refit the SMB battery.
Action
Note
1.
DANGER!
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 40

201
3 Maintenance
Continued
Action
Note
3. Reconnect the battery cable to the SMB battery Art. no. is specified in Required
pack and fit it to the frame.
4. Secure the SMB battery cover with its
attachment screws.

5. Update the revolution counter.
Detailed in chapter Calibration section Updating revolution counters

on page 415.
6.
DANGER!
Make sure all safety requirements are met

when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
202
3 Maintenance
3.5.1. Lubrication of spherical roller bearing, balancing device
3.5 Lubrication activities

Location of bearing
The spherical roller bearing is located at the front ear of the balancing device, as shown in the
figure below.
Note! The balancing device must be mounted on the robot when lubricating the bearing!
xx0200000109
Ear (spherical roller bearing located inside)
Lubrication nipple or securing screw
Sealing spacer
Hole through which the shaft is pressed
Required equipment
Equipment, etc.
Art. no.
Note
Grease
3HAA 1001-294
Optimol PDO, max. 80 ml.
Lubrication nipple
M6.
Grease pump

203
3 Maintenance
Continued
Lubrication, balancing device bearing
The procedure below details how to lubricate the spherical roller bearing.
Action
Note
1.
DANGER!
2. Replace the securing screw at the front ear
with a lubrication nipple.
M6
3. Lubricate the spherical roller bearing through

the lubrication nipple in the ear with grease.
Fill until excessive grease is forced out
between the shaft and the sealing spacer.
Art. no. and amount is specified in

Shown in the figure Location of bearing
on page 203!
The balancing device must be
mounted on the robot when lubricating
the bearing!
4. Remove the lubrication nipple and refit the

securing screw and washer.
M6 x 10, washer: D=6,4/12 T=1,6

5. 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 156.
there is no incorrect leakage from the o-rings.
204
3 Maintenance
3.5.2. Rust preventive, bearing axis 1 (Foundry Prime)

Location of bearing axis 1
The bearing axis 1 is located as shown in the illustration. (View from above).
A
xx0600002866
Plastic ring, (bearing cover)
Required equipment
Equipment
Art. no.
Note
3HAC026621-001
Equivalent:
Mercasol 3106
Brush
Rust preventive
Standard toolkit

436, in part 2 of the Product
manual.
Other tools and

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


205
3 Maintenance
Continued
Procedure
The following procedure details how to grese the bearing axis 1.
Action
Note/Illustration
1.
DANGER!
2. Remove the plastic ring.
A
xx0600002866
A: plastic ring
3. Wipe the surface under the ring
4. Apply the rust preventive on the bearing with the

brush.
A
xx0600002867
A: bearing
5. Refit the plastic ring.
206
3 Maintenance

Overview
The bearing axis 4 is located as shown in the illustration below.
xx0500002869
Plastic cover
Plastic ring
Required equipment
Equipment
Art. no.
Note
3HAC026621-001
Equivalent:
Mercasol 3106
Brush
Rust preventive
Standard toolkit

Product manual.

references to these

required.
Procedure
The following procedure details how to grease the bearing axis 1.
Action
Note/Illustration
1. Put the manipulator in a suitable

position.

207
3 Maintenance
Continued
Action
Note/Illustration
2.
DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
For Foundry Prime robots: Do not turn
off the air pressure to motors and
SMB.
3. Remove the plastic cover at the rear
end of the upper arm.
xx0600002872
A: plastic cover
B: plastic ring
4. Remove the plastic ring that covers

the bearing.
xx0600002871
A: plastic ring
5. Wipe the surface under the plastic

ring.

208
3 Maintenance
Continued
Action
Note/Illustration
6. Apply the rust preventive on the

bearing with the brush.
xx0600002868
A: bearing axis 4
B plastic ring
7. Refit the plasitc ring and cover
209
3 Maintenance
3.5.4. Rust preventive, support bearing in wrist (Foundry Prime)

Location of bearing
The support bearing in the wrist is located as shown in the illustration.
xx0500002863
Bearing
Cable bracket
Cover
Required equipment
Equipment
Art. no.
Note
3HAC026621-001
Equivalent:
Mercasol 3106
Rust preventive
Standard toolkit

Product manual.

references to these

Greasing, bearings
The procedure below details how to grease the bearing in the wrist.
Action
Note/Illustration
1. Place the robot and the upper arm in a suitable

position.

210
Brush
3 Maintenance
Continued
Action
Note/Illustration
2.
DANGER!
3. Dismantle the air hose from motor axis 6.
4. Tighten the hose clamp on motor axis 6, and
remove the air hose.
5. Remove thew cover according to the illustration.
A
xx0600002864
6. Apply the rust preventive on the bearing and cable

bracket with the brush.
A: cover
See Location of bearing on page

210.
7. Refit the cover.

See Inspection of air hoses
(Foundry Prime) on page 176.
8. Perform leakdown test.
211
3 Maintenance
3.6.1. Cleaning, robot
3.6 Cleaning activities

General
The protection class is IP 67, i.e. the robot is watertight.
Activities
This instruction specifies how to clean the robot.
Periodicity
The periodicity of cleaning the robot varies a great deal depending on the actual environment
and function of the robot. Clean a contamined robot as required.
Special points
Special points to be observed are shown in the figure below:
xx0200000239
Spiral cables to motor 6
Inside of upper arm tube
Rear of upper arm tube
Inside of lower arm
Inside of base/axis 1

212
3 Maintenance
Continued
Required equipment
Equipment, etc.
Art. no.
Steam cleaner
Note
High pressure water cleaner
Water pressure at nozzle: max.

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

The section below specifies some special considerations when cleaning the robot.
Always!
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never!
Never point the water jet at bearing seals, contacts, and other seals!
Never spray from a distance closer than 0.4 m!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 6 spiral cable (item A in the figure Special points)!
Although the robot is watertight, avoid spraying connectors and similar items with a
high pressure cleaner!
Foundry versions
In working environments, e.g. foundries, where the robot may be exposed to fluids that dry
to make a crusty surface, e.g. release agents, clean the cable harnesses to prevent the crust
damaging the cables:
Clean the spiral wound cables to motor 6 (item A in the figure Special points on page
212) with water and a cloth!
Clean the remaining sections of the cable harnesses as detailed above!
213
3 Maintenance
3.7.1. Using the SIS system
3.7 Service Information System, M2000

3.7.1. Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS for M2000 robot
systems. 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
The section is only valid for M2000 systems. For information regarding M2004 robot
systems, see additional documentation, Operating manual - Service Information System:
Art. no. is specified in section References on page 10.
Basic procedure
Action
Reference
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 217.
Maintenance intervals recommended by
ABB are specified in section Maintenance
schedule on page 131.
3. Enter these parameters in the system.
How to do this is detailed in Setting the

SIS parameters on page 219.
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 SIS
counter for any other reason is restarted.
value are shown in Description of Service
Information System (SIS) on page 215.
214
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 221.
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 222.
1. Determine which of the system functions you These are described in Description of
require.
Service Information System (SIS) on
page 215.
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 219. 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.
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.
How to access this is detailed in section Reading the SIS output logs on page 221.
The following information is available about the calendar time in the service routine.
Prev service
Date when the counter was reset last time, i.e. after the last service.
Elapsed time
Elapsed time since the counter was reset the last time.
Next service
Date when next scheduled service is planned. This date is

calculated using system parameters, as detailed in section Setting
the SIS parameters on page 219.
Remaining time
Remaining time to next scheduled service date.

215
3 Maintenance
Continued
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
the SIS parameters on page 219.
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).
Consumed time
The consumed time as a percentage of the total amount of time.
Elapsed time
Operation time for axis x since calculation began.
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 222!
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.
216
The following information is available for the axis service status in the service routine.
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 robot's 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
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.
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.

217
3 Maintenance
Continued
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:
input and output torque
gearbox spindle speed
other variables
218
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.
Action
Note
1. Open "System parameters" Detailed in the User's Guide.

using the TPU.
2. Go to "System parameters/
Manipulator/types 2".
xx0200000045
en0200000046

219
3 Maintenance
Continued
Action
Note
3. Select "0 SIS parameters"

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

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

parameters by stepping up
and down through the
parameter list.
220
Available parameters are described in section SIS system

parameters on page 217.
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.
Access to logs
How to open a log and show its contents is detailed in the User's Guide, chapter Service.
Available messages
The following messages may be shown:
Available in:
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
Proceed with the required service as detailed in
chapter Repair on page 223 or chapter
Maintenance on page 129 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 219.
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
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.
221
3 Maintenance
3.7.6. Exporting the SIS data
3.7.6. Exporting the SIS data

General
This section describes the available variables for entering SIS parameters as well as showing
any values of exceeded time limits as detected by the SIS counters.
In a 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 User's Guide.
Definitions
222
Signal
Unit
Counter type
Function
sisRestartDate
sec
Calendar time
The date on which the supervision was

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

system was started. Corresponds to the
operating time counter on the control cabinet.
sisRunT
sec
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
sec
Gearbox time
Operation time of gearbox axis 1
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2
sec
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3
sec
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6
hrs
Gearbox time
The table below defines the names and functions of all software variables available for
communication between the SIS and an external computer.
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 17 before commencing any
service work.
223
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
Action
Note
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:
knob until the correct value is shown on the
0.2 - 0.25 bar (20 - 25 kPa)
manometer.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is signifibe detected.
cantly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
respectively may occur. This is
quite normal.
6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection spray.
Bubbles indicate a leak.
8. When the leak has been localized: take the necessary
measures to correct the leak.
224
4. Disconnect the compressed air supply.
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 robot.
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 robot.
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 robot.
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.
225
4 Repair
4.2.3. Mounting instructions for seals

General
This sections details how to mount different types of seals to the robot.
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.
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).
3. Lubricate the seal with grease just before fitting. (Not too
Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page 226.
to the seal.)
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.
Flange seals and static seals

The procedure below details how to fit flange seals and static seals.
Action
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
compound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.

226
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.
4 Repair
Continued
Action
2. Clean the surfaces properly and in accordance with ABB 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.
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 may
The grooves must be geometrically correct and free from pores not be used.
and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.
227
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
4.3 Complete robot

General
This section details how to replace the cable harness that runs undivided from axis 1 to axis 6.
In case the cabling has a division point at the upper arm, it should instead be replaced as
detailed in sections:
Replacement of cable harness, axes 1-4 on page 240
Replacement of cable harness, axes 5-6 on page 249.
Location of cable harness
The cable harness of axes 1-6 is run throughout the robot as shown in the figure below.
xx0500002176
Rear cover plate
Cable guide, inside the frame
Cable gland, upper arm house
Velcro straps
Cable gland, lower arm

228
4 Repair
Continued
Required equipment
Equipment
Spare part no.
Cable harness axes 1-6

(IRB 6600)
3HAC 024385-001

(IRB 6650)
3HAC 024386-001
Note
Brush
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
Gasket
3HAC3537-1
motor axes 1-5
Gasket
3HAC12877-1
motor axis 6
Standard toolkit

Standard toolkit on page 436, in part 2
of the Product manual.
Circuit diagram

Cable brackets of the upper arm
xx0500002293
Cable bracket, wrist unit
Cable bracket, upper arm tube
Cable attachment, rear
Removal, cable harness, upper arm

The procedure below details how to remove the cable harness from the upper arm of the robot.
Action
1. In order to facilitate refitting of cable harness,
run the robot to the specified position:
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
Axis 6: no significance
Note/Illustration
Axes 2 and 3 may be tilted slightly to
improve access.

229
4 Repair
Continued
Action
Note/Illustration
2.
DANGER!
3. Remove the cover, wrist unit and the cover,
upper arm tube.
xx0200000214
A. cover, wrist unit

B. cover, upper arm tube
4.
NOTE!
Axis 5 must be oriented in the correct position
(+90) to allow the motor 6 cover to open!
5. Remove the cover of motor, axis 6 and
disconnect all connectors beneath.
Shown in the figure Cable brackets of
the upper arm on page 229.
xx0200000254
B: Attachment screws, rear of

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

8. Loosen the cable bracket in the upper arm tube
by undoing the two screws on top of the tube.

9. Disconnect the two connectors (R3.FB5 and

R3.MP5) inside the tube.

harness on page 228.
10. Remove eventual cable straps from the

harness.
11. Remove the cable attachment, rear.


230
6. Loosen the cable bracket in the wrist unit by

undoing the three attachment screws.
Two of the attachment screws are visibly
located at the rear attachment and the third is
located at the bottom of the cable bracket, in
the center.
4 Repair
Continued
Action
Note/Illustration
12. Gently pull the cable harness out from the

upper arm tube.
13. Tie the connectors into bundles, to avoid
damaging them during further removal.
14. Continue removing the cable harness as
detailed in following procedure.
Removal, cable harness, lower arm, frame and base

Action
Note/Illustration
1. Remove the rear cover plate from the robot by Shown in the figure Location of cable
removing its attachment screws.
2. Disconnect the earth cable beneath.
3. Disconnect connectors R1.MP and R1.SMB.

4. Pull the cable and connectors up through the

cable guide in the center of the frame.
5. Disconnect all connectors at motor 1 and
motor 2.
6. Open the SMB cover carefully.
The cable between the battery and the SMBunit 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!
7. Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 from the brake
release unit.
xx0200000118

231
4 Repair
Continued
Action
Note/Illustration
xx0300000560
A. Cable gland
B. Attachment screws, cable
gland
C. Attachment plate
D. Velcro strap
9. Remove the cable gland securing the cables
inside the lower arm.

232
8. 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 robot 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.
4 Repair
Continued
Action
Note/Illustration
10. Remove the cable gland securing the cables to

the arm house.
xx0100000143
11. Remove the velcro strap from the harness at

the cable fixing bracket at the arm house.
12. Disconnect all connectors at motor 3 and
motor 4.
13. Gently pull the cable harness out.
Refitting, cable harness axes 1-6

The procedure below details how to refit the cable harness to the robot.
Action
1.
Note
See Required equipment on page 229.
NOTE!
On Foundry Prime robots:
Apply rust preventive around all dismantled
covers and attachment screws with a brush.
2. 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!
3. Reconnect connectors R1.MP and R1.SMB at Shown in the figure Location of cable
the base.
Make a note of the correct positions of
the connectors!
4. Reconnect the earth cable.
5. Refit the rear cover plate to the robot with its
attachment screws.


233
4 Repair
Continued
Action
Note
6. Reconnect all connectors at motor 1 and motor

2.
7.
See Required equipment on page 229.
NOTE!

When dismantling the cables from the motors,
the gasket must be replaced.

234
4 Repair
Continued
Action
Note
8. Secure the cable gland (A) with four

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).
different versions of the attachment plate.
Make sure the correct one is used to avoid
cable failure.
xx0300000560
A.
B.
C.
D.
Cable gland
Attachment screws, cable gland
Attachment plate
Velcro strap

235
4 Repair
Continued
Action
Note
9. Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 to the brake
release unit.
Reconnect R1.G if it has been disconnected.
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 39!
12. Pull the cable harness through the lower arm.
13. Refit the cable gland securing the cables

inside the lower arm.
xx0100000142

236
4 Repair
Continued
Action
Note
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.
16. Secure the cable harness to the upper arm
house by refitting the velcro strap to the cable
bracket at the upper arm house.
17. Gently insert the cable harness from the rear
into the upper arm.
18. Connect the two connectors inside the upper Shown in the figure Cable brackets of
arm tube, R3.FB5 and R3.MP5 and secure the the upper arm on page 229.
cable bracket with the two attachment screws
to the tube.
19. Place the cabling to motor, axis 6, correctly on
the upper arm and gently pull the connectors
through the hole on top of wrist unit to motor,
axis 6.
xx0200000185
In case of excess cable length: put a

loop of cable in this area with cable
straps (A). The cables are longer in
order to fit different upper arm lengths.

237
4 Repair
Continued
Action
Note
20. Fasten the cable bracket, wrist unit with three

attachment screws, two of them visible at the
rear attachment point and the third located on
the bottom of the cable bracket, in the center.
xx0200000254

cable bracket.
cable bracket.
21. Reconnect the connectors to motor, axis 6 and

refit the motor cover.
22. Refit the cover, upper arm (B) and the cover,
wrist unit (A).
Make sure the cabling is placed correctly when
refitting the covers, and does not get jammed.
xx0200000214
23. If any cable straps have been removed, refit

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

238
4 Repair
Continued
Action
Note
25. Fit a cable protection to the lower arm, if not

already mounted, with two securing screws
(A), M6x16.
Secure the cable harness with two velcro
straps (B), with a distance of approximately
180 mm. Fix the strap by wrapping it two turns
around the largest cable before wrapping
around the complete harness.
xx0500002320
26. If the connection between the SMB battery and Detailed in section Updating revolution
the SMB unit has been broken, the revolution counters on page 415.
counters must now be updated!
27.
DANGER!

239
4 Repair

General
This section details how to replace the cable harness that runs from axis 1 to axis 4. If the
robot is equipped with an undivided cable harness, it is instead replaced as detailed in section
Replacement of cable harness, axes 1-6 on page 228.
Location of cable harness
The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in
the figure below.
xx0300000561
Rear cover plate
Attachment point for earth lug
Connector R1.MP
Connector R1.SMB
Cable guide in the center of the frame

240
4 Repair
Continued
F
Connectors at motor 1: R2.FB1 and R2.MP1
SMB recess
Cable gland, upper arm house
Cable fixing bracket + velcro strap
Connector R2.M5/6 at the cable division point
Connectors at motor 3: R2.FB3 and R2.MP3 (optional signal lamp: R2.H1 and
R2.H2)
Required equipment
Equipment, etc.
Spare part no. Art. no.
Note

(IRB 6600/6600ID)
3HAC 025503001
Includes a cable protection

that must be fitted to the
lower arm, and a velcro
strap for the harness going
up inside the lower arm!

(IRB 6650/6650ID)
3HAC 025504001
Includes a cable protection

that must be fitted to the
lower arm, and a velcro
strap for the harness going
up inside the lower arm!
Locking liquid
Standard toolkit
Loctite 638
Used to secure the
attachment screws for the
attachment plate inside the
frame.
3HAC 15571-1

Product manual.
Other tools and

procedures may be
below.

required.
Circuit Diagram
See chapter Circuit diagram

in the Product manual,
reference information.

241
4 Repair
Continued
Removal, cable harness, axes 1-4
The procedure below details how to remove the cable harness, axes 1-4.
Action
Note/Illustration
1. In order to facilitate refitting of cable harness, run the Axes 2 and 3 may be tilted
robot to the specified position:
slightly to improve access.
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
2.
DANGER!
3. Remove the rear cover plate from the robot by
removing its attachment screws.

cable harness on page 240.
4. Disconnect the earth cable.
Attachment point is shown in the

figure Location of cable harness
on page 240!
5. Disconnect connectors R1.MP and R1.SMB.
Attachment points are shown in

the figure Location of cable
6. Pull the cable and connectors up through the cable

guide in the center of the frame.
Specified and shown in the figure
Location of cable harness on
page 240!
7. Disconnect all connectors at motor 1 and motor 2.
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!

242
4 Repair
Continued
Action
Note/Illustration
9. Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 from the brake release
unit.
xx0200000118.wmf
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 robot 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

243
4 Repair
Continued
Action
Note/Illustration
11. Remove the cable gland securing the cables inside

the lower arm.
12. Remove the cable gland securing the cables to the
arm house.
xx0100000143.wmf
13. Remove the velcro strap from the harness at the

cable fixing bracket at the arm house.

14. Disconnect connector R2.M5/6 at the cable division Shown in the figure Location of
point.
cable harness on page 240!
15. Disconnect all connectors at motor 3 and motor 4.
Specified and shown in the figure

Location of cable harness on
page 240!
Refitting, cable harness, axes 1-4
Action
Note/Illustration
1.
DANGER!
2. In order to facilitate refitting of cable harness,
move the robot to the specified position:
Axis 1: 0 degrees
Axis 2: 0 degrees
Axis 3: 0 degrees
Axis 4: 0 degrees
Axis 5: +90 degrees
Axes 2 and 3 may be tilted slightly to

improve access.

244
The procedure below details how to refit the cable harness, axes 1-4.
4 Repair
Continued
Action
3. Pull the cable and connectors down through the
cable guide in the center of the frame.
Note/Illustration
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 the Make a note of the correct positions
rear cover plate.
of the connectors!
figure Location of cable harness on
page 240.
5. Reconnect the earth cable.

figure Location of cable harness on
page 240!
6. Refit the rear cover plate to the robot 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
240!

245
4 Repair
Continued
Action
Note/Illustration
xx0300000560
A: Cable gland
B: Attachment screws, cable
gland
C: Attachment plate
D: Velcro strap
9. Reconnect connectors R2.SMB, R1.SMB1-3,

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

246
8. Secure the cable gland (A) with four attachment Locking liquid is specified in
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).
different versions of the attachment plate. Make
sure the correct one is used to avoid cable failure.
4 Repair
Continued
Action
Note/Illustration
11.
WARNING!
WARNING - The brake release buttons may be
jammed after service work on page 39!
12. Pull the cable harness through the lower arm.
13. Refit the cable gland securing the cables inside
the lower arm.
xx0100000142
14. Refit the cable gland securing the cables to the

arm house.
Make sure not to twist the harness!
xx0100000143
15. Reconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
Location of cable harness on page
240!
16. Reconnect the connector R2.M5/6 gently at the
cable division point.
cable harness on page 240!
Be careful not to bend the attachment plate when M6, 2 pcs.
fastening the screws!
17. Secure the cable harness to the upper arm house Shown in the figure Location of
by refitting the velcro strap to the cable bracket at cable harness on page 240!
the upper arm house.

247
4 Repair
Continued
Action
18. Fit a cable protection to the lower arm, if not
already mounted, with two securing screws (A),
M6x16.
Secure the cable harness with two velcro straps
(B), with a distance of approximately 180 mm. Fix
the strap by wrapping it two turns around the
largest cable before wrapping around the
complete harness.
Note/Illustration
Both the protection and the strap
are included in the spare part no.,
page 241.
xx0500002320
19. 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 415.
20.
DANGER!
248
4 Repair

Location of cable harness ax 5-6
The location of the cable harness, axes 5-6, is shown in the figure below.
xx0200000213
Cable bracket, wrist unit
Cable bracket, upper arm tube
Connectors at motor axis 5; R4.FB5 and R4.MP5
Connectors in upper arm tube; R3.FB5 and R3.MP5
Cable attachment, rear
Connector at cable harness division point; R2.M5/6
Connectors at motor, axis 6; R3.FB6 and R3.MP6
Required equipment
Equipment, etc.
Spare part no.
3HAC 14140-1
Standard toolkit
Note
Standard toolkit on page 436 in part 2

249
4 Repair
Continued
Equipment, etc.
Spare part no.
Note


Circuit Diagram

Removal, cable harness, axes 5-6

The procedure below details how to remove the upper cable harness.
The separate cable that goes from the connection point inside of the upper arm tube to the
motor, axis 5, is not included in this procedure. The removal of that cable is described in
section Removal, cabling axis 5 motor on page 259.
Action
Note/Illustration
1.
DANGER!
xx0200000214
A: cover, wrist unit

B: cover, upper arm tube
3.
NOTE!
4. Remove the cover of motor, axis 6 and
disconnect all connectors beneath.
Specified in the figure Location of

cable harness ax 5-6 on page 249!

250
2. Remove the cover, wrist unit and the cover,

upper arm tube.
4 Repair
Continued
Action
5. Loosen the cable bracket on top of the wrist
unit by undoing the three attachment screws.
Two of the attachment screws are visibly
located at the rear attachment and the third is
located at the bottom of the cable bracket, in
the center.
Note/Illustration
harness ax 5-6 on page 249!
xx0200000254

cable bracket, 2 pcs
cable bracket, 1 pc
6. Pick out the cabling from motor, axis 6.

7. Loosen the cable bracket in the upper arm tube
by undoing the two screws on top of the tube.

8. Disconnect the two connectors (R3.FB5 and

R3.MP5) in the tube.

9. Remove eventual cable straps from the

harness.
10. Remove the cable attachment, rear.

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

harness division point.

Refitting, cable harness, axes 5-6

The procedure below details how to refit the upper arm cable harness. The separate cable that
goes from the connection point inside of the upper arm tube to the motor, axis 5, is not
included in this procedure. The refitting of that cable is described further down in section
Refitting, cabling axis 5 motor on page 260.
Action
Note/Illustration
1. Position the upper arm as follows:

Axis 4: 0 degrees
Axis 5: +90 degrees
2. Gently insert the cable harness from the rear
into the upper arm.
3. Connect the two connectors inside the upper Shown in the figure Location of cable
arm tube, R3.FB5 and R3.MP5 and secure the harness ax 5-6 on page 249!
cable bracket with the two attachment screws
to the tube.

251
4 Repair
Continued
Action
Note/Illustration

axis 6.
xx0200000185
In case of excess cable length:

put a loop of cable in this area
with cable straps (A). The
cables are longer in order to fit
different upper arm lengths.
5. Fasten the cable bracket, wrist unit with three Also shown in the figure Location of
attachment screws, two of them visible at the cable harness ax 5-6 on page 249!
rear attachment point and the third located on
the bottom of the cable bracket, in the center.
xx0200000254

cable bracket.
cable bracket.
7. Refit the cover, upper arm and the cover, wrist

unit.
Make sure the cabling is placed correctly when
refitting the covers, and does not get jammed.
xx0200000214
A: cover, wrist unit

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

them to the harness.
9. Refit the cable attachment, rear.
252

10. Reconnect connector R2.M5/6 gently at the

rear cable division point with two screws, M6.
Be careful not to bend the attachment plate
when fastening the screws!

11. Update the revolution counter!
Detailed in section Updating revolution

counters on page 415.
6. Reconnect the connectors to motor, axis 6 and

refit the motor cover.
4 Repair
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
Location of cable harness, axes 5-6
The cable harness of axes 5-6 is run inside the upper arm, as shown in the figure below.
xx0500001896
Cover, upper arm tube
Hood, upper arm housing
Attachment screws and washers (3 pcs), hood, upper arm housing
Connector at cable harness division point; R2.M5/6
Required equipment
Equipment
Spare part no.
3HAC 024815-001
Cable grease
Art. no.
Note
3HAC 14807-1 Optitemp RB 1

253
4 Repair
Continued
Equipment
Spare part no.
Art. no.
Note
Standard toolkit

Product manual.
Product manual SpotPack/DressPack

OrangeLine

section References on
page 10.
Removal, cable harness axes 5-6

The procedure below details how to remove the cable harness from the upper arm.
Action
1. Run the robot to its calibration position.
Note/Illustration
Shown in section Calibration scales and
correct axis position on page 412.
2.
DANGER!
3. Remove the process cabling from the
upper arm, if any.
How to remove the DressPack harness

from the upper arm / wrist unit, is detailed
in the Product manual - SpotPack/
DressPack OrangeLine.
4. Remove the cover from the upper arm tube Shown in the figure Location of cable
and the hood from the upper arm housing. harness, axes 5-6 on page 253.
5. Disconnect all the connectors at the axis 5 The connectors are specified and shown
and 6 motors, and the connector at the
in the figure Location of cable harness,
cable harness division point.
axes 5-6 on page 253.
6. Remove the two cable clamps (A) from the

bracket at the back of the upper arm
housing.
xx0500001903

254
4 Repair
Continued
Action
Note/Illustration
7. Remove the cable bracket from the upper

arm housing by removing the three
attachment screws (B).
Leave the cabling fitted to the bracket.
xx0500001905
8. Loosen the cable clamp (C) inside of the

upper arm tube.
xx0500001904
9. Remove all velcro straps and cable ties

holding the cabling inside the wrist unit.
10. Pull out the cabling from the wrist unit and
the upper arm tube. Be careful not to
damage the connectors!

255
4 Repair
Continued
Cable layout, wrist unit
The figure below shows how to run and attach the cabling inside the wrist unit.
xx0500002014
Location inside the wrist unit where to strap the cabling, next to the axis 5 motor.
Refitting, cable harness axes 5-6

The procedure below details how to refit the cable harness to the upper arm.
Action
Note/Illustration
1.

2. Make sure all the cable clamps and brackets are Spare part no. is specified in
attached properly to the new cable harness.
3. Insert the cable harness through the upper arm
tube and pull out the motor connectors at the
wrist unit.

256
DANGER!
4 Repair
Continued
Action
Note/Illustration
4. Secure the cable clamp (C) inside the upper arm

tube.
xx0500001904
5. Place the cabling inside the wrist unit according Shown in the figure Location of cable
to the cable layout shown in the figure Cable
layout, wrist unit on page 256 and fasten it with
velcro straps.
Reconnect the connectors to the axis 5 and 6
motors.
6. Wind the cabling in a spiral with four free turns.

Secure the fifth turn with two clamps (A and B) to
the bracket.
Note! The cable clamps should be positioned
approximately 1 m from the connector R2.M5/6.
Note! Adjust the clamps to make the bend of the
fifth turn equal with the others, creating a
symmetrical spiral.
xx0500001909
A: Attachment point for the

power cable, R3.MP.
B: Attachment point for the
signal cable, R3.FB.
7. Grease the cabling with cable grease.

8. Refit the cover to the upper arm tube and the

hood to the upper arm housing.

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

harness division point.

10. Update the revolution counters!
Detailed in section Updating

revolution counters on page 415.

257
4 Repair
Continued
Action
Note/Illustration
11.
DANGER!

258
4 Repair
4.3.5. Replacement of cabling, axis 5 motor

Location of cabling
The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in
the figure below.
xx0500002294
Motor axis 5 with connectors R4.FB5 and R4.MP5
Connectors R3.FB5 and R3.MP5
Required equipment
Equipment
Spare part no.
Cable harness axis 5
3HAC 14139-1
Note
Standard toolkit

Standard toolkit on page 436, in part
2 of the Product manual.


Removal, cabling axis 5 motor

The procedure below details how to remove the cabling from the axis 5 motor.
Action
Note
1.
DANGER!
2. Remove the complete wrist unit.
Detailed in section:
IRB 6600/6650:Removal, wrist
unit on page 278.
IRB 6600ID/6650ID: Removal,
wrist unit on page 283.

259
4 Repair
Continued
Action
Note
3. Remove the cover of motor, axis 5.

4. Disconnect all connectors at motor, axis 5.
5. Remove the cable gland cover at the cable
exit by unscrewing its two attachment screws.
6. Remove the cable, axis 5.
Refitting, cabling axis 5 motor

The procedure below details how to refit the cabling to the motor of axis 5.
Action
Note
1.
DANGER!
2. Reconnect all connectors at motor, axis 5.
3. Refit the cable gland cover at the cable exit
with its two attachment screws.
5. Refit the complete wrist unit.
IRB 6600/6650:Refitting, wrist
unit on page 279.
IRB 6600ID/6650ID: Refitting,
6. Recalibrate the robot.
Calibration is detailed in a separate

calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 409.
7.
DANGER!
further detailed in section DANGER - First
test run may cause injury or damage! on page
38.
260
4. Refit the cover of motor, axis 5.
4 Repair
4.3.6. Replacement of complete arm system

Location of arm system
The complete arm system is defined as the complete robot except for the base and gearbox
axis 1. This is shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views on page 477 in part 2 of the Product manual.
xx0200000224
Upper arm
Lower arm
Frame
Gearbox, axis 1
Base attachment screws
Balancing device
Block for calibration
Motor axis 1

261
4 Repair
Continued
Required equipment
Equipment, etc.
Art. no.
Note
Lifting device, manipulator
3HAC15607-1
Instruction 3HAC 15971-2 is enclosed!
Guide pins M12 x 130
3HAC022637-001
Used to guide the complete arm system

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

chain.
Standard toolkit

the Product manual.

references to these

the tools required.
Removal, arm system

The procedure below details how to lift and remove the complete arm system.
Action
Note/Illustration
1. Make sure the robot is positioned as shown Release the brakes if necessary, as
in figure to the right. If it is not, position it
detailed in section Manually releasing the
that way.
brakes on page 71.
xx0100000103

262
4 Repair
Continued
Action
Note/Illustration
2.
DANGER!
3. Drain the oil from gearbox axis 1.
Detailed in section Oil change, gearbox

axis 1 on page 182.
4. Loosen the cable connectors from the base

and pull up the cabling from the base,
through the hole in the center of the frame.
5. Remove the motor, axis 1.
Detailed in section Removal, motor axis 1

on page 338.
6. Run the overhead crane to a position above

the robot.
7. Fit the lifting device and adjust it as detailed Art. no. is specified in Required equipment
in the enclosed instructions.
on page 262!
Make sure the lift is done completely level!
How to adjust the lift is described in the
enclosed instruction to the lifting device!
Follow the instructions before lifting!
8. Remove the block for calibration from the
bottom of the frame.
Shown in the figure Location of arm system

on page 261!
9. Unfasten the arm system from the base by Shown in the figure Location of arm system
unscrewing its 24attachment screws.
on page 261!
10. Fit the two guide pins in two opposite screw
holes.
11.
CAUTION!
The complete arm system weighs 1250 kg!
accordingly!
12. Lift the arm system carefully and secure it
in a safe area.
Always move the robot at very low speeds,
making sure it does not tip.
Continue lifting even if the arm system turns
out to be unbalanced despite earlier adjustments! The risk of damaging the interfaces
is bigger if the load is lowered unbalanced!
Make sure all hooks and attachments stay

in the correct position while lifting the arm
system and that the lifting device does not
wear against sharp edges.

263
4 Repair
Continued
Refitting, arm system
The procedure below details how to lift and refit the complete arm system.
Action
Note/Illustration
1.
DANGER!
2. Fit the lifting device as detailed in enclosed Art. no. is specified in Required
instruction.
Also fit a hoisting block to the frontchain,
used to adjust the balance of the arm system
in order to lift it completely level!
3.
CAUTION!
The complete arm system weighs 1250 kg!
accordingly!
5. Fit the two guide pins to the frame

Dimension is specified in Required
attachment holes, as shown in the figure to equipment on page 262.
the right.
Fit one guide pin next to the guiding hole (for
the spring pin in the gearbox) and the other
guide pin straight across the frame.
xx0300000070
The figure above shows the frame, view

from below.
A. Attachment holes for the guide
pins, M12.
B. Guiding hole for the spring pin
located in the gearbox, axis 1.

264
4. Lift the complete arm system and move it at Make sure all the hooks and attachments
very low speed, making sure it does not tip! stay in the correct position while lifting the
Make sure the lift is done completely level. robot!
Adjust the length of the chains as detailed in
enclosed instruction or with a hoisting block!
4 Repair
Continued
Action
Note/Illustration
6. Look through the empty mounting hole of

This is a complex task to be performed
motor 1 to assist in aligning the assembly
with utmost care in order to avoid injury or
during refitting of the arm system.
damage!
The spring pin in the gearbox must be fitted
to the guiding hole of the frame (B).
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
The refitting must be made completely level!
Make sure the lifting device is adjusted prior
to refitting of arm system.
xx0600003093
7. Refit 22 of the 24 attachment screws before

the arm system is completely lowered.
8. Remove the guide pins and secure the arm Shown in the figure Location of arm
system to the base with its 24attachment
system on page 261!
screws and washers.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 432 before fitting.
9. Refit the block for calibrationat the bottom of Shown in the figure Location of arm
the frame.
system on page 261!
10. Refit the motor axis 1.
Detailed in section Refitting, motor axis 1

on page 339.
Detailed in section Replacement of motor,
axis 1 on page 337.
11. Refit the cabling in the base.

12. Perform a leak-down test of the gearbox axis Detailed in section Performing a leak1.
down test on page 224.
13. Refill the gearbox axis 1 with lubricating oil. Detailed in section Oil change, gearbox
axis 1 on page 182.

calibration tools.
included in section Calibration information
on page 409.

265
4 Repair
Continued
Action
Note/Illustration
15.
DANGER!

test run may cause injury or damage! on
page 38.
266
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)

Location
The illustration below shows the routing of the Foundry Prime air hose.
xx0500002176

267
4 Repair
Continued
Hose lenghts
Pos
Length in mm.
1A
40
1B
40
1C
1520
1D
1090
1E
310
1F
35
1G
250
1H
540
1K
4020
1L
195
1M
40
1N
40
1P
1605
1Q
100 (for option 2,8m/175kg: 350)
1R
149 (for option 2,8m/175kg: 1740)
1S
570
Required equipment
Equipment
Art. no.
Pos. in illustration
Elbow fitting
100
Rubber clamp
3HAC026523-001
T-plugg connector
3HAC026515-001
Y-plugg connector
3HAC026514-001
Bulkhead plugg connector
3HAC026513-001
Hose
3HAC026526-001
Cable strap
21662055-3

268
xx0600003027
4 Repair
Continued
Procedure
The following procedures details how to replace the Foundry Prime air nipples and hose. The
pos. no. in following procedures correspond to the illustration in Hose lenghts on page 268
and the table in Required equipment on page 268
Action
Note/Illustration
<<
DANGER!
pneumatic pressure supplies to the robot.
Localise the damaged hose or air
connector, and Continue to replace the
damaged hose route the hose according to
the following illustrations
Connection at base.
xx0600003042
Axis 1
xx0600003043

269
4 Repair
Continued
Action
Note/Illustration
Balancing device
xx0600003397

270
4 Repair
Continued
Action
Note/Illustration
Axis 1-2
xx0600003044
xx0600003162
xx0600003045

271
4 Repair
Continued
Action
Note/Illustration
Upper arm housing
xx0600003046
xx0600003047
xx0600003163
1P: Lay the hose in a spiral in the

tube shaft.

272
Tube shaft
4 Repair
Continued
Action
Note/Illustration
Wrist
xx0600003097
273
4 Repair
4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650
4.4 Upper and lower arm

Location of turning disk
The turning disk is located in the front of the wrist housing, as shown in the figure below.
views in the Product manual, reference information.
xx0200000217
Turning disk
Wrist unit
Oil plug, draining
Oil plug, filling
Attachment screws (12 pcs)
Equipment, etc.
Note
Turning disk, dia. 200
3HAC 13752-1
O-rings are not included!
O-ring
3HAB 3772-64
(1 pc)
3HAB 3772-61
(12 pcs)
Must be replaced when

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

Product manual.
Other tools and

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

required.

274
Required equipment
4 Repair
Continued
Removal, turning disk
The procedure below details how to remove the turning disk.
Action
Note
1.
DANGER!
2. Remove any equipment fitted to the turning disk.
3. Run the robot to a position where the oil plug, draining Shown in the figure Location of
of axis 6 gearbox faces downwards.
turning disk on page 274!
4. Drain the oil from gearbox 6.
Detailed in section Oil change,

5. Remove the turning disk by unscrewing its

attachment screws.

turning disk on page 274!
Refitting, turning disk

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

1. Lubricate the turning disk o-ring with grease.

Fit the o-ring to the rear of the turning disk.
Fit also the 12 o-rings, when refitting the
attachment screws.
Note/Illustration
xx0200000218
A: Sealing surface, o-ring

275
4 Repair
Continued
Action
2. Secure the turning disk with its attachment
screws.
Note/Illustration
12 pcs, M12 x 30, 12.9 quality
UNBRAKO, tightening torque: 100 Nm.
they are lubricated as detailed in
section Screw joints on page 432
before fitting.
3. Perform a leak-down test of the gearbox axis 6. Detailed in section Performing a leakdown test on page 224.
4. Refill the gearbox 6 with oil.

axis 6 on page 197.
5. Refit any equipment removed during disassembly, to the turning disk.

6.
DANGER!

276
4 Repair
4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650
Wrist unit for robot models IRB 6600 and IRB 6650
This section is valid for robot models IRB 6600 and IRB 6650. How to replace the wrist of
the models IRB 6600ID and IRB 6650ID is detailed in section Replacement of complete wrist
unit, IRB 6600ID and IRB 6650ID on page 282.
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
xx0200000184
Wrist unit
Turning disk
Cover, wrist unit
Cover, upper arm tube
Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
Cable bracket
Attachment point for lifting tool, wrist unit
Wrist unit attachment screws and washers
Upper arm tube

277
4 Repair
Continued
Required equipment
Equipment etc.
Wrist, type 2
3HAC 16626-2
Wrist, type 2, insulated

turning disk
3HAC 16626-3
Note
3HAC13056-3
Lifting tool, wrist unit
3HAC 13605-1
Standard toolkit
Always use guide pins in

pairs!
on page 436 in part 2 of the
Product manual.
Other tools and

procedures may be
below.

required.
Circuit diagram
See chapter Circuit

diagram in the Product
Removal, wrist unit

The procedure below details how to remove the complete wrist unit.
Action
Note/Illustration
1.

2. Remove all equipment fitted to the turning disk.
3. Turn axis 4 to a position where the cover, upper Shown in the figure Location of wrist
arm tube and wrist unit, faces upwards. Also turn unit on page 277!
axis 5 so that the turning disk faces to the side in
order to allow access to the motor 6 cover.
4. Remove the cover, wrist unit.
Shown in the figure Location of wrist

unit on page 277!
5. Remove the cover, upper arm tube.

unit on page 277!
6. Remove the cover of motor, axis 6 and disconnect

all connectors beneath.

278
DANGER!
4 Repair
Continued
Action
Note/Illustration
7. Loosen the cable bracket on top of the wrist by

undoing the three attachment screws.
unit on page 277!
Two of the attachment screws are visibly located
at the rear of the bracket (B) and the third located
at the bottom of the cable bracket, in the center
(C), shown in the figure to the right.
xx0200000254
B: Attachment screws, rear

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

it safely on the tube.
9. Loosen the cable bracket in the upper arm tube by Shown in the figure Location of wrist
undoing the two screws on top of the tube.
unit on page 277!
10. Disconnect the motor axis 5 by disconnecting the Shown in the figure Location of wrist
two connectors in the upper arm tube (R3.FB5,
unit on page 277!
R3.MP5).
11. Fit the lifting tool to the wrist unit.

12.
CAUTION!
The complete wrist unit weighs 130 kg!All lifting
13. Slightly raise the wrist unit to unload the screw
joint, facilitating removing the attachment screws.
14. Remove the wrist unit attachment screws and

washers.

unit on page 277!
15. Pull the wrist unit out, lift it away and place it on a
secure surface.
Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
Action
Note/Illustration
1.
DANGER!
2. Fit two guide pins, M12 in the upper arm tube, Art. no. is specified in Required
in two of the holes for the wrist unit attachment equipment on page 278!
screws.
unit on page 277!

279
4 Repair
Continued
Action
3. Fit the lifting tool to the wrist unit.
Note/Illustration
Art. no. is specified Location of wrist
unit on page 277!
4.
CAUTION!
The complete wrist unit weighs 130 kg!All
lifting equipment used must be sized accordingly!
5. Lift the wrist unit and guide it to the upper arm
tube with help of the guide pins.
Make sure the cabling from motor, axis 5 is
safely run into the arm tube and does not get
jammed.
6. Secure the wrist unit with 10 of the 12
attachment screws and washers.

unit on page 277!
12 pcs: M12 x 50, 12.9 quality
before fitting.
7. Remove the guide pins and secure the two

remaining attachment screws as detailed
above.
8. Remove the lifting tool from the wrist unit.
9. Reconnect the motor axis 5 by connecting the Shown in the figure Location of wrist
two connectors inside the upper arm tube
unit on page 277!
(R3.FB5, R3.MP5) and secure the cable
bracket with the two attachment screws to the
tube.
10.
NOTE!
axis 6.
xx0200000185
Put a loop of cable in this area with

cable straps (A), if necessary. The
cables are long enough to fit different
upper arm lengths.

280
4 Repair
Continued
Action
Note/Illustration
12. Fasten the cable bracket at top of the wrist

unit with three attachment screws. Two of
unit on page 277!
them are visible at the rear attachment point
(B) and the third is located on the bottom of
the cable bracket, in the center (C), shown in
the figure to the right.
xx0200000254

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

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

unit on page 277!
15. Refit the cover, wrist unit.

unit on page 277!
16. Recalibrate the robot!

calibration tools.
17. Refit any equipment previously removed from

the turning disk.
18.
DANGER!

281
4 Repair
4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID
Wrist unit for robot models IRB 6600ID and IRB 6650ID
This section is only valid for robot models IRB 6600ID and IRB 6650ID. How to replace the
wrist unit on the models IRB 6600 and IRB 6650 is detailed in section Replacement of
complete wrist unit, IRB 6600 and IRB 6650 on page 277.
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
views on page 477 in part 2 of the Product manual.
xx0500001567
Wrist unit
Attachment screws and washers, wrist unit
Upper arm tube
Equipment
Spare part no.
Art. no.
Note
Wrist, process
3HAC 024793-001
3HAC13056-3

pairs!
Lifting slings
Standard toolkit

references to these
Circuit diagram

on page 436, in part 2 of
the Product manual.
These procedures
include references to the
tools required.
See chapter Circuit


282
Required equipment
4 Repair
Continued
Equipment
Spare part no.
Product manual SpotPack/DressPack

OrangeLine
Art. no.
Note

section References on
page 10.
Removal, wrist unit

The procedure below details how to remove the complete wrist unit from the robot.
Action
Note
1.
DANGER!
2. Remove all equipment fitted to the turning disk.
3. Remove the integrated spotpack cabling.
How to remove the DressPack

harness from the upper arm / wrist
unit, is detailed in the Product
manual - SpotPack/DressPack
OrangeLine.
4. Disconnect the connectors from motors, axes 5 and

6. Loosen the cabling from the wrist unit.
5. Support the weight of the wrist unit with lifting slings.
6.
CAUTION!
The complete wrist unit weighs 187 kg! All lifting

7. Slightly raise the wrist unit to unload the screw joint,
facilitating removal of the attachment screws.
8. Remove the attachment screws and washer from
the wrist unit.
9. Lift away the wrist unit and place it on a secure
surface. Be careful not to damage the cabling and
the motor connectors while running them through
the wrist during removal!

283
4 Repair
Continued
Refitting, wrist unit
The procedure below details how to refit the complete wrist unit to the robot.
Action
Note
1.
DANGER!
2. Fit the two guide pins in the upper arm tube, in two of Art. no. is specified in Required
the attachment holes for the wrist unit.
3.
CAUTION!
The complete wrist unit weighs 187 kg! All lifting
4. Attach the lifting slings to the wrist unit and lift it to the
upper arm tube.
5. Insert the cabling and connectors through the wrist
unit and match the wrist against the upper arm tube
with guidance from the guide pins.
12 pcs; M12 x 50, 12.9 quality
UNBRAKO. Tightening torque:
115 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints
on page 432 before fitting.
7. Remove the guide pins and secure the two remaining

attachment screws as detailed above.
8. Reconnect the motor connectors to the motors, axes
5 and 6. Fasten the cabling as shown in the cable
layout in the figure Cable layout, wrist unit on page
256.
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
General calibration information
is included in section Calibration
10. Refit any equipment previously removed from the

turning disk.

284
6. Secure the wrist unit with 10 of the 12 attachment

screws and washers.
4 Repair
Continued
Action
Note
11.
DANGER!

285
4 Repair
4.4.4. Replacement of upper arm

Location of upper arm
The upper arm is located on top of the robot as shown in the following figure. The complete
upper arm includes the wrist unit but this section also describes how to remove the upper arm
when there is no wrist unit mounted.
Note! The lifting device is attached differently depending on whether the wrist unit is
mounted on the upper arm or not. The attachment points are shown in the following figure.

286
4 Repair
Continued
xx0200000163
Attachment hole for lifting eye, M12 (if wrist unit is mounted)
Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
Oil plug, draining, gearbox axis 3
Cable harness division; connector R2.M5/6
Motor, axis 3
Motor, axis 4
Attachment screws and washers, upper arm
Sealing, axis 2/3 (between lower arm and gearbox axis 3)
Required equipment
Equipment
Art. no.
Note
Sealing, axis 2/3
3HAC 12443-2
Always use a new sealing when

refitting the upper arm!
Washer, axis 3 (3 pcs)
3HAC 12703-1
To be replaced if damaged.
Guide pins, sealing axis 2/3 80 mm
3HAC 14628-1
For guiding "Sealing, axis 2/3".
Guide pins, sealing axis 2/3 100 mm
3HAC 14628-2
For guiding "Sealing, axis 2/3".
Power supply
24 VDC, max 1,5A

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

beneath the motor cover, when
brakes are released with 24 VDC
power supply.
Lifting eye VLBG M12
3HAC16131-1
Lifting device, upper arm
3HAC15994-1
Lifting tool (chain)
3HAC15556-1
To be used together with lifting

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

436 in part 2 of the Product
manual.

procedures in the step-by-step instructions below.

Removal, upper arm

The procedure below details how to remove the upper arm.
Action
Note
1.
DANGER!

287
4 Repair
Continued
Action
Note
2. Remove all equipment fitted to turning disk.

3. Move the upper arm to a horizontal position.
Rotate axis 4 so that the attachment hole for lifting upper arm on page 286!
eye is faced upwards!
4. Upper arm including wrist unit:
Fit the lifting eye, VLBG M12 to the attachment hole equipment on page 287!
for lifting eye on the upper arm tube.
upper arm on page 286!
Fit one of the pieces included in lifting device, upper
arm to the front attachment for lifting device on the
upper arm.
Upper arm without wrist unit:
Fit thelifting device, upper arm to the both
attachments for lifting device.

figure Location of upper arm on
page 286!
Notice the different attachment
points, depending on whether the
wrist unit is mounted or not!
6. Fasten the lifting tool (chain) onto the lifting eye, the Art. no. is specified in Required
lifting device and an overhead crane.

gearbox, axis 3 on page 188.
8. Disconnect connector R2.M5/6 at the cable

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

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

4 and disconnect all connectors inside the motors.
10. Remove all brackets securing the cabling to the
upper arm by removing their attachment screws
respectively.
11.
The complete upper arm weighs 380 kg (IRB6600,

IRB 6650) without any additional equipment fitted!
(robot model IRB 66X0ID: 437 kg!) Use a suitable
lifting device to avoid injury to personnel!
12. Raise the lifting equipment to take the weight of the
upper arm.
13. In order to release the brake of the axis 3 motor,
Connect to connector R2.MP3
connect the 24 VDC power supply.
+: pin 2
Note! When releasing the brake, the position of the
-: pin 5
upper arm is adjusted to the position given by the
lifting equipment.
14. Carefully remove the attachment screws and
washers, upper arm.

15. Lift the upper arm and place it on a secure surface.

Make sure the lift is done completely level! In case
of necessary adjustments, use the shortening loops
on the lifting tool (chain), but make sure to place the
chain the right way through the loops!

288
CAUTION!
4 Repair
Continued
Action
Note
16. Remove the sealing, axis 2/3 from the lower arm.

Refitting, upper arm

The procedure below details how to refit the upper arm.
Action
Note/Illustration
1.
DANGER!
2. Fit the two guide pins, sealing axis 2/3 in two of

the attachment screw holes on gearbox 3, see
figure to the right.
Guide the new sealing, axis 2/3 into position on
gearbox 3, using the guide pins.
Always use a new sealing when reassembling!

xx0200000166
A. Holes for the guide pins (sealing

axis 2/3).
B. Holes for the upper arm
attachment screws (33 pcs).
C. Holes for the gearbox
attachment screws (not affected
in this instruction).
Fit the lifting eye, VLBG M12 to the attachment equipment on page 287!
hole, lifting eye on the wrist unit.
Shown in the figure Location of upper
arm on page 286!

289
4 Repair
Continued
Action
Fit one of the pieces included in the lifting
device, upper arm to the front attachment for
the lifting device on the upper arm.
Upper arm without wrist unit:
Fit the lifting device, upper arm to the both
attachments for the lifting device on the upper
arm.
Note/Illustration
Attachment points are shown in the
figure Location of upper arm on page
286!
Notice the different attachment points
depending on whether the wrist unit is
mounted or not!
5. In order to release the brake of the axis 3 motor, Connect to connector R2.MP3
connect the 24 VDC power supply, after
+: pin 2
removing the motor cover.
-: pin 5
6. Fasten the lifting tool (chain) onto the lifting eye, Art. no. is specified in Required
the lifting device and an overhead crane.
7.
CAUTION!
The complete upper arm weighs 380 kg
(IRB6600, IRB 6650) without any additional
equipment fitted! (robot model IRB 66X0ID: 437
kg!) Use a suitable lifting device to avoid injury
to personnel!
8. Lift the upper arm and move to its mounting
position.
Make sure the lift is done completely level!
xx0200000165
The rotation tool is used beneath the

motor cover, directly on the motor shaft
as shown in figure above.
A: Rotation tool
10. Fit the three washers to be placed beneath the Shown in the figure Location of upper
attachment screws.
arm on page 286!

290
9. Fit in the gearbox attachment holes with the

attachment holes on the lower arm with the
guide pins.
It may be necessary to turn the gear by rotating
the motor pinion with a rotation tool, motor
beneath the motor cover.
4 Repair
Continued
Action
Note/Illustration
11. Insert 31 of the 33 attachment screws, upper

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

arm on page 286!
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.
12. Secure the lower arm to gearbox axis 3, with

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

before fitting.
13. Remove the guide pins and fit the two

remaining attachment screws. Tighten them as
detailed above!
14. Disconnect the brake release voltage and
remove the rotation tool from the motor.
15. Remove the lifting devices.
16. Refit any cabling removed during the removal
process.
17. Reconnect all connectors inside motors, axis 3
and 4. Refit the motor covers.
18. Reconnect connector R2.M5/6 gently at the

cable harness division point, with 2 screws, M6.
Be careful not to bend the attachment plate
when fastening the screws!
19. Perform a leakdown test.
Detailed in section Performing a leakdown test on page 224.
20. Refill the gearbox with oil.


calibration tools.
22.
DANGER!
291
4 Repair
4.4.5. Replacement of complete lower arm

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

The internal components of the lower arm are located as shown in the figure below:
The figure (1) shows a cut between the lower arm and the gearbox axis 3. The location
of the sealing axis 2/3 is identical between the lower arm and the axis 2.
The figure (2) shows a cut through the lower arm pivot point in axis 2 (item B in the
figure above!).

292
xx0200000255
4 Repair
Continued
xx0200000031
Gearbox
Lower arm
Balancing device piston rod ear
Frame
Shaft hole
201
Sealing, axis 2/3
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft, lower arm
406
Protection plug
409
Protection washer
Required equipment
Equipment, etc.
Art. no.
Note
Bearing
3HAC 12441-2
Always use a new bearing when reassembling!
Sealing, axis 2/3
3HAC 020123-001
Shackle, balancing device
3HAC 020997-1

293
4 Repair
Continued
Equipment, etc.
Art. no.
Note
Puller tool, balancing device 3HAC12475-1

shaft
Lifting tool, lower arm
3HAC14691-1
Tool that may be rent from ABB Robotics.

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

if necessary, when brakes are released.
Hydraulic pump, 80 MPa
3HAC13086-1

(Glycerin)
3HAC021563-012
Puller device, axis 2 shaft
3HAC021563-001
Press device, axis 2 shaft
3HAC021600-001
Press tool, axis 2 bearing
3HAC13527-1
Retaining ring plier
Grease
3HAB 3537-1
For lubrication of the shaft hole.
Isopropanol
1177 1012-208
For cleaning of the shaft.
Standard toolkit

the Product manual.

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

Replacement of lower arm shaft on page
299.

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

arm on page 287.
3. Disconnect and remove the cables from inside

the lower arm.
Release any cable attachments.
Detailed in section Removal, cable


294
Removal, lower arm
4 Repair
Continued
Action
4. Apply the shackle to the balancing device and
raise to unload the weight of the device.
Note/Illustration
Attachment is shown in the figure
Location of lower arm on page 292.
5. Unload the balancing device in order to make the Detailed in sectionUnloading the
piston rod and front ear adjustable when pulling balancing device on page 331.
the front shaft out.
6. Remove the securing screw from the balancing
device front shaft.
Shown in the figure Location of lower

arm on page 292.
7. Apply the puller tool, balancing device shaft to the

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

puller tool is M20. Do not mix up with
the shaft press tool used when
mounting the shaft.
8. Lower the balancing device until it rests safely
against the bottom of the frame.
9. Move the lower arm backwards to the lowest

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


12.
CAUTION!
The lower arm weighs 160 kg! All lifting
13. Raise the tool to unload the lower arm.
14. Remove the lower arm shaft and all additional
components, as detailed in section Removal,
lower arm shaft on page 301!

295
4 Repair
Continued
Action
Note/Illustration
15. Remove the attachment screws and washers that Shown in the figure Internal
attach the lower arm to the gearbox axis 2.
components, lower arm on page 292!
16. Lift the lower arm and place it on a secure
surface.
17. Remove the bearing and thrust washer from the Shown in the figure Internal
shaft hole in the lower arm.
On reassembly a new bearing must
be used!
18. Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Internal
On reassembly new sealings must
be used!
Refitting, lower arm

The procedure below details how to refit the lower arm.
Action
Note/Illustration
1.
DANGER!
xx0300000548
A: Attachment holes for the two

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

4. Apply the lifting tool to the lower arm.


296
2. Fit two guidings in the attachment holes of the Art. no. is specified in Required
lower arm.
4 Repair
Continued
Action
Note/Illustration
5.
CAUTION!
The lower arm weighs 160 kg! All lifting
6. Lift the lower arm and move it to its mounting
position.
7. In case the hole pattern of the lower arm and
Connect power supply to connector
the gearbox axis 2 does not match, use power R2.MP2
supply to release the motor axis 2 brakes and
+: pin 2
rotate the pinion and gear with the rotational
-: pin 5
tool.
xx0200000165
The rotation tool (A) is used beneath

the motor cover, directly on the motor
shaft as shown in figure above.
8. Disconnect the power supply, if used.

9. Secure the lower arm with 16 of the
18 pcs: M16 x 50, tightening torque:
18attachment screws and washers in gearbox, 300 Nm.
axis 2.
detailed in section Screw joints on
page 432 before fitting.
Shown in the figure Internal
10. Remove the guidings and secure the two
remaining screws as detailed above!
11. Refit the lower arm shaft and all additional
components, as detailed in section Refitting,
12. Remove the lifting tool from the lower arm.
13. Refit and restore the balancing device.
Detailed in section Refitting, balancing

device on page 326.
14. Refit the upper arm.
Detailed in section Refitting, upper arm

on page 289.
15. Perform a leak-down test.

297
4 Repair
Continued
Action
Note/Illustration

axis 2 on page 185.
17. Refit and reconnect all cables inside the lower

arm.
Resecure any cable attachments.
Detailed in section Refitting, cable


calibration tools.
19.
DANGER!

298
4 Repair
4.4.6. Replacement of lower arm shaft

Prerequisites
This section details how to remove and refit the lower arm shaft as a step in the procedure of
removing/refitting the complete lower arm. To perform the procedure described in this
section, it is required that the preceding instructions in section Replacement of complete lower
arm on page 292 are followed! These include:
removing the upper arm
removing the cabling in the lower arm
unloading the balancing device and removing the front eye shaft
draining the oil in gearbox axis 2
unloading the lower arm with specific lifting equipment.
Components, lower arm shaft
The figure below shows the components fitted to the lower arm shaft.
xx0300000487
Protection plug
Lower arm shaft (axis 2 shaft)
Thrust washer
Bearing
Protection washer
Retaining ring

299
4 Repair
Continued
Required equipment
Equipment
Art. no.
Note
Bearing
3HAC 12441-2
Always use a new bearing

when reassembling!
3HAC021563-001
3HAC021600-001
3HAC13086-1

(Glycerin)
3HAC021563-012
3HAC13527-1
Retaining ring plier
Isopropanol
1177 1012-208
For cleaning the shaft.
Grease
3HAB 3537-1
For lubrication of the bearing.
Glycerin
For lubrication of the shaft.
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
Puller device for removal of axis 2 shaft
The illustration below shows the puller tool used to remove the lower arm shaft (axis 2 shaft).
xx0400001029
Nipple for the hydraulic pump
Nipple for the glycerin pump

300
4 Repair
Continued
Press device for refitting of axis 2 shaft
The illustration below shows the press tool used to refit the lower arm shaft (axis 2 shaft).
xx0300000485
Nipple for the hydraulic pump
Nipple for the glycerin pump
Indicator
Removal, lower arm shaft

The procedure below details how to remove the lower arm shaft.
If encountering any problems when removing the shaft, contact ABB Robotics!
Action
Note/Illustration
1.
WARNING!
This procedure is a step in the complete procedure
of removing the lower arm! Make sure all the
preceding steps specified in Prerequisites on page
299 are made before removing the lower arm shaft!
2. Remove the protection plug.
Shown in the figure Components,

3. Remove the protection washer and the retaining

ring.

Use a plier for the retaining ring.

301
4 Repair
Continued
Action
4. Fit the puller device to the shaft as shown in the
figure to the right.
Note/Illustration
xx0300000010
6. Increase the pressure of the glycerin pump and, at

the same time, pull out the shaft with the puller tool
by increasing the pressure of the hydraulic pump.
Note! Do not exceed the limit of

maximum pressure classified for
the pumps!
7. Remove the bearing and thrust washer from the

shaft hole in the lower arm, recommendable after
removing the complete lower arm as detailed in
section Removal, lower arm on page 294.

302
5. Fit both the hydraulic pump and the glycerin pump to Art. no. is specified in Required
the puller device.
The attachments on the tool are
shown in figure Puller device for
removal of axis 2 shaft on page
300.
4 Repair
Continued
Refitting, lower arm shaft
The procedure below details how to refit the lower arm shaft.
Action
1. Clean the shaft with isopropanol and lubricate it
with glycerin.
Note/Illustration
2. If the robot is going to work in a water jet application

cell:
Apply Mercasol 3106 on the Support shaft axis 2.
Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
A
A
xx0600003137
A: Mercasol on marked
areas.
3. Push the shaft in by hand.

4. Refit the thrust washer to the shaft.
Also shown in the figure

Components, lower arm shaft on
page 299!
5. Apply the press device, axis 2 shaft against the

shaft.

6. Tighten the M16 nut.
7. Fit both the hydraulic pump and the glycerin pump Art. no. is specified in Required
to the press device.
The attachments on the tool are
shown in the figure Press device for
refitting of axis 2 shaft on page 301.
8. Set the indicator on the press device to zero.
Shown in the figure Press device

for refitting of axis 2 shaft on page
301.
9. 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.
10. Increase the pressure of the both pumps alternately Correct value: 2.45 mm 0.15 mm.
until the correct value is reached with the indicator Note! Do not exceed the limit of
on the press tool.
maximum pressure classified for
the pumps!
11. When a correct value is reached, release the
pressure from the glycerin pump first, then from the
hydraulic pump (approximately 1/2 minute after), in
order to avoid movement of the shaft.
12. Remove the press device, axis 2 shaft.

303
4 Repair
Continued
Action
Note/Illustration
13. Apply grease to the location of the shaft where the Art. no. is specified in Required
bearing is to be mounted.
14. Press in the new bearing with the press tool, axis 2 Always use a new bearing when
bearing.
reassembling!
15. Refit the protection washer and the retaining ring. Shown in the figure Components,
lower arm shaft on page 299.
16. Refit the protection plug.

lower arm shaft on page 299.
17. Proceed with the refitting procedure of the lower

arm, detailed in section Refitting, lower arm on
page 296.
304
4 Repair
4.4.7. Securing the lower arm

General
This section details how to secure the lower arm with a specific fixture prior to performing
certain service activities to the robot.
Attachment points, robot
The special equipment used to secure the lower arm is fitted to the attachment points shown
in the figure below.
xx0400000708
Attachment hole, securing screw
Holes for M12 bolts
Holes for M16 bolts

305
4 Repair
Continued
Required equipment
Equipment, etc
Art. no.
Note
Fixture lower arm
3HAC020729-001
Includes the locking screw for securing the

lower arm.
Standard toolkit
3HAC 15571-1

Standard toolkit on page 436 in part 2 of the
Product manual.
Fixture, lower arm

The attachment bolts, locking screw, adjusters and ring nuts are attached to the fixture tool as
shown in the figure below. Move them to the attachment points shown in the instruction.
Locking screw
Adjusters, 2 pcs
M16 bolts, 4 pcs
Ring nuts, 2 pcs
M12 bolts and washers, 2 pcs
Placeholder

306
4 Repair
Continued
Securing the lower arm
The procedure below details how to secure the lower arm by fitting the fixture to the robot.
Action
Note/Illustration
1.
DANGER!
2. Remove any load or equipment fitted to the upper
arm or turning disk.
3. Move the robot to the calibration position. The upper
arm can be directed in three different ways, shown in
The lowered position, as in figure A, is
recommended as it gives the least load on the tool.
xx0200000260
4. If the robot is fitted with moveable mechanical stops

on axis 2 (not stock equipment), these must be
removed at this point.
The attachment holes of the mechanical stops are
used to attach the fixture.
5. Remove the locking screw from the fixture, where it Shown in the figure Fixture, lower
is attached.
arm on page 306.
Art. no. of the fixture is specified in
6. Secure the lower arm to the frame by inserting the
locking screw into a specific attachment hole
through the frame, into the lower arm.
Shown in the figure Attachment

points, robot on page 305.

307
4 Repair
Continued
Action
7. Fit the fixture, lower arm to the frame and the lower
arm, according to following instruction:
1. Fit the both adjusters in the correct holes and
make sure that they are screwed back (C).
2. Align the fixture with the frame and lower
arm.
3. Make sure the fixture is pressed tightly
against the lower arm before securing with
screws!
4. Fit and tighten the four M16 bolts in the
attachment holes on the inside of the frame
with tightening torque: 220 Nm (A).
5. Screw in the two adjusters until they rest
against the flats on the lower arm. Tighten by
hand.
6. Lock, using the two ring nuts.
7. Fit and tighten the two M12 bolts in the
attachment holes on the lower arm with
tightening torque: 91 Nm (C).
Note/Illustration
Attachment holes on the frame
and on the lower arm are shown in
the figure Attachment points, robot
on page 305!
The adjusters, bolts and ring nuts
are shown in the figure Fixture,
lower arm on page 306.
A: Holes for M16 bolts.

Choose the 2 suitable
holes for current robot
model.
B: Holes for M16 bolts.
C: Holes for M12 bolts (2
pcs), adjusters, ring nuts
and washers. Choose the
suitable holes for current
robot model.
8. The lower arm is now secured and it is safe to

remove the gearbox of axis 2, according to section
Removal, gearbox axis 2 on page 393, provided that
the balancing device is unloaded.
308
xx0300000610
4 Repair
4.5.1. Replacement of SMB unit
4.5 Frame and base

Location of SMB unit
The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame
as shown in the figure below.
xx0200000203
SMB cover
SMB unit
Pins
Battery cable
Required equipment
Equipment, etc.
Spare part no.
SMB unit
3HAC 16014-1
Art. no.
Note
Brush
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
Standard toolkit

Product manual.
Circuit Diagram


309
4 Repair
Continued
Removal, SMB unit
The procedure below details how to remove the SMB unit.
Action
Note

2.
DANGER!
3.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 40
4. Remove the SMB cover by unscrewing its
attachment screws.

SMB unit on page 309!
5. Remove the connectors X8, X9 and X10 from the

brake release board, if need of more space.
6. Remove the nuts and washers from the pins securing Shown in the figure Location of
the board.
SMB unit on page 309!
7. Gently disconnect the connectors from the SMB unit Connectors R1.SMB1-3,
when pulling the board out.
R1.SMB4-6 and R2.SMB
SMB unit on page 309.
8. Disconnect the battery cable from the SMB unit.

310
4 Repair
Continued
Refitting, SMB unit
The procedure below details how to refit the SMB unit.
Action
Note
1.
DANGER!
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
3. Connect the battery cable to the SMB unit.

unit on page 309.
4. Connect all connectors to the SMB board and fit Art. no. is specified in Required
the SMB unit onto the pins.
unit on page 309!
R1.SMB1-3, R1.SMB4-6 and R2.SMB
5. Secure the SMB unit to the pins with the nuts and
washers.
6. If disconnected, reconnect the connectors X8, X9

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

unit on page 309!
8. Update the revolution counter!
Detailed in chapter Calibration section Updating revolution counters

on page 415!
9.
DANGER!

311
4 Repair
Continued
Replacement of SMB unit (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedure with the following
additions.
Action
Note/Illustration
1.
DANGER!
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
40
3. Remove the SMB unit according to step 4 - 8 in
Removal, SMB unit on page 310
4. Refit the new SMB unit according to step 3 - 6 in
Refitting, SMB unit on page 311
5.
NOTE!
Make sure that the gasket under the SMB cover is

not damaged!
6. Apply rust preventive on the surface around the
SMB cover and under/on top of the screw heads.
7. Perform a leakdown test according to Inspection of
air hoses (Foundry Prime) on page 176.
312
4 Repair
4.5.2. Replacement of brake release unit

Location of brake release unit
The brake release unit is located together with the SMB unit on the left hand side of the frame,
right next to the gearbox, axis 2, as shown in figure below.
xx0200000226
Brake release unit
Attachment screws, brake release unit (4 pcs)
Buttons
SMB cover
Push button guard
Required equipment
Equipment, etc.
Art. no.
Note
Brake release unit with buttons
3HAC 16035-1
Located together with the SMB-unit at

the left hand side of the frame.
Standard toolkit

the Product manual.



313
4 Repair
Continued
Removal, brake release unit
The procedure below details how to remove the brake release unit.
Action
Note/Illustration
1.
DANGER!
2.
esd
WARNING!
ESD! on page 40
3. Remove the push button guardfrom the SMB Shown in the figure Location of brake
cover.
release unit on page 313.
The guard must be removed to ensure a
correct refitting of the brake release unit.
4. Open the SMB cover by unscrewing the
attachment screws.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
Shown in the figure Location of brake

release unit on page 313!
6. Disconnect the connectors X8, X9 and X10

from the brake release unit.
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons
Location of brake release unit is shown
in the figure Location of brake release
unit on page 313!

314
5. Remove the complete brake release unit

(including brake release unit and bracket)
from the SMB recess, by removing its two
attachment screws.
4 Repair
Continued
Action
Note/Illustration
7. Remove the brake release unit from the

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

The procedure below details how to refit the brake release unit.
Action
Note/Illustration
1.
DANGER!
2.
esd
WARNING!
ESD! on page 40
3. Fasten the brake release unit on the bracket

with the attachment screws.
Make sure the unit is positioned as straight as
possible on the bracket! The push buttons can
otherwise get jammed when the SMB cover is
refitted.

4. Connect the connectors X8, X9 and X10 to the

brake release unit.
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons

315
4 Repair
Continued
Action
Note/Illustration
5. Refit the complete brake release unit

(including brake release unit and bracket) to
the SMB recess with the two attachment
screws.
6. Refit the SMB cover with its attachment
screws.
The push button guard must not be mounted
on the cover before the check described below
is made!
7.
WARNING!
WARNING - The brake release buttons may
be jammed after service work on page 39!
8. Refit the push button guardto the SMB cover.

release unit on page 313.
9. If the battery has been disconnected the

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

page 415.
10.
DANGER!

316
4 Repair
4.5.3. Replacement of spherical roller bearing, balancing device

Location of bearing
The bearing is located at the front ear of the balancing device, as shown in the figure below.
xx0500002249
Spherical roller bearing
Sealing ring
O-ring
Sealing spacer
Front ear of balancing device
Required equipment
Equipment
Spherical roller
bearing
3HAA 2167-18
Sealing spacer
3HAC 12649-1
2 pcs required.
O-ring
3HAB 3772-75
2 pcs required.
Sealing ring
3HAC 11581-5
Grease
Note
2 pcs required.
3HAB 3537-1
For lubrication of the components.

317
4 Repair
Continued
Equipment
Toolkit
3HAC
021984-001
Other tools and

procedures may
be required. See
references to
these procedures
in the step-by-step
instructions below.
Note
Includes:
Threaded bar 3HAC15945-1
Dolly 3HAC15948-2
Press tool 3HAC15941-2
Press tool 3HAC15846-2
Hexagon nut M12 9ADA267-9
Plain washer 9ADA312-9
The tools in the set are shown in the
figure Tool set on page 318.
Tool set
The parts of the tool set for replacement of the spherical roller bearing are shown in the figure
below.
Threaded bar
Dolly
Press tool for removal of bearing
Press tool for refitting of bearing
Hexagon nut, M12 (2 pcs)
Plain washer 13x24x2,5 (2 pcs)
xx0500002259

318
4 Repair
Continued
Removal, bearing
The procedure below details how to remove the bearing from the balancing device front ear.
Action
Note/Illustration
1.
DANGER!
2. Remove the balancing device from the robot. Detailed in section Removal,
balancing device on page 325.
3. Remove the both sealing spacers with a
screwdriver or any equal tool.

bearing on page 317.
4. Insert the threaded bar through the bearing.

5. Fit the press tool and dolly to the threaded bar.
Secure with the nut and washer at each end.
xx0500002255
A. Threaded bar 3HAC15945-1

B. Dolly 3HAC15948-2
C. Press tool 3HAC15941-2
6. Press out the bearing from the front ear.
Refitting, bearing
The procedure below details how to refit the bearing to the balancing device front ear.
Action
Note/Illustration
1.
DANGER!
2. Grease the inside walls of the front ear.

319
4 Repair
Continued
Action
Note/Illustration
3. Insert the threaded bar through the new

Spare part no. is specified in
bearing and place it at the front ear. Fit also the Required equipment on page 317.
press tool and the dolly to the bar as shown in
Secure with the nut and washer at each end.
xx0500002257

4. Press in the bearing properly inside the ear.
5. Apply grease to the new sealing rings and orings and fit one of each to the new sealing
spacers. Also, grease the sealing spacers.
Spare part no:s are specified in

xx0500002258

7. Refit the balancing device to the robot.
Detailed in section Refitting,

8. Lubricate the spherical roller bearing in the ear. Detailed in section Lubrication of
Note! The balancing device must be mounted spherical roller bearing, balancing
device on page 203.
on the robot when lubrication is performed!
9. Make sure no incorrect leakage occures. It
could indicate damaged o-rings.
Further information is available in

section Check for leakage on page
156.

320
6. Press in the sealing spacers with the press

tools, as shown in the figure to the right.
Secure the press tool and dolly with nuts and
washers.
Note! Fit the sealing spacers one at a time!
4 Repair
Continued
Action
Note/Illustration
10.
DANGER!

321
4 Repair
4.5.4. Replacement of balancing device

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

322
4 Repair
Continued
Attachment points, balancing device
The attachment points for the lifting tools etc. are located as shown in the figure below.
xx0300000482
Lifting eye for the lifting equipment
Securing screw attachment hole, secures the bearing attachment to the balancing
device (remove the protection plug)
Hole in the frame to access the balancing device shaft with the puller/press tool
Locking screw attachment hole, secures the lower arm to the frame
Required equipment
Equipment
Spare part no.
Art. no.
Note
Balancing device
(IRB 6600 and IRB
6600ID)
3HAC 020691-001
IRB 6600
Includes balancing device
3HAC 17117-2!
Includes end cover gasket
3HAC 17188-1.
Balancing device
(IRB 6650 and IRB
6650ID)
3HAC 020692-001
IRB 6650
Includes balancing device
3HAC 17117-3!
Includes end cover gasket
3HAC 17188-1.

323
4 Repair
Equipment
Art. no.
Note
Gasket, end cover
3HAC 17188-1
To be replaced if damaged!
Locking screw
3HAA1001-266
M16 x 60
For securing the lower arm.
Securing screw
9ADA 183-66
M12 x 35, 2 pcs required

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

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

For lubrication of spherical
roller bearing in ear, in case
of new balancing device.
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
Locking liquid
Loctite 243
To apply to the securing
screw in the shaft.
Grease pump
To lubricate spherical roller

bearing.
3HAC13120-5

pairs!
Shackle, balancing
device
3HAC 020997-1
3HAC15556-1
Press tool, balancing

device
3HAC020902-001
Puller tool, balancing

device shaft
3HAC12475-1

device shaft
3HAC17129-1
Hydraulic cylinder
3HAC11731-1
To be used with the press

and puller tools.
Hydraulic pump, 80
MPa
3HAC13086-1
To be used with the

hydraulic cylinder.
Standard toolkit

Product manual.
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
Spare part no.

required.

324
Continued
4 Repair
Continued
Removal, balancing device
The procedure below details how to remove the balancing device.
Action
Note/Illustration
1. Move the lower arm to a position close to the

calibration position.
2.
DANGER!
3. Secure the lower arm to the frame by inserting Attachment hole for the locking screw
the locking screw into the attachment hole in
is shown in the figure Attachment
the frame.
points, balancing device on page 323.
4.
CAUTION!
The balancing device weighs 210 kg! All lifting

5. Fit the shackle to the balancing device and
raise to unload the weight.

Attachments are shown in the figure
Attachment points, balancing device
on page 323.
6. Unload the balancing device with the press tool

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

Detailed in section Unloading the
7. Remove the securing screw from the balancing Shown in the figure Location of
device shaft.
balancing device on page 322!
8. Apply the puller tool, balancing device shaft to
the shaft through the hole in the frame.
The shaft has a M20 thread diameter, as shown
in the figure to the right.
Pull the shaft out using the puller tool and the
hydraulic pump.
xx0300000056
Note! The dimension of the shaft

puller tool is M20. Do not mix up with
the shaft press tool used when
mounting the shaft.
The hole in the frame is shown in the
figure Attachment points, balancing
device on page 323!

325
4 Repair
Continued
Action
9. Restore the balancing device.
10. Secure the two bearing attachments to the
balancing device by replacing the protection
plug on the outside of each attachment, with
securing screws.
The protection plugs must be refitted after
refitting the balancing device, do not loose
them!
Note/Illustration
Detailed in section Restoring the
Shown in the figure Attachment points,
Dimensions for the securing screws
are specified in Required equipment
on page 323.
11. Remove the two bearing attachments from the Shown in the figure Location of
frame by unscrewing their four attachment
screws.
Make sure the parallel pins inside are
not lost!
12. Fit two guide pins through the upper holes of
the bearing attachments, to the frame.

13. Lift the balancing device gently backwards to a Note! Make sure not to burden the
secure area, allowing the bearing attachments guide pins with the weight of the
to slide on the guide pins.
balancing device!
Refitting, balancing device

The procedure below details how to refit the balancing device.
Action
Note
1.
DANGER!
2. Secure the lower arm to the frame by inserting Art. no. is specified in Required
the locking screw into the attachment hole in
the frame.
Attachment hole is shown in the
device on page 323.
3. Secure the bearing attachments to the
balancing device with securing screws.
Shown in the figure Attachment

points, balancing device on page
323!
Dimension of the securing screws is
page 323.
4. Refit the two parallel pins in the frame.

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

frame, where the bearing attachments are to be
attached.

326

4 Repair
Continued
Action
6. Fit the shackle to the balancing device.
Note
Attachments are shown in the figureAttachment points, balancing device
on page 323.
7.
CAUTION!
The balancing device weighs 210 kg! All lifting
8. Lift the balancing device and bring it forward, Note! Make sure not to burden the
gliding the bearing attachments on to the guide guide pins with the weight of the
pins.
balancing device!
9. Remove the guide pins.
10. Secure the rear of the balancing device by
fastening the two bearing attachments to the
frame with their four attachment screws.

4 pcs, M16x70, 12.9 quality
UNBRAKO, tightening torque: 300
Nm.
11. Remove the screws from outside of the bearing

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

the balancing device shaft may be inserted
through the piston shaft front eye.
13. Unload the balancing device with the press
tool.
Detailed in section Unloading the

For an easier reassembling of the
shaft, the piston rod may be pressed
out more than necessary and then
pressed in when fitting the shaft.
14. Lubricate the shaft with grease.

15. Apply the shaft press tool to the lubricated

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

device on page 323!
Note! Make sure the shaft is pressed
all the way to the bottom.
16. Refit the securing screw into the shaft using

locking liquid.

Locking liquid is specified in

327
4 Repair
Continued
Action
Note
17. Lubricate the bearing in the ear with grease

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

Lubrication is further detailed in
section Lubrication of spherical roller
bearing, balancing device on page
203.

19.
DANGER!
The rear cover of the balancing device is a
safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the robot!
20. Remove the locking screw that secures the
lower arm to the frame.
xx0300000483
A. Attachment hole for the

securing screw.
21.
DANGER!

328
4 Repair
Continued
Replacement of balacing device (Foundry Prime)
The repair must be done according to the repair chapter in the Product Manual with the
following additions.
Action
Note/Illustration
1.
DANGER!
2. Pull out the sealing spacers out, they shall still
remain on the ear.
Apply rust preventive abundantly in the
gap
press the sealing back in place
wipe off surplus material.
xx0600003131
A: sealing spacers
3. Apply Mercasol 3106 to the shaft and hole in

frame.
xx0600003130
A: Mercasol on shaft and in

hole
B: Mercasol between piston
rod and ear

329
4 Repair
Continued
Action
Note/Illustration
4.
DANGER!

330
4 Repair
4.5.5. Unloading the balancing device

Prerequisite
This section details how to unload the balancing device with the press tool.
The lower arm must be secured before unloading the balancing device! How to secure the
lower arm is detailed in the current repair activity, e.g removal of the balancing device.
Press tool and hydraulic cylinder
The figure below shows the hydraulic cylinder mounted on the press tool.
The press tool includes two press devices that are used to different models of the balancing
device.
xx0200000174
Press block
Hydraulic cylinder
Press device
Bolt, press device
Moving pin with marking
Bolt (4 pcs)
Pin, attached to the fix plate

331
4 Repair
Continued
Required equipment
Equipment, etc.
Art. no.
Note
Press tool, balancing device
3HAC020902-001
Includes
press device 3HAC 15767-2
press device 3HAC 18100-1
Choose the correct device, depending
on model of balancing device.
Hydraulic cylinder
3HAC11731-1
To be used with the press tool.
3HAC13086-1
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 17117-2 (IRB 6600), 3HAC 17117-3

(IRB 6650)
Art. no: 3HAC 18100-1
xx0300000599
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
334.
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 332.
The moving pin is shown in the figure
Press tool and hydraulic cylinder on
page 331.
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 331.
device.
Note! Make sure the bolt is secured properly!

332
xx0300000602
4 Repair
Continued
Action
Note/Illustration
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 gasket 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 331!
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 hydraulic
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.
333
4 Repair
4.5.6. 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.
Press block
Hydraulic cylinder
Press device
Bolt, press device
Moving pin with marking
Bolt (4 pcs)
Pin, attached to the fix plate
Required equipment
The different designs of the balancing device are sealed in different ways beneath the rear
cover of the balancing device.
Equipment, etc.
Art. no.
Note
Hydraulic cylinder
3HAC11731-1
To be used with press tool.
3HAC13086-1
To be used with hydraulic cylinder.

334
xx0200000174
4 Repair
Continued
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.
Gasket, end cover
3HAC 17188-1
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.
Action
1. Refit the hydraulic cylinder to the press tool, in
case it has been removed.
Note/Illustration
Shown in the figure Press tool and
hydraulic cylinder on page 334!
2. Apply Mercasol 3106 between piston rod and ear. See illustration above.
3. 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".

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

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

5. Remove the hydraulic cylinder.

6. Remove the press tool by unscrewing the bolts.

7. Refit the gasket to the rear of the balancing

device.
8. Refit the rear cover to the balancing device with

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

torque: 50 Nm.

335
4 Repair
Continued
Action
Note/Illustration
9.
DANGER!
The rear cover of the balancing device is a safety

device for the piston rod during operation! Make
sure the cover is properly secured before commissioning of the robot!
336
4 Repair
4.6.1. Replacement of motor, axis 1
4.6 Motors
Location of motor
The motor axis 1 is located on the left hand side of the robotas shown in the figure below.
xx0200000200
Motor, axis 1
Motor attachment screws and washers
Required equipment
Equipment, etc.
Spare part no.
Art. no.
Motor including pinion 3HAC 15879-2

3HAC15879-3
(Foundry Prime)
3HAC027316-001
(Foundry Prime)
Note
Includes
motor
pinion
o-ring 2152 2012430.
O-ring
2152 2012-430

reassembling motor!
Sikaflex 251FC
3HAC026620-001
Option Foundry Prime
Mercasol 3106
3HAC026621-001
Gasket
3HAC3438-1

Must be replaced if the
cabling is dismantled from
the motor.

337
4 Repair
Continued
Equipment, etc.
Spare part no.
Art. no.
Note
Grease
3HAB 3537-1
Used to lubricate the oring.
Removal tool, motor

M12x
3HAC 14631-1
Always use the removal

tools in pairs!
Lifting tool, motor ax 1,

4, 5
3HAC 14459-1
Power supply
24 VDC, max. 1,5 A

Standard toolkit

on page 436 in part 2 of
the Product manual.
Calibration Pendulum
toolkit
3HAC15716-1
Complete kit that also

includes operating
manual.
Other tools and

procedures may be
required. See
references to these
procedures in the
Circuit Diagram

required.
See chapter Circuit

Removal, motor axis 1

The procedure below details how to remove motor, axis 1.
Action
Note/Illustration
1.
DANGER!
2. Remove the cover for connector access on top of
the motor by unscrewing its four attachment screws.

338
4 Repair
Continued
Action
Note/Illustration
3. Remove the cable gland cover at the cable exit by

unscrewing its two attachment screws.
xx0200000199
A: Cable gland cover

Make sure the gasket is not
damaged!
4. Disconnect all connectors beneath the motor cover.
5. Apply lifting tool, motor axis 1, 4, 5 to the motor.

6. In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1
power supply.
+: pin 2
-: pin 5
7. Remove the motor by unscrewing its four
attachment screws and plain washers.

motor on page 337!
8. If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 337!
holes.
Always use the removal tools in
pairs!
9.
CAUTION!
The motor weighs 25 kg! All lifting equipment used
must be sized accordingly!
10. Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
11. Remove the motor by gently lifting it straight up.
Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.
Action
Note
1.
DANGER!
2. Make sure the o-ring on the circumference of the Art no. is specified in Required
motor is seated properly. Lightly lubricate the o-ring equipment on page 337!
with grease.

339
4 Repair
Continued
Action
Note
3.
CAUTION!
4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in Required
5. In order to release the brake, connect the 24 VDC
power supply.

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

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

correct way, i.e. connection of
motorcableforwards..
Make sure the motor pinion does
not get damaged!
7. Secure the motor with its four attachment screws

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

Nm.
8. Disconnect the brake release voltage.

9. Reconnect all connectors beneath the motor cover.
10. Refit the cable gland cover at the cable exit with its Make sure the cover is tightly
two attachment screws.
sealed!
11. Refit the motor cover with its four attachment
screws.
Make sure the cover is tightly

sealed!
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration tools.
13.
DANGER!

340
4 Repair
Continued
Replacement of the motor axis 1 (Foundry Prime)
Action
Note/Illustration
1.
DANGER!
the motor by unscrewing its four attachment
screws.
B
A
C
xx0600002874
A: attachment screw
B: air hose
C: top cover
D: motor unit
3.
note
NOTE!
Keep the old top cover, with the air nipple
mounted.
4. Remove the motor unit, according to step 5 to 12
in Removal, motor axis 1 on page 338.

341
4 Repair
Continued
Action
Note/Illustration
5. Fill the four screw recesses on the new motor with

Sikaflex. (After hardening, Sikaflex can be formed
with a knife)
xx0600002875
A: motor unit
B: Sikaflex in screw
recesses
6. Continue to refitt the new motor according to,

Refitting, motor axis 1 on page 339.
7. After mounting the motor on the manipulator, the
surface between the motor and the base frame
must be protected with Mercasol 3106.
xx0600002877
A: base frame
B: motor unit
8. Perform a leak test according to Inspection of air

hoses (Foundry Prime) on page 176
342
4 Repair
4.6.2. Replacement of motor axis 2

Location of motor
The motor, axis 2, is located on the left hand side of the robot as shown in the figure below.
xx0400001067
Motor, axis 2
Hole for locking screw
Cable gland cover (located on the lower side of the motor)
Motor attachment holes (4 pcs)
Required equipment
Equipment, etc.
Spare part no.
Motor including pinion
3HAC 021030-001
Art. no.
Note
Includes
motor
pinion
o-ring 2152 2012430
O-ring
2152 2012-430

reassembling motor!
Sikaflex 251FC
3HAC026620001
Option Foundry Prime.

343
4 Repair
Equipment, etc.
Spare part no.
Art. no.
Note
Gasket
3HAC3438-1

cablling is dismantled from
the motor.
Grease
3HAB 3537-1
For lubricating the o-ring.
Locking screw
3HAA 1001-266 M16 x 60

For securing the lower arm.
Removal tool, motor

M12x
3HAC 14631-1

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

Guides are to be used in
pairs!
Lifting tool, motor ax 2, 3,

4
3HAC 15534-1
Extension bar, 300 mm

for bits 1/2"
3HAC 12342-1
Power supply
24 VDC, 1.5 A
Rotation tool
3HAC 17105-1
Used to rotate the motor

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

Product manual.
toolkit
3HAC15716-1

includes operating manual.
Other tools and

procedures may be

required.
Circuit diagram
See chapter Circuit

Removal, motor
The procedure below details how to remove the motor, axis 2.
Action
1. Move the robot to a position close enough to its
calibration position, to allow the lock screw to be
inserted into thehole for lock screw .
Note
motor on page 343!

344
Continued
4 Repair
Continued
Action
Note
2.
DANGER!
3. Lock the lower arm by inserting the lock screw into Art. no. and dimension is specified
the hole.
in Required equipment on page
343!
4. Drain the oil from gearbox, axis 2.

5. Remove the cover on top of the motor by

unscrewing its four attachment screws.
6. Remove the cable gland cover at the cable exit by Shown in the figure Location of
motor on page 343!
damaged!
7. Disconnect all connectors beneath the motor
cover.
8.
Use the lock screw to lock the lower

arm, as detailed above!
DANGER!
Secure the weight of the lower arm properly before
releasing the brakes of motor, axis 2!
When releasing the holding brakes of the motor,
the lower arm will be movable and may fall down!
9. In order to release the brake, connect the 24 VDC Connect to connector R2.MP2
power supply.
+: pin 2
-: pin 5
11. Fit the two guide pins in two of the motor
attachment holes.

motor on page 343!
the removal tool, motor to the remaining motor
attachment holes.
motor on page 343!
pairs!
13. Remove the removal tools and fit the lifting tool,
motor axis 2, 3, 4 to the motor.


345
4 Repair
Continued
Action
Note
14.
CAUTION!
15. Lift the motor to get the pinion away from the gear. Make sure the motor pinion does
not get damaged!
16. Remove the motor by gently lifting it straight out
and place it on a secure surface. Disconnect the
brake release voltage.
Refitting, motor
The procedure below details how to refit the motor axis 2.
Action
Note/Illustration
1.
DANGER!
2. Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 343!
the o-ring with grease.
4. Fit the lifting tool, motor axis 2, 3, 4 to the

motor.

5. Fit the two guide pins in the two lower motor Art. no. is specified in Required
attachment holes.
Shown in the figure Location of motor on
page 343!
6.
CAUTION!
The motor weighs 32 kg! All lifting equipment
7. Lift the motor and guide it on to the guide pins,
as close to the correct position as possible
without pushing the motor pinion into the
gear.
Make sure that the motor is turned the right
direction, i.e. the cables facing downwards.
8. Remove the lifting tool and allow the motor to
rest on the guide pins.

346
3. In order to release the brake, remove the

cover on top of the motor and connect the 24
+: pin 2
VDC power supply.
-: pin5
4 Repair
Continued
Action
Note/Illustration
9. Use the rotation tool in order to rotate the

motor pinion when mating it to the gear (see equipment on page 343!
the figure to the right). Fit the motor, making
sure the motor pinion is properly mated to the
gear of gearbox axis 2 and that it doesnt get
damaged.
xx0200000165

motor cover, directly on the motor shaft
as shown in figure above.
A: Rotation tool
11. Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
and plain washers.
13. Reconnect all connectors beneath the motor Connect in accordance with markings
cover.
on connectors.

page 343!
15. Refit the cover on top of the motor with its four Make sure the cover is tightly sealed!
attachment screws.
16. Remove the lock screw from the hole for lock Shown in the figure Location of motor on
screw.
page 343!
17. Perform a leak down test.
Detailed in Performing a leak-down test

on page 224.

axis 2 on page 185.

calibration tools.
20.
DANGER!

347
4 Repair
Continued
Action
1. Move the robot to a position close enough to its
calibration position, to allow the lock screw to be
inserted into the hole for lock screw.
Note/Illustration
motor on page 343!
2.
DANGER!
3. Lock the lower arm by inserting the lock screw into Art. no. and dimension is specified
the hole.
in Required equipment on page
343!


screws.
B
A
C
xx0600002874
A: attachment screw
B: air hose
C: top cover
D: motor unit

cover.
7.
note
NOTE!
Keep the old top cover with the air nipple
mounted.

348
4 Repair
Continued
Action
Note/Illustration
8.
DANGER!
Secure the weight of the lower arm properly
before releasing the brakes of motor, axis 2!
When releasing the holding brakes of the motor,
the lower arm will be movable and may fall down!
9. Continue to remove the motor unit, according to
step 9 to 17 in Removal, motor on page 344.
with a knife)
xx0600002875
A: motor unit
B: Sikaflex in screw
recesses

Refitting, motor on page 346.

hoses (Foundry Prime) on page 176.
349
4 Repair

Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure below.
xx0200000186
Motor axis 3
Cable gland cover, motor axis 3
xx0600003051
Motor, axis 3

350
4 Repair
Continued
Required equipment
Equipment, etc. Spare part no.
Motor including
pinion
Art. no.
3HAC 15885-2
Note
Includes
motor
pinion
o-ring 2152 2012-430
O-ring
2152 2012-430
Must be replaced when reassembling motor!
Sikaflex 251FC
3HAC026620-001 Foundry Prime
Gasket
3HAC3438-1
Foundry Prime
Removal tool,
motor M12x
Lifting tool, motor
ax 2, 3, 4
3HAC 15534-1
Mech stop ax 3
3HAC 12708-1
May be used to fix axis 3.

Use attachment screws 3HAB
3409-86 (M16 x 60).
Grease
3HAB 3537-1
Removal tool,
motor M12x
3HAC 14631-1
Always use the removal tools

in pairs!
Lifting tool, motor

ax 2, 3, 4
3HAC 15534-1
Mech stop ax 3
3HAC 12708-1
Washers for mech

stop axis 3
3HAA 1001-186
Guide pins M10 x

100
3HAC 15521-1
Guide pins M10 x

150
3HAC 15521-2
Rotation tool
3HAC 17105-1

released with 24 VDC power
supply.
Power supply
24 VDC, max. 1.5 A

Standard toolkit

Product manual.
Calibration
Pendulum toolkit
3HAC15716-1

May be used to fix axis 3.

Use attachment screws 3HAB
3409-86 (M16 x 60).

351
4 Repair
Continued
Equipment, etc. Spare part no.
Art. no.
Note
Other tools and

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

required.
Circuit Diagram
See chapter Circuit diagram in

the Product manual,
Removal, motor
Action
Note/Illustration
1.
DANGER!
xx0300000051
Fit the mechanical stop to the third

and final attachment hole (A),
below the fixed stop (B) in the
upper arm. See the figure above!

4. Remove any equipment hindering access to motor

axis 3.
unscrewing its two securing screws.

motor on page 350!
damaged!
7. Disconnect all connectors beneath the motor cover.

352
2. Unload the upper arm of the robot by either:

Use a fork lift to rest the upper arm onto.
Use lifting slings and an overhead crane to
rest the upper arm.
Use a mechanical stop to rest the upper arm.
Fit the mechanical stop in the attachment
hole (A) with tightening torque: 115 Nm.
The upper arm must be positioned as horizontal as
possible!
4 Repair
Continued
Action
Note/Illustration
8.
DANGER!
Secure the weight of the upper arm properly before
releasing the brakes of motor, axis 3.
When releasing the holding brakes of the motor, the
upper arm will be movable and may fall down!
9. Release the brake by connecting the 24 VDC power Connect to connector R2.MP3
supply.
+: pin 2
-: pin 5
10. Unscrew the motors four attachment screws and
plain washers .

motor on page 350!
11. Fit the two guide pins in two of the motor attachment Art. no. is specified in Required
screw holes.
12. Press the motor out of position by fitting removal
tool, motor to the remaining motor attachment screw equipment on page 351!
holes.
pairs!
13. Apply the lifting tool, motor axis 2 ,3, 4 to the motor. Art. no. is specified in Required
14.
CAUTION!
15. Lift the motor to get the pinion away from the gear.
16. Remove the motor by gently lifting it straight out and Make sure the motor pinion is not
disconnect the brake release voltage.
damaged!
Refitting, motor
Action
Note/Illustration
1.
DANGER!
2. Make sure the o-ring on the circumference of the Art no. is specified in Required
motor is seated properly. Lightly lubricate it with equipment on page 351!
grease.
3. Fit the lifting tool, motor axis 2, 3, 4 to the motor.
Art no. is specified in Required


353
4 Repair
Continued
Action
4. Fit the two guide pins in the two lower motor
attachment holes.
Note/Illustration
motor on page 350!
5.
CAUTION!
The motor weighs 27 kg! All lifting equipment
6. Lift the motor and guide it onto the guide pins, as
close to the correct position as possible without
pushing the motor pinion into the gear.
7. Remove the lifting tool and allow the motor stay on
the guide pins.
8. In order to release the brake, connect the 24 VDC Connect to connector R2.MP3
power supply.
+: pin 2
-: pin 5
Make sure the motor pinion does not
get damaged!
Make sure the motor is turned the
right direction, i.e. the cables facing
forwards.
xx0200000165

motor cover, directly on the motor
shaft as shown in figure above.
A: Rotation tool.
11. Secure the motor with four attachment screws
and plain washers.

50 Nm.

13. Reconnect all connectors beneath the motor
cover.
Connect in accordance with

markings on connectors.
14. Refit the cable gland cover at the cable exit with Make sure the cover is tightly
its two attachment screws.
sealed!
motor on page 350!

354
9. Use the rotation tool in order to rotate the motor

pinion when mating it to the gear!
Fit the motor, making sure the motor pinion is
properly mated to the gear of gearbox, axis 3.
4 Repair
Continued
Action
15. Refit the cover on top of the motor with its four
attachment screws.
Note/Illustration
Make sure the cover is tightly
sealed!
16. Remove the equipment used to unload the upper

arm.
Detailed in section Performing a

leak-down test on page 224.


calibration manual, enclosed with
the calibration tools.
20.
DANGER!

Action
Note/Illustration
1.
DANGER!
2. Remove the motor accordingto step 2 - 4 in
Removal, motor on page 352.

355
4 Repair
Continued
Action
Note/Illustration

screws.
B
A
C
xx0600002874
A: attachment screw
B: air hose
C: top cover
D: motor unit
4.
note
NOTE!
mounted.
5. Continue to remove the motor unit, according to
step 6 to 17 in Removal, motor on page 352.
xx0600002875
A: motor unit
B: sikaflex in screw recesses

Refitting, motor on page 353.
356

with a knife)
4 Repair

Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0200000202
Motor, axis 4
xx0500003050
Motor, axis 4

357
4 Repair
Continued
Required equipment
Equipment, etc.
Spare part no.
Motor including
pinion
3HAC 15889-2
Art. no.
Note
Includes
motor
pinion
o-ring 2152 2012-430
O-ring
2152 2012-430
Must be replaced when reassembling motor!
Sikaflex251FC
3HAC026620-001
Gasket
3HAC3438-1
Lifting tool, motor ax

1, 4, 5
3HAC 14459-1
Removal tool, motor

M10x
2, 3, 4
3HAC 14459-1
1, 4, 5
Grease
3HAC 3537-1
Used to lubricate the o-ring.
Removal tool. motor

M10x
3HAC 14972-1
Always use the removal tools

in pairs!
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Rotation tool
3HAC 17105-1

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

Standard toolkit

Product manual.
Calibration
Pendulum toolkit
3HAC15716-1

Other tools and

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

required.
Circuit Diagram


358

2, 3, 4
4 Repair
Continued
Action
Note
1. Move the robot to a position where the upper Draining of oil is described in section
arm is pointed straight up.
Draining, oil on page 192.
This position enables the motor to be
replaced without draining the gear oil, which
in turn saves time.
Any other position of the upper arm requires
a draining of oil from the gearbox for axis 4.
2.
DANGER!
3. Remove the cable gland cover at the cable
exit of the motor by unscrewing its two
attachment screws.

page 357!
Make sure the gasket is not damaged!

5. Disconnect all connectors beneath the
motor cover.
6. In order to release the brake, connect the 24 Connect to connector R2.MP4
VDC power supply.
+: pin 2
-: pin 5
7. Unscrew the motors four attachment screws Shown in the figure Location of motor on
and plain washers.
page 357!
attachment screw holes.
9. If required, press the motor out of position by Art. no. is specified in Required
fitting removal tool, motor to the motor
Always use the removal tools in pairs!
10. Lift the motor to get the pinion away from the
gear and disconnect the brake release
voltage.
11. Remove the motor by gently lifting it straight Make sure the motor pinion is not
out.
damaged!

359
4 Repair
Continued
Action
Note/Illustration
1.
DANGER!
3. Fit the lifting tool to the motor.
Choose the correct lifting tool:

lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned
vertically
lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned horizontally.
4. In order to release the brakes, connect the

24 VDC power supply.
Connect to connector R2.MP4:

+: pin 2
-: pin 5
5. Fit the two guide pins in two of themotor

attachment holes.

page 357!
6. Fit the motor, with guidance of the pins,

making sure the motor pinion is properly
mated to the gear of gearbox 4.
Make sure the motor pinion does not get

damaged!
2. Make sure the o-ring on the circumference

of the motor is seated properly. Lightly
lubricate the o-ring with grease.

360
4 Repair
Continued
Action
7. Use the rotation tool in order to rotate the
motor pinion when mating it to the gear!
Fit the motor, making sure the motor pinion
is properly mated to the gear, axis 4.
Note/Illustration
Make sure the motor pinion does not get
damaged!
Make sure the motor is turned the right
direction, i.e. the cables facing forwards.
xx0200000165

motor cover, directly on the motor shaft as
shown in figure above.
A: Rotation tool.
9. Secure the motor with four attachment
screws and plain washers.
4 pcs: M8 x 25, tightening torque: 24 Nm.

cover.
12. Refit the cover on top of the motor with its
four attachment screws.
Make sure the cover is tightly sealed!
13. Refit the cable gland cover at the cable exit Shown in the figure Location of motor on
page 357!
14. Perform a leak-down test if gearbox has
been drained.
15. Refill the gearbox with oil if drained.
Detailed in section Filling, oil on page 192.

calibration tools.
included in section Calibration information
on page 409.
17.
DANGER!
test run may cause injury or damage! on
page 38.

361
4 Repair
Continued
Action
Note/Illustration
1.
DANGER!
screws.
B
A
C
A: attachment screw
B: air hose
C: top cover
D: motor unit
3.
note
NOTE!
mounted.
4. Remove the motor unit, according to step 4 to 12
in Removal, motor axis 4 on page 359.

362
xx0600002874
4 Repair
Continued
Action
Note/Illustration

with a knife)
xx0600002875
A: motor unit
B: sikaflex in screw recesses


363
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650

Reused pinion
The pinion in the motor, axis 5, is matched with the beveral gear for axis 5. When the motor
is replaced the pinion must therefore be removed from the dismounted motor and fitted onto
the new motor shaft as detailed in this section.
Location of motor
The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
Motor, axis 5
Upper arm tube
Wrist unit
Required equipment
Equipment, etc.
Spare part no.
Art. no.
Note
3HAC026982-001
(Foundry Prime)
3HAC027319-001
(Foundry Prime)
Motor
Set of shim, motor
3HAC 17484-10
Does not include pinion.

Use the pinion from the
motor to be replaced.
Includes o-ring 2152 2012430.
3HAC 7941-28
Used to obtain the correct

distance between motor
flange and outer surface of
motor pinion.

364
xx0200000204
4 Repair
Continued
Equipment, etc.
Art. no.
Note
O-ring
2152 2012-430

reassembling motor!
Sikaflex 251FC
3HAC026621-001 Option Foundry Prime
Mercasol 3106
3HAC026620-001 Option Foundry Prime
Gasket
3HAC3438-1
Option Faundry Prime

cabling is dismantled from
the motor.
Grease
3HAC 3537-1
Isopropanol
1177 1012-208
For cleaning motor pinion

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

shaft and pinion hole.
Removal tool, motor

M10x
3HAC 14972-1

tools in pairs!
Oil injector / max

500 MPa
3HAC021590-001 For pressing out the pinion,

motor 5.
Motor press pinion
3HAC021883-001 For pressing the pinion on to

the new motor.
Measuring tool
6896134-GN
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Power supply
24 VDC, 1.5 A
Standard toolkit

Product manual.
Other tools and

procedures may be
required. See
references to these
procedures in the
Circuit Diagram
Spare part no.

required.
3HAC025090-001 See chapter Circuit diagram


365
4 Repair
Continued
Removal, motor, axis 5
Action
Note
1.
DANGER!

3. Remove the wrist unit.
Detailed in section Removal, wrist

unit on page 278.
4. Place the wrist unit safely on a workbench, in a

fixture or similar.
8. In order to release the brake, connect the 24 VDC Connect to either:

power supply.
- connector R4.MP5 (in the motor):
+ : pin 2
- : pin 5
- connector R3.MP5 (on the
separate cable, if not removed):
+: pin C
-: pin D

11. If required, press the motor out of position by

fitting removal tool, motor, M10 to the motor

Always use the removal tools in pairs
and diagonally!
12. Lift the motor to get the pinion away from the gear Make sure the motor pinion is not
and disconnect the brake release voltage.
damaged!
13. Remove the motor by gently lifting it straight out. Keep track of the shims between the
motor flange and the wrist housing.
14. Measure the distance between the motor flange, Art. no. is specified in Required
included eventual shims, and the outer surface of equipment on page 364!
the pinion, with measuring tool.
Make a note of the distance.

366

cover and remove theseparate cable of the axis 5
motor.
4 Repair
Continued
Action
Note
15. Press out the pinion from the dismounted motor,

with the equipment included in the oil injector kit.
Note! If the pinion is damaged the complete wrist
unit must be replaced!
Replacing the complete wrist unit is

detailed in section Replacement of
complete wrist unit, IRB 6600 and
IRB 6650 on page 277. Art. no. is
page 364.
Refitting, motor, axis 5

Action
Note
1.
DANGER!

2. Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.

3. Clean the motor pinion and the motor pinion

hole in the motor, with isopropanol.
Note!If the pinion is damaged the complete
wrist unit must be replaced!

Replacing the complete wrist unit is
detailed in section Replacement of
complete wrist unit, IRB 6600 and IRB
6650 on page 277.
4. Apply a thin film of mineral oil to the pinion

shaft and the pinion hole in order to make the
pinion run smoothly and to achieve an even
friction torque when assembling the pinion.

5. Place the motor and pinion in the press fixture. Art. no. is specified in Required
6. Press the pinion onto the new motor and check
the pressing force.
For an axis diameter of 15.5 mm, use min.
pressing force: 18.5 kN and max. pressing
force: 39.5 kN.
If the pressing force is outside the

given range or if the pinion "jumps" in
bit by bit, it must be dismounted,
checked, cleaned and oiled before it is
assembled once again!
7. Measure the distance between the motor

flange and the outer surface of the pinion with equipment on page 364.
the measuring tool.
Modify the distance with shims in order to
obtain the same distance as measured when
dismounting the old motor (+ 0-0,05 mm).

367
4 Repair
Continued
Action
Note
8. In order to release the brake, connect the 24

VDC power supply.
Connect to either:
- connector R4.MP5 (in the motor):
+: pin 2
-: pin 5
- connector R3.MP5 (on the separate
cable, if not removed):
+: pin C
- : pin D

attachment holes.

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

Make sure the motor pinion does not
making sure the motor pinion is properly mated get damaged!
to the gear of axis 5.
11. Secure the motor with four attachment screws 4 pcs: M8 x 25; tightening torque: 24
and plain washers.
Nm.
13. Refit theseparate cable of the axis 5 motor and
reconnect all connectors beneath the motor
cover.
17. Refit the wrist unit.
Detailed in section Refitting, wrist unit

on page 279.
18. Refill the gear with oil.


calibration tools.
20.
DANGER!

368
15. Refit the cover on top of the motor with its four Make sure the cover is tightly sealed!
attachment screws.
4 Repair
Continued
The repair must be done according to the previous repair procedures with the following
additions.
Action
Note/Illustration
1.
DANGER!
2. Perform step 2 - 4 in Removal, motor, axis 5
on page 366
3. Remove the cover for connector access on

top of the motor by unscrewing its four
attachment screws.
xx0600002904
A: attachment screw
B: air hose
C: top cover
D: motor unit
4.
note
NOTE!
Keep the old top cover with air nipple
mounted.
cover and remove the separate cable of the
axis 5 motor.

369
4 Repair
Continued
Action
Note/Illustration
6. Continue to remove the motor unit,

according to step 8 to 15 in Removal, motor,
axis 5 on page 366.
7. Fill the four screw recesses on the new
motor with Sikaflex. (After hardening,
Sikaflex can be formed with a knife)
xx0600002880
A: air hose
B: motor unit
C: sikaflex in screw recesses

9. After mounting the motor in the wrist, the
surface between the motor and the wrist
must be protected with Mercasol 3106.
xx0600002879
A: wrist unit
B: attachment screw (4 pcs)
C: surface to protect with
Mercasol
D: motor unit
10. Perform a leak test according to Inspection

of air hoses (Foundry Prime) on page 176.
370
4 Repair
4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID

Location of motor, axis 5
The motor of axis 5 is located on the bottom side of the wrist, when axis 4 is placed in
calibration position.
xx0500001573
Motor, axis 5
Motor connectors, R3.MP5 and R3.FB5
Wrist side with the axis 5 gearbox
Required equipment
Equipment
Spare part no.
3HAC 023745-003
Art. no.
Note
Includes o-ring 3HAB 377222.
Grease
3HAB 3537-1 For lubricating the o-ring.
Power supply
24 VDC, 1.5A
Allen key and socket
A specific length is required

for accessing the
attachment screws of the
motor. The dimensions are
shown in the figure Removal
tools, motor attachment
screws on page 372.
Standard toolkit

Product manual.
Other tools and

procedures may be
Circuit diagram

required.


371
4 Repair
Continued
Removal tools, motor attachment screws
The figure below shows the required dimensions of the tools, in order to access the
attachment screws of the motor.
xx0500002271
Allen key, 6 mm
Socket, 12 mm
Torque wrench

Action
Note
1. Move axis 4 +90 so that the gearbox of axis 5 is faced

downwards. This makes it possible to remove the motor
without draining the gearbox oil.
2.

3. Disconnect the motor connectors from the axis 5 motor. Shown in the figure Location
of motor, axis 5 on page 371.
4. In order to release the brakes, connect the 24 VDC
power supply to the motor.
Connect to connector
R3.MP5:
+ : pin C
- : pin D
5. Remove the three attachment screws of the motor.
Dimensions of the tools are

specified in the figure
Removal tools, motor
attachment screws on page
372.
6. Remove the motor by gently lifting it straight out. Lift

carefully to get the pinion away from the gear.

372
DANGER!
4 Repair
Continued
The procedure below details how to refit the motor, axis 5.
Action
Note
1.
DANGER!
2. Make sure the o-ring on the circumference of the Article numbers are specified in
motor is seated properly. Replace it if damaged. Required equipment on page 371.
Lightly lubricate the o-ring with grease.
3. In order to release the brakes, connect the 24
VDC power supply to the motor.

+ : pin C
- : pin D

properly mated to the gear of axis 5.
5. Secure the motor with the three attachment
screws and washers.
3 pcs: M8x25. Tightening torque: 24

Nm.
Dimensions of the tools are specified
in the figure Removal tools, motor
attachment screws on page 372.
6. Disconnect the brake release and reconnect the Shown in the figure Location of
motor connectors.
motor, axis 5 on page 371.
8. Refill the axis 5 gearbox with oil, if previously

drained.
Filling is detailed in section Filling, oil,

axis 5 on page 196.

calibration tools.
10.
DANGER!
373
4 Repair

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0200000222
Wrist unit
Motor, axis 6
Required equipment
Equipment, etc.
Spare part no.
3HAC 15991-4
Art. no.
Note
Includes:
motor
pinion
o-ring 2152 2012430

374
4 Repair
Continued
Equipment, etc.
Spare part no.
O-ring
Art. no.
Note
2152 2012-430

reassembling motor!
Merkasol 3106
3HAC026621-001
Sikaflex
3HAC026620-001
3HAC12877-1

replacing motor
Loctite 574
Loctite 480
Gasket
Removal tool, motor
M10x
3HAC 14972-1

tools in pairs!
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Power supply
24 VDC, 1.5 A
Grease
3HAB 3537-1
Standard toolkit

Product manual.
toolkit
3HAC15716-1

Other tools and

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

required.
Circuit Diagram
See chapter Circuit

Removal, motor
Action
Note
1. Move the robot to a position where the motor in axis

6 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
2.
DANGER!

375
4 Repair
Continued
Action
Note
3. Remove the rear motor cover by unscrewing the five

attachment screws.
4. Disconnect all connectors beneath the cover.
5. In order to release the brake, connect the 24 VDC
power supply.

+: pin 2
-: pin 5

A: Tilthouse
B: Motor, axis 6
C: Attachment screws (4
pcs)
removal tool, motor to the motor attachment screw equipment on page 374!
holes.
pairs!
8. Lift the motor carefully to get the pinion away from Make sure the motor pinion is not
the gear and disconnect the brake release voltage. damaged!
9. Remove the motor by gently lifting it straight out.
Refitting, motor
Action
Note
1.
DANGER!
2. Make sure the o-ring on the circumference of the Art. no. is specified in Required
motor is seated properly. Lightly lubricate the o- equipment on page 374!
ring with grease.
3. In order to release the brake, connect the 24
VDC power supply.

+: pin 2
-: pin 5

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 6.
Make sure the pinion on the motor

shaft is not damaged!
A: Tilthouse
B: Motor, axis 6
C: Attachment screws

7. Secure the motor with its four attachment screws 4 pcs: M8 x 25, tightening torque: 24
and plain washers.
Nm.

376

4 Repair
Continued
Action
Note

cover.
10. Refit the cover on top of the motor with its five
attachment screws.
Make sure the cover is tightly sealed!
11.
NOTE!
When changing motor, keep the cover from the
old motor.

calibration tools.
13.
DANGER!

The repair must be done according to the previous repair procedure with the following
additions.
Action
Note/Illustration
1. Move the robot to a position where the motor in

axis 6 is pointed straight up. This position
enables the motor to be replaced without
draining the gear oil, which in turn saves time.
2. Move the robot to one of the recommended
positions:
to a position where the motor in axis 6
is pointed straight up. This position
enables the motor to be replaced
without draining the gear oil, which in
turn saves time.
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.

377
4 Repair
Continued
Action
Note/Illustration
3.
DANGER!
4. In horizontal position: drain the oil from the axis Detailed in section: Draining, oil, axis 6
6 gearbox.
on page 198.
5. Remove the rear motor cover by unscrewing
the five attachment screws.
xx0600002885
A: motor unit 3106

B: attachment screw (5pcs)
C: air nipple
D: rear motor cover
E: gasket
6. Continue to remove the motor unit, according

to step 6 to 11 in Removal, motor on page 375.
7.
note
NOTE!
Keep the old rear motor cover with the air
nipple,

378
4 Repair
Continued
Action
Note/Illustration
8. Fill the four screw recesses on the new motor

with Sikaflex. (After hardening, Sikaflex can be
formed with a knife)
xx0600002884
A: mercasol
B: motor unit
C: attachment screw (4pcs)
D: sikaflex in screw recesses
E: loctite 570
F: tilt house
9. Apply mercasol 3106 on the surface between

tilt house and motor (pinion side), and Loctite
570 between gasket and tilt house.
10. Continue to refitt the new motor according to
step2 - 14, Refitting, motor on page 376.
11. Perform a leak test according to Inspection of
air hoses (Foundry Prime) on page 176
379
4 Repair

Location of motor, axis 6
The motor of axis 6 is located on top of the wrist, when axis 4 is placed in calibration position.
xx0500001574
Motor, axis 6
Motor connectors, R3.MP6 and R3.FB6
Wrist side with axis 6 gearbox inside
Required equipment
Spare part no.
3HAC 023746-003
Art. no.
Note
Includes o-ring 3HAB 3772-22.
Grease
3HAB 3537-1 For lubricating the o-ring.
Power supply
24 VDC, 1.5 A
Allen key and socket
A specific length is required for

accessing the attachment
screws of the motor. The
dimensions are shown in the
figure Removal tools, motor
372.
Standard toolkit

Product manual.
Other tools and

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

required.

380
Equipment
4 Repair
Continued
Equipment
Spare part no.
Circuit diagram
Art. no.
Note
See chapter Circuit diagram in

the Product manual, reference
information.

Action
Note
1. Move axis 4 -90 so that the axis 6 gearbox is facing

downwards. This enables the motor to be replaced
without draining the gearbox oil from axis 6.
2.
DANGER!
3. Disconnect the motor connectors.
Shown in the figure Location

of motor, axis 6 on page 380.
4. In order to release the brakes, connect the 24 VDC

power supply to the motor.
Connect to connector
R3.MP6:
+ : pin C
- : pin D
5. Unfasten the motor by unscrewing its three attachment Dimensions of the tools are
screws and washers.
specified in the figure
Removal tools, motor
372.
6. Remove the motor by gently lifting it straight out. Lift

carefully to get the pinion away from the gear.

The procedure below details how to refit the motor, axis 6.
Action
Note
1.
DANGER!
2. Make sure the o-ring on the circumference of
the motor is seated properly. Ligthly lubricate
with grease.
The article numbers are specified in


381
4 Repair
Continued
Action
3. In order to release the brakes, connect the 24
VDC power supply to the motor.
Note
+ : pin C
- : pin D

properly mated into the gear of axis 6.
5. Secure the motor with its three attachment
screws and washers.
3 pcs, M8x25. Tightening torque: 24

Nm.
Dimensions of the tools are
specified in the figure Removal
tools, motor attachment screws on
page 372.

7. Reconnect the motor connectors.

motor, axis 6 on page 380.
Detailed in section Performing a

leak-down test on page 224.
9. Refill the axis 6 gearbox with oil, if previously

drained.
Detailed in section Filling, oil, axis 6

on page 199.

11.
DANGER!

382
4 Repair
4.7.1. Replacement of gearbox, axis 1
4.7 Gearboxes
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
xx0300000015
Gearbox, axis 1
Frame
Base
Attachment screws, gearbox axis 1 (not shown in figure)
Required equipment
Equipment, etc.
Note
Gearbox
3HAC 10828-8
Includes:
gearbox
all o-rings and sealing
rings
O-ring
3HAB 3772-54
Replace only when damaged!

383
4 Repair
Continued
Equipment, etc.
Note
O-ring
3HAB 3772-55
Sealing ring
3HAC 11581-4
Grease
3HAC 3537-1
For lubricating the o-rings.
Rust preventive
3HAC026621001
Mercasol 3106 (Foundry Prime)
Support, base
3HAC15535-1
Lifting device, base
3HAC15560-1
3HAC15556-1
Standard toolkit
Other tools and

procedures may be
required. See
references to these
procedures in the

436 in part 2 of the Product
manual.
Removal, gearbox axis 1

The procedure below details how to remove gearbox, axis 1.
Action
Note/Illustration
1. Move the robot to its most stable position,

xx0300000022
2.
DANGER!
Detailed in section Draining oil, axis 1 on

page 183.

384
4 Repair
Continued
Action
Note/Illustration
4. Disconnect all cabling in the rear of the

robot 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.
Detailed in section Removal, arm system

on page 262.
7. Remove the robot's 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.

9.
CAUTION!
The base and gearbox weighs 423 kg
together! All lifting equipment must be used
accordingly!
10. Lift the robot base to allow fitting the
support, base and gear 1 on each sides of equipment on page 383!
the base.
11. Fit the support, base.
Make sure the base remains in a stable
position before performing any work
underneath the base!
12. Remove the bottom plate from underneath

the base in order to get access to the
attachment screws. It may be necessary to
also remove the rear connector plate.
xx0300000612
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove

385
4 Repair
Continued
Action
Note/Illustration
13. Unscrew the 18 attachment screws and

remove the 3 washers, shown in the figure
to the right.
xx0200000227
A view from below:

A: Oil drain hose
B: Attachment screws, gearbox
axis 1, 18 pcs
C: Washers, 3 pcs
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)
CAUTION!
The gearbox weighs 160 kg! All lifting
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.
Action
Note/Illustration
1. If the base is not supported with support, base Mounting of the support, base and gear
and gear 1, this should be done first.
1 is detailed in section Removal,

386
15.
4 Repair
Continued
Action
Note/Illustration
2. Make sure the two o-rings (C, D) on the cirArt no. is specified in Required
cumference 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
A: Guide pin
C: O-ring 3HAB 3772-54
D: O-ring 3HAB 3772-55
E: Sealing ring 3HAC 11581-4
3. Refit the cable guide in the center of gearbox

1 with its attachment screws.
xx0200000256
4. Fit the lifting device, base and the lifting tool

(chain) to the gearbox.
A: Location for attachment

screws, cable guide (cable
guide removed in figure)

5.
CAUTION!
6. Lift the gearbox to its mounting position in the
center of the base.
7. Make sure the guide pin in the bottom face of Shown in the figure xx0200000055
the gearbox is properly aligned with the base. above!

387
4 Repair
Continued
Action
Note/Illustration
8. Secure the gearbox and the three washers

18 pcs, M16 x 70, 12.9 quality
with the 18 attachment screws, gearbox axis UNBRAKO, tightening torque: 300 Nm.
1.
before fitting.
xx0200000227
A view from below:

A: Oil drain hose
B: Attachment screws, gearbox
axis 1, 18 pcs
C: Washers, 3 pcs
9. Refit the bottom plate underneath the robot
1 screw: M6 x 8.
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.
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
10.
CAUTION!
The base and gearbox weighs 423 kg
together! All lifting equipment must be used
accordingly!
11. Lift the robot base and gearbox 1 to allow
removing the support, base and gear.
12. Secure the base to the mounting site.
Detailed in section Orienting and

securing the robot on page 78.

388
xx0300000612
4 Repair
Continued
Action
13. Refit the complete arm system.
Note/Illustration
Detailed in section Refitting, arm
system on page 264.
This is a complex task to be performed
with utmost care in order to avoid injury
or damage!
14. Refit the cable support plate inside of the base

and reconnect the cabling in the rear of the
robot base.
Detailed in section Filling oil, axis 1 on

page 184.

calibration tools.
18.
DANGER!
Refitting, gearbox axis 1 (Foundry Prime)

Action
Note/Illustration
1.
DANGER!

389
4 Repair
Continued
Action
Note/Illustration
2. Apply Mercasol 3106 on unpainted areas.
xx0600003132
A: surface on the underside of

the frame
B: Radial sealing gear axis 1,
against base
3.
DANGER!

390
4 Repair
4.7.2. Replacement of gearbox axis 2

TypeA and typeB of robot
The gear of axis 2 differs depending on the type of robot. Read more about the difference in
section Type A and type B of IRB 6600/6650 on page 427.
Location of gearbox
The gearbox for axis 2 is located in the lower arm rotational center, underneath the cover.
xx0400001065
Gearbox axis 2 (behind cover, not shown in figure )
Attachment hole for locking screw, lower arm
Attachment holes inside of frame for fixture, lower arm
Attachment holes for fixture, lower arm
Balancing device
Motor axis 2
Rear attachment screws, gearbox
Attachment screws, cover
Cover, axis 2

391
4 Repair
Continued
Required equipment
Spare part no.
Gearbox axis 2
3HAC 021541-001
Art. no.
Note
Includes
gearbox
o-ring.
Does not include "Sealing,
axis 2/3"!
O-ring
3HAB 3772-77
O-ring
3HAB 3772-73
O-ring in the cover, axis 2,

1 pc. Should be replaced if
damaged!
Rust preventive
3HAC026621-001
Only Foundry Prime

Equivalent:
Mercasol 3106
Sealing, axis 2
3HAC 020123-001 A new sealing must be

used on each assembly!
Grease
3HAB 3537-1
Fixture lower arm
3HAC020729-001
Lifting tool, gearbox

axis 2
3HAC020386-001
Guide pins M12 x

150
3HAC13056-2
For guiding the gearbox.
Guide pins M12 x

200
3HAC13056-3

device
3HAC020902-001
Hydraulic cylinder
3HAC11731-1

tool and the hydraulic
pump, when unloading the
balancing device.
Hydraulic pump, 80
MPa
3HAC13086-1

tool and the hydraulic
cylinder, when unloading
the balancing device.
Guide pins, sealing

ax 2/3, 80mm
3HAC14627-2
For guiding the sealing!
Guide pins, sealing

ax 2/3, 100mm
3HAC14627-3
For guiding the sealing!
Gearbox crank, axis

2
3HAC020999-001
Used to turn the gear in

correct position.
Standard toolkit

Product manual.
Other tools and

procedures may be
required. See
references to these
procedures in the
For lubricating o-rings.

required.

392
Equipment
4 Repair
Continued
The procedure below details how to remove the gearbox, axis 2.
Action
Note/Illustration
1.
DANGER!
2. Secure the lower arm with the special fixture
equipment according to section Securing the lower
arm on page 305.
3. Unload the balancing device shaft by using the press Art. no. is specified in Required
tool, balancing device, according to section
Unloading the balancing device on page 331!
4. Drain the gearbox, axis 2.
Notice! Time-consuming activity!

Detailed in section Removal,

motor on page 344.
6. Remove the rear attachment screws, gearbox from

inside of the lower arm.

7. Remove the cover, axis 2 by unscrewing its 14

attachment screws.

8. Remove the front attachment screws, gearbox,

xx0300000550
A: Front attachment
screws, gearbox (32 pcs)
B: M12 holes for pressing
the gearbox out
9. Fit two guide pins in 180 relation to each other in the Art. no. is specified in Required
empty holes of the front gearbox attachment screws. equipment on page 392!
10. If required, apply two M12 screws to the holes,
shown in the figure above, to press it free.

393
4 Repair
Continued
Action
Note/Illustration
11. Fit the lifting tool, gearbox axis 2 to the gearbox.

12.
CAUTION!
The gearbox weighs 100 kg! All lifting equipment
13. Remove the gearbox axis 2 using an overhead crane
or similar, with guidance from the mounted guide
pins.
14. Remove the sealing from the lower arm.

The procedure below details how to refit the gearbox axis 2.
Action
Note/Illustration
1.
DANGER!
xx0300000551
3. Fit the lifting tool, gearbox axis 2 to the

gearbox.
A: O-ring, gearbox axis 2


394
2. Make sure the o-ring is fitted to the gearbox as Art. no. is specified in Required
shown in the figure to the right. Lightly lubricate equipment on page 392!
it with grease.
4 Repair
Continued
Action
Note/Illustration
4. Fit the guide pins, sealing axis 2/3 to the rear

of the gearbox, axis 2.
Use the attachment holes shown in the figure
to the right!
xx0300000552
5. Fit the new sealing, axis 2/3 on to the guide

pins on the gearbox.
Note! Do not remove the guide pins for the
sealing until the rear attachment screws are
secured.
A: Rear attachment screws,

gearbox (18 pcs)
B: Holes for the guide pins,
sealing axis 2/3 on the gearbox

6. Fit two guide pins, M12 in 180 relation to each Art. no. is specified in Required
other in the frame, in the screw holes for the
gearboxes front attachment screws.
7.
CAUTION!
8. Lift the gearbox to its mounting position and
slide it onto the guiding pins attached in the
frame, through the front attachment screw
holes.
9. Align the gearbox attachment screw holes to
the hole patterns in the lower arm, with help
from the guide pins, sealing axis 2/3.
If necessary, use a gearbox crank to turn the
gear!
Use the gearbox crank with caution! The
gearbox may be damaged if the crank is
inserted too far into the gear!

10. Fit the gearbox with guidance from the guide

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

395
4 Repair
Continued
Action
Note/Illustration
12. Insert and secure 30 of the 32 front attachment 32 pcs: M12 x 60, tightening torque:
screws, gearbox.
115 Nm.
Remove the guide pins, M12 and refit the two
remaining screws.
13. Lubricate the o-ring at the sealing surface of
the cover, axis 2. Replace it if damaged.

14. Refit the cover, axis 2 to the frame with the

attachment screws, cover.

gearbox on page 391.
15. Insert and secure 16 of the 18rear attachment Shown in the figure Location of
screws, gearbox on the inside of the lower arm. gearbox on page 391!
300 Nm.
16. Remove the guide pins, sealing axis 2/3, and
tighten the two remaining screws as detailed
above.
17. Refit the motor.
Detailed in section Refitting, motor on

page 346.


21. Remove the fixture, lower arm.

22. Remove the locking screw, lower arm, and reattach it to the fixture tool.
24. Refit any equipment to the turning disk if such

was removed during disassambly.

calibration tools.
26.
DANGER!

396
23. Refit any mechanical stops if such were

removed during disassembly.
4 Repair
Continued
Action
Note/Illustration
1.
DANGER!
2. Lift the protection ring and apply Mercasol
3106. between gear and protection ring.
A
B
xx0600003135
A: protection ring
B: Mercasol on surface
3. Apply Mercasol 3106 on the gear according to

the illustration to the right before assembly.
xx0600003134
A: Mercasol 3106 on surfaces

397
4 Repair
Continued
Action
Note/Illustration
4. Apply Mercasol 3106 on the lower arm

according to the illustration to the roght before
assembly.
xx0600003135
A: Mercasol 3106 on surfaces
5.
DANGER!

398
4 Repair

Location of gearbox
xx0200000194
Gearbox, axis 3
Motor, axis 3
Upper arm
Attachment screws, gearbox (24 pcs)
Required equipment
Equipment, etc.
Spare part no.
Gearbox
3HAC 021127-001
O-ring
Art. no.
Note
Includes
gearbox
o-ring.
Does not include the
sealing, axis 2/3!
3HAB 3772-68
1 pc on the gearbox.

399
4 Repair
Equipment, etc.
Spare part no.
Art. no.
Note
Grease
3HAB 3537-1
For lubricating the o-rings.
Rust preventive
3HAC026621001
Only Foundry Prime

Equivalent:
Mercasol 3106
Sealing, axis 2/3
3HAC 17212-1
A new sealing must be

used on each assembly!
Mech stop ax 3
3HAC 12708-1
Used to secure the upper

arm. Use attachment
screws 3HAB 3409-86
(M16 x 60).
Washers for mech stop

axis 3
3HAA 1001-186
Lifting eye M12
3HAC14457-3
3HAC13056-3

Use guides in pairs!
3HAC13056-4

Guide pins, sealing ax 2/

3, 80mm
3HAC14628-1
For guiding the sealing,

axis 2/3.
Guide pins, sealing ax 2/

3, 100mm
3HAC14628-2
For guiding the sealing,

axis 2/3.
Standard toolkit

on page 436 in part 2 of
the Product manual.
toolkit
3HAC15716-1

includes operating
manual.
Other tools and

procedures may be

required.

Action
Note/Illustration
1.
DANGER!

400
Continued
4 Repair
Continued
Action
2. Secure the upper arm in a horizontal position
using a mechanical stop.
Fit the mechanical stop to the third and final
attachment hole (A), below the fixed mechanical
stop (B) in the upper arm, shown in the figure to
the right.
Tightening torqure: 115 Nm.
Note/Illustration
xx0300000051
Detailed in section Removal, motor

on page 352.
Note! When removing the motor
axis 3, the brake on axis 3 is
released. Make sure the upper arm
is secured and disabled to move!
4. Remove the upper arm.
Detailed in section Removal, upper

arm on page 287.
5. Remove the sealing, axis 2/3 between the

gearbox and lower arm.
On reassembly a new sealing must

be used! Art. no. is specified in
6. Place the upper arm safely on a workbench, in a

fixture or similar.
7. Remove the attachment screws, gearbox.

8. Fit the two guide pins in 180 relation to each

other in the gearbox attachment screw holes.

9. Fit the lifting eye to the gearbox, in one of the

attachment screw holes that attaches the gearbox equipment on page 399!
to the lower arm (position C in the figure to the
right).
If required, use screws in the holes (A) shown in
the figure to the right to press the gearbox free.
xx0200000201
A: M12 holes for pressing

the gearbox out
B: Attachment screw holes,
gearbox - upper arm
C: Attachment screw holes,
gearbox - lower arm

401
4 Repair
Continued
Action
Note/Illustration
10.
CAUTION!
11. Remove the gearbox, with guidance from the
guide pins, using an overhead crane or similar.

Action
Note/Illustration
1.
DANGER!
2. Turn the upper arm in such a position that the
gear mating surface faces upwards.
3. Fit two guide pins in 180 relation to each other in Art. no. is specified in Required
the holes in the upper arm, used for the gearbox equipment on page 399!
attachment screws.
4.
CAUTION!
5. Fit the lifting eye to the gearbox.


402

4 Repair
Continued
Action
Note/Illustration
6. Make sure the o-rings are fitted to the gearbox.

Apply grease to the o-rings to make sure they
stick in their grooves during assembly.
Make sure the o-ring is fitted to the rear of the
gearbox. Apply grease to it to make sure it sticks
in its groove during assembly!
xx0200000173
7. Lift the gearbox to its mounting position.

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

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

12. Refit the upper arm with a new sealing, axis 2/3 . Art. no. is specified in Required
Detailed in section Refitting, upper
arm on page 289.
13. Refit the motor.
Detailed in section Refitting, motor

on page 353.
14. Remove the mechanical stop used to secure the

upper arm.


403
4 Repair
Continued
Action
Note/Illustration
16.
DANGER!

Action
Note/Illustration
1.
DANGER!
xx0600003138
3.
DANGER!
404
2. Apply Mercasol on surfaces on lower arm and

gear before assembly.
gaps around screw heads and
washers.
4 Repair

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
xx0200000219
Gearbox, axis 6
Attachment screws and washers, gearbox (18 pcs)
Oil plug, draining
Oil plug, filling
O-ring (not shown in figure)
Required equipment
Equipment, etc.
Spare part no.
Gearbox
3HAC 10828-13
Art. no.
Note
Includes o-ring 3HAB 377257.
Washers
3HAA 1001-172
Not included in gearbox!

O-ring
3HAB 3772-58
Must be replaced when reassembling gearbox!
Grease
3HAB3537-1
Rust preventive
3HAC026621-001
Only Foundry Prime

Equivalent:
Mercasol 3106

405
4 Repair
Continued
Equipment, etc.
Spare part no.
Art. no.
Note
Standard toolkit

Product manual.
Calibration
Pendulum toolkit
3HAC15716-1

Other tools and

procedures may be
required. See
references to these
procedures in the

required.
Removal, gearbox
Action
Note/Illustration
1.
DANGER!
axis 6 on page 197.
3. Remove the turning disk.
Detailed in section Removal, turning

disk on page 275.
4. Remove the gearbox by unscrewing its 18

attachment screws.
Shown in the figure Location of gearbox

on page 405.
5. If required, apply M8 screws to the holes

shown in the figure beside to press the gearbox
out.
xx0200000220
A: M8 holes for pressing out the

gearbox

406
4 Repair
Continued
Action
6. Remove the gearbox axis 6 by lifting it out
carefully.
Note/Illustration
Be careful not to damage the motor
pinion!
Refitting, gearbox
Action
Note/Illustration
1.
DANGER!
2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment
the gearbox. Lubricate the o-ring with
on page 405!
grease.
xx0100000132
3. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in Required equipment
on page 405.
Shown in the figure Location of gearbox on
page 405.
Make sure the gears of the gearbox mate
with those of the motor!
4. Secure the gearbox with the attachment
screws and washers.
Shown in the figure Location of gearbox on

page 405.
8 pcs : M8 x 40, 12.9 quality UNBRAKO,
5. Refit the turning disk.
Detailed in section Refitting, turning disk on

page 275.

407
4 Repair
Continued
Action
Note/Illustration
6. If the robot is going to work in a water jet

application cell:
apply Mercasol on unpainted
surfaces between gea box and
turning disk
apply Mercasol on the screw heads
in the front of the turning disk.
xx0600003143
Detailed in section Performing a leak-down

test on page 224.

axis 6 on page 197.

calibration tools.
General calibration information is included
in section Calibration information on page
409.
10.
DANGER!
408

when performing the first test run. These
are further detailed in section DANGER First test run may cause injury or damage!
on page 38.
5.1. Introduction
5.1. Introduction
General
This chapter includes general information about different calibration methods and also details
procedures that do 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 410, 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 415. 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 Abslolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
409
5.2. Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
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, and 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 absacc-compensation 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

410
Types of calibration
Continued
Calibration methods
Each calibration method is detailed in a separate manual. 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.
Two different routines are available for the Calibration Pendulum method:
Calibration Pendulum II
Reference Calibration.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,

including the operating manual for Calibration Pendulum, which describes the method and
the different routines further.
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 does not have as good of 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 operating manual for Levelmeter Calibration is enclosed with the Levelmeter
2000.
CalibWare - Absloute 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 CalibWare 2.0
Users Guide (M2000).
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.
References
Article numbers for the calibration tools are listed in section Special tools on page 437 in part
2 of the Product manual. A calibration manual is enclosed with the calibration tools.
The article numbers for the operating manuals for calibration are also listed in section
411
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.
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, 3 and 6 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.

412
xx0200000176
Continued
Calibration scales/ marks, IRB 6600ID and IRB 6650ID
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.
xx0500002016
Calibration mark, axis 2
Calibration mark, axis 3
Calibration plate, axis 5
Calibration plate, axis 6
Calibration marks at axes 2 and 3

The calibration marks at axes 2, 3 and 6 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.
413
5.4. Calibration movement directions for all axes
5.4. Calibration movement directions for all axes

Overview
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.
Calibration movement directions, 6 axes
Note! The figure shows an IRB 7600, but the positive direction is the same for all 6-axis
robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite
direction!
xx0200000089
414
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 the pendant.
Step 1 - 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.
Action
Note
1. Select axis-by-axis motion mode.

2. Jog the robot to place the calibration marks
within the tolerance zone.
IRB 140, 1400, 2400, 4400, 6600ID/
6650ID: Axes 5 and 6 must be positioned
together!
Shown in section Calibration scales and

3. When all axes are positioned, store the

revolution counter settings.
Step 2 - Storing the revolution counter
setting with the TPU on page 416
(RobotWare 4.0).
Step 2 - Storing the revolution counter
setting with the FlexPendant on page 417
(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 can be
calibrated at the wrong turn, resulting in wrong calibrated robot.
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 correct calibration position will be lost due to
uneven gear ratio. This affects the following robots:
Robot variant
Axis 4
Axis 6
IRB6600-175/2.55
Yes
No
IRB6600/6650 / others
Yes
Yes
IRB6600ID/6650ID
Yes
No
If the calibration marks seem to be wrong (even if the motor calibration data is correct), try
to rotate the axis one turn, update the revolution counter and check the calibration marks
again (try both directions, if needed).

415
Continued
Step 2 - 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).
Action
Note
1. 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.
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.

416
Continued
Action
Note
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 419.
Step 2 - 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).
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
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.

417
Continued
Action
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 419.
418
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
Action
Note
1. Create 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 The calibration marks are shown in
correctly. If they do not, update the revolution
section Calibration scales and
counters!
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 415
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.
Action
Note
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]]\NoEOffs, v1000, z50, Tool0
5. Run the program in manual mode.
6. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution
section Calibration scales and
counters!
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 415.

419
Continued
Using the Jogging window on the TPU, S4Cplus
This section describes how to jog the robot to all axes zero position.
Action
Illustration/Note
1. Open the Jogging window.
xx0100000195
2. Choose running axes-by-axes.
xx0100000196
3. Manually run the robot axes to a position where the

axis position value read on the TPU, is equal to zero.
4. Check that the calibration marks for the axes align
The calibration marks are
correctly. If they do not, update the revolution counters! shown in section Calibration
scales and correct axis position
on page 412.
Detailed in section Updating
revolution counters on page
415.
Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.
Action
Note
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.
5. Check that the calibration marks for the axes align

correctly. If they do not, update the revolution counters!
420
The calibration marks are

shown in section Calibration
scales and correct axis
position on page 412.
How to update the counters
is detailed in section
Updating revolution counters
on page 415.
4. Manually run the robots axes to a position where the axis

position value read on the FlexPendant, is equal to zero.
5.7. Additional calibration instruction, IRB4400

Instrauction
Before updating the revolution counters (coarse calibration) on IRB 4400, the stainless steel
metal ring on axis 4 need to be removed.
Illustration
xx0600003124
Upper arm
Stainless steel ring
hose clamp
421
422
6 Decommissioning
6.1. Environmental information
6 Decommissioning
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:
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.
423
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.
The device must be dismantled by a decommissioning company.
Required equipment
Equipment
Art. no.
Note
Standard toolkit

the Product manual.
Cutting torch
For opening housing and cutting coils

procedures in the step-by-step
instructions below.

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!
Action on field, decommissioning
The procedure below details the actions to perform on field, when the balancing device is to
be decommissioned.
Note
1. Remove the balancing device from the robot. Detailed in section Removal, balancing
device on page 325.
2. Send the device to a decommissioning
company.
Make sure the decommissioning

company is well informed about the
stored energy built up by high tensioned
compression springs and that the device
contains some grease.
The following procedure contains useful
information about decommissioning.

424
Action
6 Decommissioning
Continued
Decommissioning at decommissioning company, balancing device
The instruction below details how to decommission the balancing device. Contact ABB
Robotics for further consultation.
Action
Note/Illustration
1.
DANGER!
There is stored energy built up by high
tensioned compression springs inside the
balancing device! The device also contains
some grease!
2. Place the device on a workbench or
similar. Make sure it is clamped in position
with a vice or similar.
3. Open a hole in the side of the housing as
shown in the figure.
Use a cutting torch. The measurements

shown below are maximum values!
xx0400000700
4. Cut the coils of the three springs inside the Use a cutting torch.
housing as specified below:
Outer spring: cut at least five coils!
Middle spring: cut at least four coils!
Inner spring: cut at least four coils!
5. Double-check the number of coils cut and
make sure all the tension in the springs is
removed.
425
6 Decommissioning
426
7 Robot description
7.1. Type A and type B of IRB 6600/6650
7 Robot description
Type B - enlarged gear
Type B robots of IRB 6600/6650 have an enlarged gear on axis 2. As a result of this
enlargement, following main parts on the robot differ from type A:
frame
lower arm
motor, axis 2
adjustable mechanical stop, axis 2
limit switches, axis 2.
How to know which type the robot is?

The identification plate on the cabinet and the lower arm of the robot tells if the robot has the
enlarged gear or not.
Those robots with the original gear are named IRB 6600 Type A / IRB 6650 Type A or simply
IRB 6600 / IRB 6650.
Those robots with the enlarged gear are named IRB 6600 Type B / IRB 6650 Type B.
427
7 Robot description
428
8.1. Introduction
8.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
429
8.2. Applicable Safety Standards
8.2. Applicable Safety Standards

Standards, general
The robot is designed in accordance with the requirements of:
EN ISO 10218-1:2006 - Robots for industrial environments - Safety requirements Part 1 Robot.
EN 292-1 - Basic terminology.
EN 292-2 - Technical principles.
EN 418 - Emergency stop.
EN 563 - Temperatures of surfaces.
EN 954-1 - Safety related parts of control systems.
EN ISO 60204-1:2005 - Safety of machinery - Electrical equipment of machines - Part

1 General requirements.
EN 1050 - Principles for risk assessment.
ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.
DIN 19258 - Interbus-S, International Standard
Standards, robot cell
430
EN 953 - Fixed and moveable guards
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 349 - Minimum gaps to avoid crushing of parts of the human body.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
EN 1088 - Interlocking devices
EN 999 - The positioning of protective equipment in respect of approach speeds of the

human body.
ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing

systems.
The following standards are applicable when the robot is part of a robot cell:
8.3. Unit conversion
8.3. Unit conversion

Converter table
Use the table below to convert units used in this manual.
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
14.5 psi
Quantity
431
8.4. Screw joints
8.4. Screw joints

General
This section details how to tighten the various types of screw joints on the robot.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618

432
2. Apply lubricant between the plain washer and screw head.
8.4. Screw joints
Continued
Tightening torque
Before tightening any screw, note the following:
Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
Use the correct tightening torque for each type of screw joint.
Only use correctly calibrated torque keys.
Always tighten the joint by hand, and never use pneumatical tools.
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension

433
8.4. Screw joints
Continued
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Dimension
Tightening torque
(Nm)
Tightening torque
(Nm)
Tightening torque
(Nm)
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
M24
725
960
1150
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension

Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
M24
790
950
434
Dimension
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
8.5. Weight specifications
8.5. Weight specifications

Definition
In installation, repair and maintenance procedures, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.
Example
Below is an example of how a weight specification is presented, inside a procedure table:
Action
Note
CAUTION!

435
8.6. Standard toolkit
8.6. Standard toolkit

General
All service (repairs, maintenance and installation) procedures contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents, standard toolkit
Tool
Ring-open-end spanner 8-19 mm
Socket head cap 5-17 mm
Torx socket no: 20-60
Box spanner set
Torque wrench 10-100 Nm
Torque wrench 75-400 Nm
Ratchet head for torque wrench 1/2
Hexagon-headed screw M10x100
Socket head cap no: 14, socket 40 mm bit L 100 mm
Rem.
To be shortened to 12 mm
Qty
436
8.7. Special tools
8.7. Special tools

General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in section Standard toolkit on page 436,
and of special tools, listed directly in the instructions and also gathered in this section.
Basic tools
The table below specifies the tools in the basic toolkit (3HAC 15571-3) that are used for the
current robot model. This toolkit is necessary primarly when removing and refitting the
motors.
The tools are also listed directly in the instructions.

Description
Qty
Art. no.
Bolts (M16 x 60) for Mech stop ax 3
3HAB 3409-86
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
3HAC 15521-1
3HAC 15521-2
Lifting tool, wrist unit
IRB6600, IRB 6650:

3HAC 13605-1
Lifting tool, motor ax 1, 4, 5
3HAC 14459-1
Lifting tool, motor ax 2, 3, 4
3HAC 15534-1
Mech stop ax 3
3HAC 12708-1
Removal tool, motor M10x
3HAC 14972-1
Fits motors, axes 4, 5 and 6.
Removal tool, motor M12x
3HAC 14631-1
Fits motors axes 1, 2 and 3.
Rotation tool
3HAC 17105-1
Standard toolkit (content described in

section Standard toolkit on page 436)
3HAC 15571-1
Washers for mech stop axis 3
3HAA 1001-186
Special tools
The table below specifies the special tools required during several of the service procedures.
The tools may be ordered separately and are also specified directly in concerned instructions
in the Product manual, procedures.
Description
Qty
Art. no.
Fixture lower arm
3HAC020729-001
Gearbox crank, axis 2
3HAC020999-001
3HAC022637-001
3HAC13056-2
3HAC13056-3
3HAC13056-4

437
8.7. Special tools
Continued
Description
Qty
Art. no.
3HAC13120-5
Guide pins, sealing ax 2/3, 100mm
3HAC14628-2
Guide pins, sealing ax 2/3, 80mm
3HAC14628-1
Hydraulic cylinder
3HAC11731-1
3HAC13086-1
Hydraulic pump, 150 MPa (Glycerin)
3HAC021563-012
Lifting device, base
3HAC15560-1
Lifting device, manipulator
3HAC15607-1
Lifting device, upper arm
3HAC15994-1
Lifting eye VLBG M12
3HAC16131-1
Lifting eye M16
3HAC14457-4
3HAC15556-1
Lifting tool, gearbox axis 2
3HAC020386-001
Measuring tool
6896134-GN
Motor press pinion
3HAC021883-001
Oil injector / max 500 MPa
3HAC021590-001
3HAC13527-1
3HAC021563-001
3HAC021600-001
Press tool, balancing device
3HAC020902-001
Press tool, balancing device shaft
3HAC17129-1
Puller tool, balancing device shaft
3HAC12475-1
Shackle, balancing device
3HAC020997-1
Support, base
3HAC15535-1
Tool set balancing device
3HAC021984-001
The table below specifies the tools that may be rented from ABB in order to perform certain
service procedures as described in the Product manual.
The special tools are also listed directly in the instructions.
Description
Art. no.
Note
Lifting tool, lower arm
3HAC14691-1
Includes
guidings, 3HAC14446-1
Calibration equipment, Levelmeter (alternative method)

The table below specifies the calibration equipment required when calibrating the robot with
the alternative method, Levelmeter Calibration.
Description
Art. no.
Angel bracket
68080011-LP
Calibration bracket
3HAC 13908-9
Calibration tool ax1
3HAC 13908-4
Note

438
Tools that may be rented
8.7. Special tools
Continued
Description
Art. no.
Note
Levelmeter 2000 kit
6369901-347
Includes one sensor.
Measuring pin
3HAC 13908-5
Sensor fixture
68080011-GM
Sensor plate
3HAC 0392-1
Sync. adapter
3HAC 13908-1
Turn disk fixture
3HAC 68080011-GU
Calibration equipment, Calibration Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with
the Calibration Pendulum method.
Description
Art. no.
Note
Calibration Pendulum toolkit
3HAC15716-1
Complete kit that also includes operating

manual.

The table below specifies the recommended equipment for oil exhange.
Art. no.
Note
3HAC 021745-001
Includes
vacuum pump with
regulator, hose and coupling
couplings and adapters
pump (manual) with hose
and coupling
graduated measuring glass
oil gun
user instructions.
Description
439
8.8. Lifting equipment and lifting instructions
8.8. Lifting equipment and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
440

9.1. Introduction

9.1. Introduction
Definitions
This chapter specifies all spare parts and replacement articles of the robot.
441

9.2.1. Introduction
9.2 Spare part list

9.2.1. Introduction
Overview
This section specifies all articles considered spare parts of the robot. The spare parts are also
specified as required equipment directly in the repair instruction of the current spare part.
442

9.2.2. Spare part list

Repair instructions
Each spare part is replaced as described in corresponding repair instruction in the Product
manual, procedures.
Location, spare parts, IRB 6600 and IRB 6650
The figure below shows the spare parts of the IRB 6600 and IRB 6650.
xx0400001022

443

Continued
Location, spare parts, IRB 6600ID and IRB 6650ID
The figure below shows the spare parts of the IRB 6600ID and IRB 6650ID.
xx0500001796

444

Continued
Parts
The table below specifies all the recommended spare parts for the robot.
Item
Description
Spare part no.
Note

3HAC 15879-2
3HAC 15879-3
Axis 1
Foundry Prime
Gearbox
3HAC 10828-8
Axis 1

3HAC 021030-001
Axis 2
3HAC026975-001
Foundry Prime
Gearbox axis 2
3HAC 021541-001
Axis 2

3HAC 15885-2
Axis 3
3HAC026976-001
Foundry Prime
Gearbox
3HAC 021127-001
Axis 3

3HAC 15889-2
Axis 4
3HAC026977-001
Foundry Prime
SMB unit
3HAC 16014-1
Battery pack
3HAC 16831-1
Wrist, type 2
3HAC 16626-2
(IRB 6650 -125/3.2, -200/2.75, IRB 6600
-175/2.8, -225/2.55)
Wrist, type 2
3HAC026879-001
Foundry Prime
Wrist, type 2, insulated turning disk

3HAC 16626-3
(IRB 6650 -125/3.2, -200/2.75, IRB 6600
-175/2.8, -225/2.55)
Wrist, process
(IRB 6600ID and IRB 6650ID)
3HAC 024793-001
Turning disk, diam. 200 (175/2,55)
3HAC025571-001
Turning disk, dia. 200
3HAC 13752-1
Balancing device (IRB 6600 and IRB

6600ID)
3HAC 020691-001
Balancing device (IRB 6650 and IRB

6650ID)
3HAC 020692-001

3HAC 023745-003
Axis 5

3HAC 023746-003
Axis 6

3HAC 024815-001
Cover, wrist unit (includes sealing)

3HAC 024810-001
Foundry Prime

445

Continued
Item
Description
Spare part no.
Note

3HAC 021325-001
Axis 5

3HAC 021675-001
Axis 5
Hood
3HAC 021222-001
Cover with gasket

(IRB 6600 and IRB 6650)
3HAC 025899-001
Cable cover
(IRB 6600 and IRB 6650)
3HAC 022172-003
Cable harness axes 1-4 (IRB 6600/

6600ID)
3HAC 025503-001

(IRB 6650/6650ID)
3HAC 025504-001
3HAC026981-001
Cable harness axes 1-6 (IRB 6600)
3HAC 024385-001
Cable harness axes 1-6 (IRB 6650)
3HAC 024386-001
Cable harness axis 5
3HAC 14139-1
Motor
3HAC 17484-10
3HAC026982-001
Axis 5
Foundry Prime
Gearbox
3HAC 10828-13
Axis 6
3HAC 15991-4
3HAC026983-001
Axis 6
Foundry Prime

(IRB 6600 and IRB 6650)
3HAC 14140-1
3HAA 2167-18
At front ear of the

balancing device.
Sealing spacer
3HAC 12649-1
2 pcs. At front ear

of the balancing
device.
O-ring
3HAB 3772-75
2 pcs. At front ear

of the balancing
device.
Sealing ring
3HAC 11581-5
2 pcs. At front ear

of the balancing
device.
Complete maintenance kit, balancing

device
3HAC 021592-001
Maintenance kit with bearings, balancing 3HAC 021593-001

device

446
Foundry Prime

Continued
Optional equipment
All components required for installation of optional equipment, such as cabling, extra
attachment plates etc., are listed in the installation procedure for the equipment. The table
below points out the installation procedures for the equipment (in part 1: Procedures, of the
Product manual).
Equipment
Installation is detailed in:
25-3
Installation of position switches (option) on page

111
30-1
33-1
37-1
Base plate
Securing the base plate on page 74
87-1
Cooling fan, axis 1
Installation of cooling fan for motors, axes 1-3

(option) on page 97
88-1
Cooling fan, axis 2
89-1
Cooling fan, axis 3
159-1
Fork lift device
Lifting robot with fork lift on page 61
184-1
Insulated tool flange
213-1
Safety lamp
536-1
Chip protection
Installation of chip and dust protection (option)

on page 87
571-1
Base spacers
Installation of base spacers (option) on page 95
430-1
Upper arm covers
Option no.
447

9.3.1. Introduction
9.3 Part list

9.3.1. Introduction
Overview
This section specifies all the replacement articles of the robot. The parts are shown in
exploded views or in foldouts, either in this or in a separate chapter.
Specific spare parts are listed separately in a Spare part list.
448

9.3.2. Rebuilding parts

Overview
The robot has some rebuilding parts that differ from eachother, depending on the robot
version. This section is a general overview of which parts belong to which versions.
The following section, Part list on page 448 also gives further details of the parts specified
below, according to the item numbers given.
Rebuilding parts
Art. no.
Part
IRB 6600-
Item no
and type
IRB 6650- IRB 6650S-
175/ 225/ 175/ 200/ 125/ 200/ 125/ 90/

2.55 2.55 2.8 2.75 3.2 3.0 3.5 3.9
3HAC15866-1
Frame / typeA
3HAC020136-004 Frame / typeB

X
101.2.1
101.2.1
3HAC 10141-1
Lower arm /typeA
105
3HAC 13940-1
Lower arm / typeA
105
3HAC020671-003 Lower arm / typeB
105
3HAC020129-003 Lower arm / type B
105
3HAC026574-001 Lower arm / type B

(Foundry Prime)
105
3HAC020505-003 Lower arm

3HAC17212-1
Sealing axis 2/3 / typeA
105
3HAB3409-84
Screw M16x50
18X
18X
108.202
3HAA1001-186
Washer 7x25x3
18X
18X
108.204
3HAC021071-001 Cable protection / typeB

3HAC020123-001 Sealing axis 2/3 / typeB
3HAC020958-001 Cable protection / typeA
3HAC16926-1
Lower arm cable protection
3HAC020507-001 Lower arm cable protection

3HAC14940-1
Harness ax. 1-4
3HAC16331-1
Harness ax.1-4
3HAC024385-001 Harness ax.1-6
X
X
X
X
108.201
108.235
X
108.235
108.211
108.211
106
106
3HAC024386-001 Harness ax.1-6
108.201
106
X
106
3HAC9760-3
Arm extender 250mm
111.501
Standard
3HAC15859-2
Arm extender 250mm
111.501
Standard
and Foundry
3HAC9760-7
Arm extender 450mm
2X
111.501
Standard
3HAC15859-3
Arm extender 450mm
2X
111.501
Standard
and Foundry
3HAB7700-69
Screw M12x50
12X
12X
24X 111.503
12X

449

Continued
Art. no.
Part
IRB 6600-
Item no
and type
IRB 6650- IRB 6650S-
175/ 225/ 175/ 200/ 125/ 200/ 125/ 90/

2.55 2.55 2.8 2.75 3.2 3.0 3.5 3.9
3HAA1001-134
Washer 13x19x1,5
12X
12X
12X
24X 111.504
9ABA107-56
Parallel pin 10x20
2X
9ADA618-56
Screw M6x16
4X
6X
6X
12X 111.507
3HAC9760-9
Cover 250mm
111.506
111.506
3HAC026454-001 Cover 250mm

(Foundry Prime)
3HAC9760-10
Cover 450mm
3HAC15879-2
Motor axis 1
3HAC15882-2
Motor axis 2
3HAC15885-2
Motor axis 2/typeA
109.307
3HAC021030-001 Motor axis 2/typeB
109.307
3HAC021541-001 Reduction gear / type B

3HAC16829-1
Cover ax2 / typeA
3HAC020138-003 Cover ax2 / typeB
3HAC020122-001 Attachment plate / typeB

3HAC14792-1
Bracket
3HAC15882-2
Motor axis 3
3HAC15885-2
2X
111.506
109.306
109.307
3HAC020098-001 Guiding plate ax2

3HAC020745-001 Attachment plate
109.301
109.301
109.302
X
109.302
109.336
109.336
109.336
109.338
Motor axis 3
102.3.5
3HAB3409-71
Screw M12x50
8X
8X
8X
8X
8X
8X
8X
109.304
3HAA1001-134
Washer 13x19x1.5
8X
8X
8X
8X
8X
8X
8X
109.305
3HAB3772-69
O-ring / typeA
3HAB3772-73
O-ring / typeB
3HAC15887-2
Motor axis 4
3HAC15889-2
Motor axis 4
3HAC020691-001 Balancing device
102.3.5
X
X
3HAC11427-1
Shaft, balancing device
3HAC16627-3
Wrist, type 1
3HAC16626-2
Wrist, type 2
450
102.4
104
X
X
104

109.318
102.4

3HAC12534-1
109.318
104
110.410
110.410
103
103
3HAC021127-001 Reduction gear / typeA
111.505

9.3.3. Part list, overview
Part list
Item Qty
Art. number
Description
Note / Dimension
3HAC 17358-1
Mechanical stop ax 1,
assembly
101
3HAC 020854-001 Base incl frame ax 1
See section Base incl

frame ax 1 on page 453
102
3HAC 10746-1
Axis 3-4
See section Axis 3-4 on

page 454
102
3HAC 10746-4
Axis 3-4, Foundry
See section Axis 3-4,

Foundry on page 458
103
3HAC 8114-3
Wrist, type 2
See section Wrist, type 2,

standard, IRB 6600 and
IRB 6650 on page 460
103
3HAC026578-001
Wrist, type 2 (Foundry Prime)
103
3HAC 8114-5
Wrist, type 2, Foundry

Foundry on page 466
103
3HAC 8114-8
Wrist, type 2, insulated

insulated on page 467.
103
3HAC 023639-001 Wrist, process (IRB 6600ID/

6650ID)
104
3HAC 17117-2
Balancing Device A (6600225/2.55, 6600-175/2.8,

6600-175/2.55, 6600ID-185/
2.55)
104
3HAC 17117-3
Balancing Device B (6650125/3.2, 6650-200/2.75,

6650ID-170/2.75)
105
3HAC 020129-003 Lower arm (6600-225/2.55,

6600-175/2.8, 6600ID-185/
2.55 )
105
3HAC 020671-003 Lower arm (6650-125/3.2,

6650-200/2.75, 6650ID-170/
2.75)
106
3HAC 14940-1
Cable harness, man. ax1-4

(6600-225/2.55, 6600-175/
2.8, 6600-175/2.55, 6600ID185/2.55)
106
3HAC 16331-1
Cable harness, man ax 1-4

(6650-125/3.2, 6650-200/
2.75, 6650ID-170/2.75)
106
3HAC 024385-001 Cable harness, man. ax1-6

(6600-225/2.55, 6600-175/
2.8, 6600-175/2.55)
106
3HAC024386-001
See section Wrist,

process, IRB 6600ID and
6650ID on page 464.
Cable harness, man ax 1-6

(6650-125/3.2, 6650-200/
2.75)

451

Continued
Item Qty
Art. number
Description
Note / Dimension
108
3HAC 13263-1
Material set manipulator
See section Material set,

manipulator, 3HAC
13263-1 on page 469
109
3HAC 13264-1
Material set ax 1-2

axis 1-2, 3HAC 13264-1
on page 470
110
3HAC 13265-1
Mtrl.set balancing device

balancing device, 3HAC
13265-1 on page 473
111
3HAC 12311-4
Arm extension set 250mm

(IRB 6600 - 175/2.8)
See section Arm

extension set, 250 mm,
3HAC 12311-4 on page
474
111
3HAC 12311-5
Arm extension set 450mm

(IRB 6650 - 125/3.2)
See section Arm

extension set, 450 mm,
475
112
2 or 1 3HAC 12129-1
Cover plate
t=1,5 mm
112
Cover plate (Foundry Prime) t=1,5 mm
113
8 or 4 9ADA 618-56
Torx pan head screw
M6 x 16
114
3HAC 13416-1
Protection cover
Shell size 16
115
3HAC 18281-1
Cover
3HAC026188-001
452

9.3.4. Base incl frame ax 1
9.3.4. Base incl frame ax 1

Part list
Item
Qty Art. number
Description
Note / Dimension
101.1
3HAC 17224-4
Base, machining
See block Base,

machining on page 453.
101.1
3HAC026572-001
Base, machining (Foundry

Prime)
101.2
3HAC 020858-001
Frame incl ax 1 gearbox
See block Frame incl ax

1 gearbox on page 453
101.3
3HAC 11732-2
Washer
T=3
101.4
18
3HAB 7700-5
Hex socket head cap screw M16 x 70
101.5
3HAC 11529-1
Rubber lined clip
101.6
3HAC 14453-1
Hose with flange
101.7
3HAC 14453-2
Plug
101.8
3HAC 4428-2
Hose Clip
D=23-27
101.9
9ADA 618-56
Torx pan head screw
M6 x 16
D=28
Base, machining
Item
Qty Art. number
Description
101.1.1 1
3HAC 17224-2
Base, casting
101.1.2 5
3HAC 4836-7
Protection plug
101.1.3 1
3HAC 1383-2
Protection Cover compl.
101.1.4 1
3HAC 14024-1
Protection screw
Dimension
16 x 12.3 x 9 x 7
Frame incl ax 1 gearbox
Item
Qty Art. number
Description
Dimension
101.2.1 1
3HAC 020136-004
Frame machining
101.2.1 1
3HAC026573-001
Frame machinning
(Foundry Prime)
101.2.2 1
3HAC 10828-8
RV 320C-224,26 assembly
101.2.3 24
3HAB 3409-73
101.2.4 24
3HAA 1001-134
Washer
13 x 19 x 1.5
453

9.3.5. Axis 3-4
9.3.5. Axis 3-4

Overview
Item
Qty Art. number
Description
Note
102.1
3HAC 13350-1
Material set ax 4
See block Material set ax 4, 3HAC

13350-1 on page 454
102.2
3HAC 020049-001
Tube shaft 2,55
See block Tube shaft 2.55, 3HAC

020049-001 on page 455
102.3
3HAC 13351-1
Axis 3
See block Axis 3, 3HAC 13351-1 on

page 456
102.4
3HAC 14752-1
Rot ac motor incl

gearbox
See block Rot ac motor incl gearbox

on page 457
Material set ax 4, 3HAC 13350-1

Qty
Art. number
Description
Dimension / Note
102.1.1
3HAC 12261-1
Gear Z4 /4
102.1.3
9ADA 183-37
Hex socket head cap

screw
M8 x 25
102.1.4
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
102.1.5
3HAC 12259-1
Wheel unit ax4 225kg
See sub-block Wheel unit

ax 4, 225 kg, 3HAC
12259-1 on page 455
102.1.6
3HAA 1001-99
Wedge
102.1.7
3HAC 12560-1
Stud bolt
M8 x 65
102.1.8
12
9ADA 334-7
Spring washer, conical
8.4 x 18 x 2
102.1.9
9ADA 267-7
Hexagon nut
M8
102.1.10 3
3HAB 3409-63
Hex socket head cap

screw
M10 x 110
102.1.11 3
9ADA 334-8
10.5 x 23 x 2.5
102.1.12 1
3HAC 13564-1
Damper axis 4
See sub-block Damper,

axis 4, 3HAC 13564-1 on
page 455
102.1.13 1
3HAA 1001-17
Stop, Axis 4, Casting
102.1.14 1
3HAC 11925-1
Mechanical stop head
102.1.15 2
3HAB 3409-81
Hex socket head cap

screw
M16 x 35
102.1.16 1
3HAA 1001-98
Gasket
T=1
102.1.17 1
3HAC 12149-4
Cover ax4 with sealing
See sub-block Cover axis

4 with sealing, 3HAC
12149-4 on page 455
102.1.17 1
3HAC026309-001
Cover ax4 with sealing(Foundry Prime)
102.1.18 14
9ADA 618-56
Torx pan head screw
102.1.20 1
3HAC 17218-1
Set of shims
102.1.21 1
3HAC 17219-2
Thrust washer
102.1.22 1
9ABA 135-45
Retaining ring, shaft
M6 x 16
170

454
Item

9.3.5. Axis 3-4
Continued
Item
Qty
Art. number
Description
Dimension / Note
102.1.23 2
2213 253-5
Ball bearing
170 x 215 x 22
102.1.24 1
2216 261-18
Sealing
170 x 200 x 15
102.1.25 1
2216 0086-4
Sealing (Nilos)
180 x 215 x 4
102.1.26 1
3HAB 4317-1
Sealing
102.1.27 1
3HAC 022620-001
Spacer ring
102.1.28 1
21522012-535
O-ring
169.3 x 5.7
102.1.29 1
9ABA 107-56
Parallel pin
10 x 20
102.1.30 8,100 1171 2016-604

ml
Lubricating oil:
Mobilgear 600 XP320
102.1.31 30 g
3HAB 3537-1
Bearing grease
102.1.32 1 ml
3HAB 7116-1
Locking liquid
102.1.33 1 ml
3HAB 7116-2
Locking liquid
102.1.34 1
3HAC 16721-1
Magnetic plug
R 1/2
Wheel unit ax 4, 225 kg, 3HAC 12259-1

Item
Qty
Art. number
Description
Dimenstion / Note
102.1.5.1 1
3HAC 11742-1
Intermediate hub, machine
102.1.5.2 1
3HAC 12259-2
Gear unit Z2, 3/4
See sub-block below.
102.1.5.3 1
2126 2851-104
Lock nut
M20 X 1
102.1.5.4 1
2213 3802-11
Taper roller bearing
40 x 68 x 19
102.1.5.5 1
3HAA 1001-129
Taper roller bearing
102.1.5.6 1 ml
3HAB 7116-2
Locking liquid
Gear unit Z2, 3/4, 3HAC 12259-2

Item
Qty
Art. number
Description
102.1.5.2.0
3HAC 12259-3
Pinion Z3 /4
102.1.5.2.0
3HAC 12259-4
Gear Z2 /4
Item
Qty
Art. number
Description
102.1.12.2
3HAC 13564-2
Plate for damper
Dimension
Damper, axis 4, 3HAC 13564-1

Dimension
Cover axis 4 with sealing, 3HAC 12149-4

Item
Qty
Art. number
Description
Dimension
102.1.17.1
3HAC 12149-3
Cover ax4 with gasket
102.1.17.2
3HAA 1001-628
Sealing
Tube shaft 2.55, 3HAC 020049-001

Item
Qty
Art. number
Description
102.2.1
3HAC 10139-2
Tube shaft 2,55, casting
Note

455

9.3.5. Axis 3-4
Continued
Item
Qty
Art. number
Description
Note
102.2.2
3HAC 1383-2
Protection Cover compl. See sub-block Protection

cover compl., 3HAC 1383-2
on page 456
Protection cover compl., 3HAC 1383-2

Item
Qty
Art. number
Description
Dimension
102.2.2.1 1
9ADA 624-69
Torx counters. head screw
M8 x 20
102.2.2.2 1
3HAB 3772-66
O-ring
8x2
102.2.2.3 1
3HAC 1383-1
Protection Cover
102.2.2.4 1
3HAC 1383-3
Gasket
Axis 3, 3HAC 13351-1

Qty
Art. number
Description
102.3.1
3HAC 10133-1
Axis 4 housing
102.3.1
3HAC026577-001
Axis 4 housing
(Foundry Prime)
102.3.2
3HAC 021127-001 RV 410F-270,176

assembly
See sub-block RV 410F270, 176 assembly, 3HAC

021127-001 on page 456
102.3.3
24
3HAB 3409-71
Hex socket head

cap screw
M12 x 60
102.3.4
24
3HAA 1001-134
Washer
13 x 19 x 1.5
102.3.5
3HAC 14750-1
Rot ac motor incl

pinion
See sub-block Rot ac

motor incl pinion, 3HAC
14750-1 on page 456
102.3.6
3HAB 3409-50
Hex socket head

cap screw
M10 x 40
102.3.7
3HAB 4233-1
Washer
102.3.8
3HAC 16721-1
Magnetic plug
102.3.9
2,500 ml 3HAC 16843-1
102.3.9
2,500 ml 3HAC 032140-001 Lubricating oil,

Kyodo Yushi
TMO150
Do not mix different types

of oil!
102.3.10
10 x 30
9ABA 142-92
Dimension / Note
R 1/2
Lubricating oil, RMO Do not mix different types

150
of oil!
Spring pin, slotted
RV 410F-270, 176 assembly, 3HAC 021127-001

Item
Qty
Art. number
Description
Dimension
102.3.2.1 1
3HAC 10828-11
RV 410F, i=270,176
102.3.2.2 1
3HAB 3772-68
O-ring
276 x 3.53
Rot ac motor incl pinion, 3HAC 14750-1

Item
Qty
Art. number
Description
Dimension
102.3.5.1
3HAC 17484-9
Rotational ac motor M9
102.3.5.2
3HAC 10122-15
Input gear

456
Item

9.3.5. Axis 3-4
Continued
Item
Qty
Art. number
Description
Dimension
102.3.5.3
2152 2012-430
O-ring
89.5 x 3
102.3.5.4
9ADA 183-444
Hex socket head cap screw
M8 x 130
102.3.5.5
3 ml
3HAB 7116-1
Locking liquid
Rot ac motor incl gearbox

Qty
Art. number
Description
102.4.1
3HAC 17484-10
102.4.2
3HAC 12260-1
Pinion Z1 /4
102.4.3
2152 2012-430
O-ring
Dimension
89,5x3
Item
457

9.3.6. Axis 3-4, Foundry
9.3.6. Axis 3-4, Foundry

Overview
Item
Qty
Art. number
Description
Note
102.1
3HAC 13350-1
Material set ax 4
See block Material set ax 4,

3HAC 13350-1 on page 454
102.2
3HAC 020053-001 Tube shaft 2,55 foundry
102.3
3HAC 13351-1
Axis 3
102.4
3HAC 14752-1
Rot ac motor incl gearbox See block Rot ac motor incl

gearbox on page 457
See block Axis 3, 3HAC

13351-1 on page 456
458

9.3.7. Axis 3-4 Foundry Prime
9.3.7. Axis 3-4 Foundry Prime

Overview
Qty
Art. number
Description
102.1
3HAC 13350-1
Material set ax 4
102.2
3HAC 020053-001 Tube shaft 2,55 foundry
102.3
3HAC 13351-1
Axis 3
102.4
3HAC 14753-1

(6600-175/2.55)
102.4
3HAC 14752-1
Note
Item
459

9.3.8. Wrist, type 2, standard, IRB 6600 and IRB 6650

Overview
Item
Qty
Art. number
Description
Dimension / Note
103.1
3HAC 8114-4
Material set
See block Material set, 3HAC

8114-4 on page 460
103.2
3HAC 7941-30
Rot ac motor incl

gearbox
See block Rot ac motor incl

gearbox on page 462
103.3
10
3HAB 3409-89
Hex socket head

cap screw
M16 x 80
103.4
3HAC 13890-1
Axis 6 complete
See block Axis 6 complete, 3HAC

13890-1/2 on page 462
103.5
3HAC 020566001
Label
Item
Qty
Art. number
Description
103.1.1
3HAC 7956-1
Wrist housing, 225kg
103.1.2
3HAC 7941-28
Set of shim, motor
103.1.3
3HAC 7941-19
Set of shim, bevel gear
103.1.4
9ADA 183-37
103.1.5
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
103.1.6
3HAA 2166-11
VK-Cover
D=80 B=10
103.1.7
3HAC 4334-3
Cylindrical roll. bearing
50 x 90 x 20
103.1.8
3HAC 12560-1
Stud bolt
M8 x 65
103.1.9
1 ml
Material set, 3HAC 8114-4
3HAB 7116-2
Locking liquid
103.1.10 16
9ADA 334-7
8.4 x 18 x 2
103.1.11 4
9ADA 267-7
Hexagon nut
M8
103.1.12 4
3HAA 1001-99
Wedge
103.1.13 1
3HAB 7299-1
Sealing
Di=115 Dy=140 B=12
103.1.14 1
3HAA 2166-23
VK-Cover
D=120, B=12
103.1.15 1
3HAC 7941-32
Support shaft incl bearing
See sub-block Support

shaft incl bearing, 3HAC
7941-32 on page 461
103.1.16 6
9ADA 183-39
103.1.17 2
3HAB 4337-2
Damper axis 5
103.1.18 1
3HAC 9953-1
Syncplate with nonie
T=1.5
103.1.19 1
3HAC 16721-1
Magnetic plug
R 1/2
103.1.21 27
9ADA 618-56
Torx pan head screw
M6 x 16
103.1.22 2
9ADA 334-6
Plain washer
6.4 x 14 x 1.5
103.1.23 1 ml
3HAB 7116-1
Locking liquid
103.1.24 1
3HAC 14139-1
Manip. Harness ax 5
103.1.25 6,700 1171 2016-604

ml
Lubricating oil:
Mobilgear 600 XP320

460
Dimension / Note

Continued
Item
Qty
Art. number
Description
Dimension / Note
103.1.26 1
3HAC 7941-6
Interm.wheel unit/5 225kg
See sub-block Interm.

wheel unit/5 225 kg,
3HAC 7941-6 on page
461
103.1.27 1
3HAC 022695001
Screw
103.1.28 1
3HAC 7941-21
Gear wheel unit z6/5 225
103.1.29 1
3HAC 8081-8
Cover with gasket, 225kg
103.1.30 1
3HAC 022172001
Cable cover
103.1.31 1
3HAC 14140-1
Manip. Harn. ax 5/6
103.1.32 2
2166 2055-3
Cable straps, outdoors
4.8 x 208
103.1.33 5
3HAA 1001-106
Washer
D/d =15/6.4 t=3
103.1.34 5 ml
1171 2016-618
Lubricant, paste
See sub-block Gear

wheel unit z6/5 225,
461
Support shaft incl bearing, 3HAC 7941-32

Item
Qty
Art. number
Description
Dimension
103.1.15.1
3HAC 14731-1
Shaft
103.1.15.2
3HAB 3643-11
Groove ball bearing
130 x 165 x 18
103.1.15.3
9ADA 618-56
Torx pan head screw
M6 x 16
103.1.15.4
1 ml
3HAB 7116-1
Locking liquid
Interm. wheel unit/5 225 kg, 3HAC 7941-6

Item
Qty
Art. number
Description
Dimension / Note
103.1.26.1
3HAC 7946-1
Hub ax5, machining
103.1.26.2
3HAA 1001-130
Taper Roller Bearing
103.1.26.3
3HAC 7941-12
Gear Unit z4-z5/5 225kg
See sub-block below!
103.1.26.4
3HAC 13142-1
Washer
17 x 30 x 6
103.1.26.5
3HAC 7941-11
Locking Nut
103.1.26.6
1 ml
3HAB 7116-2
Locking liquid
Gear unit Z4-Z5/5 225 kg, 3HAC 7941-12

Item
Qty Art. number
Description
103.1.26.3.1
3HAC 7941-7
Pinion z5/5 225kg
103.1.26.3.2
3HAC 7941-5
Gear z4/5 225kg
Dimension
Gear wheel unit z6/5 225, 3HAC 7941-21

Item
Qty
Art. number
Description
Dimension
103.1.28.1
3HAC 7941-8
Gear z6/5 225kg
103.1.28.2
3HAB 4271-1
Groove ball bearing 110 x 150 x 20
103.1.28.3
3HAB 6686-1
Support ring

461

Continued
Item
Qty
Art. number
Description
103.1.28.4
1 ml
3HAB 7116-2
Locking liquid
Dimension

Item
Qty
Art. number
Description
Dimension
103.2.1
3HAC 17484-10
103.2.2
3HAC 7941-1
Bevelgear set unit z1-3/5
103.2.3
2152 2012-430
O-ring
89.5 x 3
Axis 6 complete, 3HAC 13890-1/2

Item
Qty
Art. number
Description
Dimension / Note
103.4.1
3HAC 13752-1
Turning disk
103.4.2
3HAC 10828-13
RV 70F-125,8 assembly
103.4.3
3HAC 11522-2
Tilt housing RV70
103.4.3
3HAC 16009-1
Tilt housing RV70, foundry
103.4.4
3HAC 14754-1
Rot ac motor incl pinion

motor incl. pinion, 3HAC
14754-1 on page 463
103.4.5
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
103.4.6
9ADA 183-37
Hex socket head cap

screw
M8 x 25
103.4.7
18
3HAA 1001-172
Washer
8.4 x 13 x 1.5
103.4.8
2522 122-1
Magnetic plug
R1/4
103.4.9
450 ml 3HAC 16843-1
Lubricating oil, RMO 150
Do not mix different

types of oil!
103.4.9
450 ml 3HAC 032140001
Lubricating oil, Kyodo

Yushi TMO150
Do not mix different

types of oil!
103.4.10
2 ml
3HAB 7116-1
Locking liquid
103.4.11
3HAB 3772-64
O-ring
150.0 x 2.0
103.4.12
12
3HAB 3772-61
O-ring
13.1 x 1.6
103.4.13
3HAC 16862-1
Syncplate 175 kg
103.4.14
12
3HAB 7700-65
Hex socket head cap

screw
M12 x 30
103.4.15
18
3HAB 7700-55
Hex socket head cap

screw
M8 x 40
103.4.18
9ADA 618-32
Torx pan head screw
M4 x 8
103.4.20
3HAC 14263-1
Protection Cover
103.4.21
9ADA 624-69
Torx counters. head screw M8 x 20
RV 70F-125,8 assembly, 3HAC 10828-13

Item
Qty
Art. number
Description
103.4.2.1
3HAC 10828-14
RV 70F, i=125,8
103.4.2.2
3HAB 3772-57
O-ring
Dimension
164.69 x 3.53

462
See sub-block RV 70F125,8 assembly, 3HAC

10828-13 on page 462

Continued
Rot ac motor incl. pinion, 3HAC 14754-1
Qty
Art. number
Description
Dimension
103.4.4.1
3HAC 17484-8
103.4.4.2
3HAC 11173-3
Pinion RV 70F.125,8
103.4.4.3
2152 2012-430
O-ring
89.5 x 3
103.4.4.4
9ADA 183-415
M5 x 55
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
Item
463

9.3.9. Wrist, process, IRB 6600ID and 6650ID

Overview
The items listed below are shown in the exploded view Wrist complete, IRB 6600ID and IRB
6650ID on page 483.
Item
Qty
Art. no.
Description
Note/Dimension
103.1
3HAC023745-001 Motor incl pinion, z1/5
103.2
3HAC023660-001 Gear unit z2-3/5
103.3
3HAC023659-001 Middle gear unit z4-5/5
103.4
3HAC023748-001 Wheel unit z6/5
103.5
3HAC023746-001 Motor incl pinion, z1/6
103.6
3HAC023661-001 Gear unit z2-3/6
103.7
3HAC023663-001 Middle gear unit z4/6
103.8
3HAC13406-7
103.9
3HAC023740-001 Tilthouse unit z6-7/6
103.10
3HAC18172-3
Wrist housing, proc
103.11
19
3HAC11409-6
Shoulder Screw
103.12
19
3HAC11409-6
Shoulder Screw
103.13
3HAC021044-001 Wrist Cover
103.14
3HAC021044-001 Wrist Cover
103.15
3HAB3701-30
Radial Seals w. dust lip
103.16
3 ml
12690014-413
Locking liquid
103.17
3 ml
12690014-413
Locking liquid
103.18
3HAC021237-001 Adjust screw
103.19
3HAC021237-001 Adjust screw
103.20
3HAC16721-1
Magnetic plug
103.21
3HAC16721-1
Magnetic plug
103.22
3HAC18146-1
Bearing screw
103.23
3HAC18146-1
Bearing screw
103.24
11
9ADA624-56
Steel 8.8-A2F
M6x16
103.25
9ADA624-56
Steel 8.8-A2F
M6x16
103.26
3HAB3409-51
Hex socket head cap screw Steel 12.9 Gleitmo 610

M10x30
103.27
5,000ml 11712016-604
Lubricating oil
Mobilgear 600 XP320
103.28
6,000ml 11712016-604
Lubricating oil
Mobilgear 600 XP320
103.29
3HAC021675-001 Damper 2, ax 5
103.30
3HAC021325-001 Damper 1, ax5
103.31
3 ml
3HAB7116-1
Locking liquid
103.32
3 ml
3HAB7116-1
Locking liquid
103.33
9ADA618-56
Torx pan head screw
Steel 8.8-A2F
M6x16

464
Gear z5/6

Continued
Item
Qty
Art. no.
Description
Note/Dimension
103.34
9ADA312-6
Plain washer
6,4x12x1,6
103.35
9ADA183-37
Hex socket head cap screw Steel 8.8-A2F

M8x25
103.36
9ADA183-37
Hex socket head cap screw Steel 8.8-A2F

M8x25
103.37
9ADA312-7
Plain washer M8
103.38
9ADA312-7
Plain washer M8
103.39
18
3HAB3409-88
Hex socket head cap screw Steel 12.9 Gleitmo 610

M16x70
103.40
3HAB3772-85
O-ring
103.41
3HAC13142-1
Washer
103.42
3HAA1001-99
Wedge
103.43
3HAA1001-99
Wedge
103.44
3HAC12560-1
Stud bolt
103.45
3HAC12560-1
Stud bolt
103.46
16
9ADA334-7
Spring washer,conical
103.47
16
9ADA334-7
Spring washer,conical
103.48
9ADA267-7
Hexagon nut M8
103.49
9ADA267-7
Hexagon nut M8
103.50
3HAC022695-001 Screw
103.51
3HAC18246-1
103.52
3HAC021177-001 Screw
103.53
3HAB3701-38
Radial Seals w. dust lip
103.54
2 ml
11712016-618
Lubricant, paste
103.55
2 ml
11712016-618
Lubricant, paste
103.56
3HAC024631-001 WRIST 3HAC023639-001/

3HAC024793-001
Washer
465

9.3.10. Wrist, type 2, Foundry
9.3.10. Wrist, type 2, Foundry

Overview
Item
Qty
Art. number
Description
Dimension
103.1
3HAC 8114-4
Material set
See block Material set,

3HAC 8114-4 on page
460
103.2
3HAC 7941-30
See block Rot ac motor

incl gearbox on page 462
103.3
10
3HAB 3409-89
103.4
3HAC 13890-2
Axis 6 complete Foundry
103.5
3HAC 020566001
Label
See block Axis 6

complete, 3HAC 13890-1/
2 on page 462
466

9.3.11. Wrist, type 2, insulated
9.3.11. Wrist, type 2, insulated

Overview
Item
Qty Art. no.
Description
Note/Dimension
103.1
3HAC 8114-4
Material set
See block Material set, 3HAC

8114-4 on page 460.
103.2
3HAC 7941-30
See block Rot ac motor incl

gearbox on page 462.
103.3
10
3HAB 3409-89
103.4
3HAC 025176001
Ax 6, insulated
103.5
3HAC 020566001
Label
103.6
3HAC 025177001
Axis 6 complete, insulated

FA
See block Ax 6 complete,

insulated, 3HAC 025177-001
on page 467.
Ax 6 complete, insulated, 3HAC 025177-001

Item
Qty
Art. no.
Description
103.4.1
3HAC 17196-1
Axis 6 insulated
103.4.2
3HAC 14754-1

motor incl pinon, 3HAC
14754-1 on page 467.
103.4.3
9ADA 312-7
Plain washer
M8
103.4.4
9ADA 183-37
103.4.5
450
ml
3HAC 032140001
Lubricating oil, Kyodo Yushi

TMO150
103.4.5
450
ml
3HAC 16843-1
Lubricating oil, RMO 150
103.4.6
2 ml
3HAB 7116-1
Locking liquid
103.4.7
3HAC 16862-1
Syncplate 225 kg
103.4.8
9ADA 618-32
Torx pan head screw
103.4.9
3HAC 14263-1
Protection cover
9ADA 624-69
Torx counters, head screw
103.4.10 1
Note/Dimension
Rot ac motor incl pinon, 3HAC 14754-1

Item
Qty
Art. no.
Description
103.4.2.1
3HAC 17484-8
103.4.2.2
3HAC 11173-3
Pinion RV70F-125,8
103.4.2.3
21522012-430
O-ring
103.4.2.4
9ADA 183-415
Hex socket head screw
103.4.2.5
2 ml
3HAB 7116-1
Locking liquid
103.4.2.6
3HAC 12877-1
Gasket
Note
467

9.3.12. Wrist, type 2, Foundry Prime
9.3.12. Wrist, type 2, Foundry Prime

Overview
Qty
Art. number
Description
Dimension
103.1
3HAC 8114-4
Material set
103.2
3HAC 7941-30
103.3
10
3HAB 3409-89
103.4
3HAC 13890-2
Axis 6 complete Foundry
103.5
3HAC 020566001
Label
Item
468

9.3.13. Material set, manipulator, 3HAC 13263-1
9.3.13. Material set, manipulator, 3HAC 13263-1

Overview
Art. number
Description
Dimension /
Note
108.201 1
3HAC 020123-001
Sealing axis 2/3
Axis 2
108.201 1
3HAC 17212-1
Sealing axis 2/3
Axis 3
108.202 18
3HAB 3409-84
M16 x 50
108.202 33
3HAB 7700-69
M12 x 50
108.203 3
3HAC 12703-1
Washer, axis 3
108.204 18
3HAA 1001-186
Washer
17 x 25 x 3
108.206 12
3HAB 7700-69
M12 x 50
108.207 12
3HAA 1001-134
Washer
13 x 19 x 1.5
108.210 1
3HAC 14300-1
Cable protector
108.211 1
3HAC020507-001

(IRB6650 and IRB 6650ID)
108.211 1
3HAC 16926-1

(IRB6600 and IRB 6600ID)
108.212 1
3HAC 11771-1
Cable guide, end part
108.213 1
3HAC 13960-1
Connection plate, ax3
108.214 2
3HAC 12320-1
Damper, axis 3
108.215 2
3HAC 12991-1
Damper, axis 2
108.216 2
9ADA 624-65
M6 x 60
108.217 2
9ADA 334-7
8.4 x 18 x 2
108.218 2
9ADA 618-57
Torx pan head screw
M6 x 20
108.220 2
3HAC 9953-1
Syncplate with vernier
T=1.5
108.222 1
3HAC 12719-1
Syncplate with vernier ax3
T=1.5
108.223 2
9ADA 183-48
M10 x 16
108.224 1
3HAC 12844-1
Cable cover
108.224 1
3HAC026340-003
Cable cover
Foundry Prime
108.225 21
9ADA 618-56
Torx pan head screw
M6 x 16
108.228 1
3HAC 3261-1
Cover
108.229 1
3HAC 15431-1
Cable protection
108.230 1
3HAC 14880-1
Cable fixing bracket
108.231 1
21520441-1
Washer
108.232 6
3HAC 16721-1
Magnetic plug
R 1/2
108.233 1
2522122-1
Magnetic plug
G 1/4"
108.234 3
9ADA 618-56
Torx pan head screw
M6 x 16
108.235 1
3HAC 021071-001
Cable protection lower arm
Item
Qty
t = 4 mm
t=3
469

9.3.14. Material set, axis 1-2, 3HAC 13264-1
Item
Qty
Art. number
Description
Dimension / Note
109.301
3HAC 021541-001
Reduction gear
See block Reduction

gear on page 471
109.302
3HAC 022812-003
Cover, axis 2
109.304
32
3HAB 3409-71
Hex socket head cap

screw
M12 x 60
109.305
32
3HAA 1001-134
Washer
13 x 19 x 1.5
109.306
3HAC 14749-1
See block Rot ac motor

incl pinion, 3HAC
14749-1 on page 471
109.307
3HAC020219-001
Motor incl. pinion
See block Motor incl

pinion, 3HAC 020219001 on page 472
109.308
3HAB 3409-50
Hex socket head cap

screw
M10 x 40
109.309
3HAB 4233-1
Washer
109.310
3HAC 12252-1
Bottom plate
T=3
109.310
3HAC026052-001
Bottom plate
(Foundry Prime)
T=2
109.311
3HAC 14131-1
Connection plate, base
t=3 mm
109.311
3HAC026186-001
Connection plate, base

(Foundry Prime)
t=3 mm
109.312
3HAC 11774-3
Adapter, complete
See block Adapter,

complete, 3HAC 117743 on page 472
109.313
3HAC 11769-1
Cable guide, ax.1
109.315
14
9ADA 183-39
Hex socket head cap

screw
M8 x 35
109.316
14
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
109.318
3HAB 3772-73
O-ring
410 x 4
109.320
3HAC 021287-001
Sync plate
109.320
3HAC026185-001
Sync plate
109.321
3HAC 12671-6
Block for calibration
109.322
3HAC 14024-1
Protection screw
See block Protection

screw, 3HAC 14024-1
on page 472
109.324
24
9ADA 618-56
Torx pan head screw
M6 x 16
109.325
9ADA 618-57
Torx pan head screw
M6 x 20
109.326
3HAC 16014-1
Serial measurement unit
109.327
109.328
3HAC 16831-1
Battery pack
109.329
3HAC 13151-1
Cable battery/SMB
L=350 20
109.330
3HAC 11526-1
Stud screw
M6 x 150
Foundry Prime
Cover SMB and BRU
See block Cover SMB

and BRU on page 472

470
Overview

Continued
Item
Qty
Art. number
Description
Dimension / Note
109.332
3HAC 14791-3
Cover battery box
See block Cover,

battery box, 3HAC
14791-3 on page 472
109.322
3HAC026190-001
Cover battery box

(Foundry Prime)
109.334
9ADA 618-53
Torx pan head screw
M6 x 8
109.336
3HAC 020745-001
Attachment plate
IRB 6600
109.336
3HAC 020122-001
Attachment plate
IRB 6650
109.337
3HAC 12625-1
Strap, Velcro
25 x 450
109.338
3HAC 14792-1
Bracket
T=3
109.339
3HAC 15619-1
Cable, FB7-SMB 1.7
109.340
1 ml
12690014-413
Locking liquid
109.341
7,300 3HAC16843-1
ml
Lubricating oil, RMO 150 Do not mix the types of

oil!
109.341
7,300 3HAC 032140-001

ml

Yushi TMO150
109.342
5,800 3HAC 16843-1

ml
Lubricating oil, RMO 150 Do not mix the types of

oil!
109.342
5,800 3HAC 032140-001

ml

Yushi TMO150
109.344
1 ml
3HAB 7116-1
Locking liquid
109.345
9ADA 267-6
Hexagon nut
109.346
3HAC 16035-1
BU w. buttons DSQC 563
109.347
3HAC 6499-1
Push button guard
109.348
9ADA 629-56
Torx pan head roll. screw M6 x 16
109.349
9ADA 618-58
Torx pan head screw
109.350
3HAC 4813-1
Cover, push button guard
109.350
3HAC026331-001
Cover, push button guard Foundry Prime
109.351
10
9ADA 618-44
Torx pan head screw
109.352
3HAC 14024-1
Protection screw
109.353
3HAC 17423-1
Washer
109.354
9ADA 269-4
Hexagon nut
109.360
3HAB 3558-14
Lock washer
Art. number
Description
Do not mix the types of

oil!
Do not mix the types of

oil!
M6
M6 x 25
M5 x 12
M8
Reduction gear
Item
Qty
109.301.1 1
3HAC 021543-001 Reduction gear
109.301.2 1
3HAB 3772-77
Dimension
O-ring
345 x 3.1
Rot ac motor incl pinion, 3HAC 14749-1

Item
Qty
Art. number
Description
Dimension
109.306.1 1
3HAC 17484-6
109.306.2 1
3HAC 11350-1
Pinion RV 500C & RV 320C

471

Continued
Item
Qty
109.306.3 1
Art. number
Description
Dimension
2152 2012-430
O-ring
89.5 x 3
Motor incl pinion, 3HAC 020219-001

Item
Qty
Art. number
Description
Dimension
109.307.1 1
3HAC 020208-001 Rotation AC motor, M11
109.307.2 1
3HAC 020131-001 Pinion
109.307.3 1
9ADA 183-446
Hexagon socket head screw
M8 x 150
109.307.4 1
2152 2012-430
O-ring
89.5 x 3
109.307.5 1 ml
3HAB 7116-1
Locking liquid
Art. number
Description
109.312.1 1
3HAC 11774-1
Adapter, machined
109.312.2 2
2152 2012-428
O-ring
109.312.3 1 ml
1234 0011-125
Acrylate adhesive
Adapter, complete, 3HAC 11774-3

Item
Qty
Dimension
79.5 x 3
Protection screw, 3HAC 14024-1

Item
Qty
Art. number
Description
Dimension
109.322.1 1
3HAC 13582-1
Protection screw
109.322.2 1
3HAB 3772-32
O-ring
17 x 3
Item
Art. number
Description
Dimension
109.327.1 1
3HAC 14692-1
Cover
109.327.2 1
3HAC 14692-2
Gasket
109.327.3 1
3HAC 14692-4
Rubber cloth
Art. number
Description
Dimension
109.332.1 1
3HAC 14791-1
Cover
T=4
109.332.2 1
3HAC 14791-2
Gasket
T=3
109.332.3 1
3HAC 16977-1
Warning label battery
Qty
Cover, battery box, 3HAC 14791-3

Item
472
Qty
Cover SMB and BRU

9.3.15. Material set, balancing device, 3HAC 13265-1
9.3.15. Material set, balancing device, 3HAC 13265-1

Overview
Item
Qty
Art. number
Description
Dimension
110.401
3HAC 12441-2
65 x 120 x 38
110.402
3HAC 12481-1
Thrust washer
110.403
3HAC 12627-1
Bushing
110.404
9ABA 135-31
Retaining ring, shaft
110.405
3HAC 12480-1
Shaft
110.406
3HAC 4836-7
Protection plug
16 x 12.3 x 9 x 7
110.407
3HAB 7700-5
M16 x 70
110.408
9ABA 107-56
Parallel pin
10 x 20
110.409
3HAC 12548-1
Protection washer
T=1
110.410
3HAC 12534-1
110.411
3HAA 1001-186
Washer
110.412
50 ml 3HAA 1001-294
Grease
110.413
3HAC 4836-1
Protection plug
20 x 14.6 x 7.5 x 5.5
110.414
9ADA 183-490
M16 x 180
110.415
9ADA 312-10
Plain washer
17 x 30 x 3
65
17 x 25 x 3
473

9.3.16. Arm extension set, 250 mm, 3HAC 12311-4

Overview
Item
Qty
Art. number
Description
Dimension
111.501
3HAC 9760-3
Arm extender 250mm
111.501
3HAC 15859-2
Arm extender 250mm, Foundry
111.503
12
3HAB 7700-69
M12 x 50
111.504
12
3HAA 1001-134
Washer
13 x 19 x 1.5
111.505
9ABA 107-56
Parallel pin
10 x 20
111.506
3HAC 9760-9
Cable cover 250mm
111.507
9ADA 618-56
Torx pan head screw
M6 x 16
474


Overview
Item
Qty
Art. number
Description
Dimension
111.501
3HAC 9760-7
Arm extender, 450mm
111.501
3HAC 15859-3
Arm extender, 450mm, Foundry
111.503
12
3HAB 7700-69
M12 x 50
111.504
12
3HAA 1001-134
Washer
13 x 19 x 1.5
111.505
9ABA 107-56
Parallel pin
10 x 20
111.506
3HAC 9760-10
Cable cover 450mm
111.507
9ADA 618-56
Torx pan head screw
M6 x 16
475
476
10 Exploded views
10.1. Introduction
10 Exploded views
10.1. Introduction
Definitions
This chapter contains detailed views of the components on the manipulator.
The numbered details are specified with item numbers in the Part List.
The exploded views are divided into:
Base, incl. frame
Frame-Lower arm 1
Frame-Lower arm 2
Upper arm
Wrist complete
477
10 Exploded views
10.2. Base incl. Frame
10.2. Base incl. Frame
Exploded view
xx0200000329
478
10 Exploded views
10.3. Frame-Lower arm 1
Exploded view
xx0500002513
479
10 Exploded views
Exploded view
xx0200000335
480
10 Exploded views
10.5. Upper arm
10.5. Upper arm
Exploded view
xx0200000337
481
10 Exploded views
10.6. Wrist complete, IRB 6600 and IRB 6650
10.6. Wrist complete, IRB 6600 and IRB 6650
Exploded view
xx0200000336
482
10 Exploded views
10.7. Wrist complete, IRB 6600ID and IRB 6650ID
Exploded view
xx0500002407
483
10 Exploded views
484
11 Circuit Diagram
11.1. Introduction
11 Circuit Diagram
11.1. Introduction
Overview
This chapter includes the circuit diagram for the robot.
Use the correct circuit diagram (IRB 6600, IRB 6650 and IRB 6650S)
The cable harness of the robot is available in two different designs. Either the cabling is
divided between the upper and lower arm, or not. Accordingly there are also two different
versions of the circuit diagram. Determine which circuit diagram that is valid for the robot,
by checking the article number for the cable harness.
485
11 Circuit Diagram
11.2.1. Validity of circuit diagram 3HAC 025744-1
11.2 Circuit diagram 3HAC 025744-001

Is this circuit diagram valid for your robot?
The validity of the circuit diagram depends on which cable harness is fitted to the robot.
Check the article number of the cable harness fitted to the robot and see page 3 of the circuit
diagram in order to determine if the diagram is valid for the harness or not.
Where to find the article number
Action
Label on the cable harness
The label is located at the connectors in the base.

Remove the rear cover plate to see the label.
WebConfig
486
The information in this document 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 document.
Except as may be expressly stated anywhere in this document, 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.
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
In no event shall ABB be liable for incidental or consequential damages arising from use of this document.
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document 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
Lab/Office:
Latest revision:
Status:
2007-04-20
APPROVED
Prepared by, date:
Approved by, date:
COPYRIGHT page
Title page/cover sheet
Document no.
=
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 1
Next 2
Total 21
3HAC025744-001
02
Table of contents
Page
Page description
ABB Contents1
Comment
COPYRIGHT page
Table of contents: (1 - 150)
Valid For
Connection point location
IRB 6600 / 6640 / 6650 / 7600
IRB 6660
Legend
IRB 66XX / 7600
10
Brake Release Unit
IRB 66XX / 7600
20
Serial Measuring Board
IRB 66XX / 7600
30
Axis 1
IRB 66XX / 7600
40
Axis 2
IRB 66XX / 7600
50
Axis 3
Incl. optional signal lamp IRB 66XX / 76
60
Axis 4
IRB 66XX / 7600
70
Axis 5
IRB 7600
80
Axis 5
IRB 66XX
90
Axis 5
IRB 66XX ID
100
Axis 6
IRB 7600
110
Axis 6
IRB 66XX
120
Axis 6
IRB 66XX ID
130
Pos. switch Axis 1
Optional IRB 66XX / 7600
140
Pos. switch Axis 2
150
Pos. switch Axis 3
Lab/Office:
Latest revision:
Status:
2007-04-20
APPROVED
Prepared by, date:
Approved by, date:
Table of contents: (1 - 150)

Table of contents
Document no.
=
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 2
Next 3
Total 21
3HAC025744-001
02
Valid For:
This circuit diagram is valid for the following cable harness assemblies:
3HAC 024385-001 Manipulator harness axis 1-6 (IRB 6600 / 6640)
3HAC 024386-001 Manipulator harness axis 1-6 (IRB 6640 / 6650 / 6650S)
3HAC14940-1 rev 3 and later. Manipulator harness axis 1-4 (IRB 6600 ID / 6640 ID / 7600)
3HAC16331-1 rev 1 and later. Manipulator harness axis 1-4 (IRB 6640 ID / 6650 ID)
3HAC14139-1 Manipulator harness axis 5 (IRB 6600 / 6640 / 6650 / 6650S)
3HAC11440-1 Manipulator harness axis 5-6 (IRB 7600)
3HAC023717-001 Manipulator harness axis 5-6 (IRB 6600 ID / 6640 ID / 6650 ID)
3HAC15930-1 UL signal lamp (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S / 7600)
3HAC12498-1 Pos SW 3 functions (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S / 7600)
3HAC12587-1 Pos SW 2 functions (IRB 6600 / 6650 / 6600 ID / 6650 ID / 6650S / 7600)
3HAC15374-1 Fan (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S /6660 / 7600)
3HAC15390-1 Pos Sw/ Fan cable harness (IRB 6600 / 6600 ID / 7600)
3HAC16659-1 Pos Sw/ Fan cable harness (IRB 6650 / 6650 ID / 6650S)
3HAC023599-001 Fan cable harness (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S /6660 / 7600)
3HAC026733-001 Manipulator harness axis 1-6 (IRB 6660)
3HAC028206-001 UL signal lamp (IRB 6660)
See circuit diagram 3HAC13347-1 in the following cases:
- If IRB6600, 6650 or 6650S with 3HAC14940-1, 3HAC16331-1
- If cable harness 3HAC14940-1 rev 2 or earlier
- If cable harness 3HAC16331-1 rev 0
Lab/Office:
Latest revision:
Status:
2007-04-20
APPROVED
Prepared by, date:
Approved by, date:
Valid For
Text view
Document no.
=
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 3
Next 4
Total 21
3HAC025744-001
02
R3.FB5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID)

R3.MP5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID)
R3.MP6
R3.MP5 (IRB 6600, 6640, 6650, 6650S)
R3.FB6
R3.FB5 (IRB 6600, 6640, 6650, 6650S)
R4.MP5 (IRB 6600, 6640, 6650, 6650S)
R4.FB5 (IRB 6600, 6640, 6650, 6650S)
R1.MP
R2.M5/6
(On IRB7600, 6600 ID,
6640 ID, 6650 ID)
1 10 17 24
2
3
12 11 10 9
6
R2.MP4
R2.FB4
8
2
7
B
1
4
5
R2.SW3
12 11 10 9
R3.FAN3
R2.FB3
R2.MP3
R2.H1
R2.H2
26
27
13 20 28
29
14 21
7
1
12 19
7
C
5
6
25
11 18
30
15 22
31
16 23 32
R2.M5/6 (IRB7600, 6600 ID, 6640 ID, 6650 ID)

R2.MP2
R2.FB2
R1.G
R1.SMB1.7
R3.FAN2
R2.FB7
R2.G
R2.SMB
R1.SMB1-3
R1.SMB4-6
R2.SW2
X8
X9
X10
R2.MP1
R2.FB1
R1.MP
R1.SMB
R1.SW1
R1.SW2/3
Lab/Office:
Latest revision:
Status:
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 6600 / 6640 / 6650 / 7600
= 6600/6640-50/7600
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 4
Next 5
Total 21
3HAC025744-001
02
R3.MP6
R3.FB6
R3.MP5
R3.FB5
R2.CP/CS
R2.MP4
R2.FB4
R2.MP3
R2.FB3
R2.H1
R2.H2
R2.MP2
R2.FB2
R2.MP1
R2.FB1
R1.SMB1-3
R1.SMB4-6
R2.SMB
X8
X9
X10
R1.MP
R1.SMB
R1.CP/CS
Lab/Office:
Latest revision:
Status:
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 6660
= IRB6660
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 5
Next 9
Total 21
3HAC025744-001
02
Motor
Protective Earth
PTC
Brake
Twisted wires
Temp sensor (PTC- resistor)
Screened wires
Resolver
XX
Battery Pack
BU
Brake Release Unit
FB
Feedback unit
SMB
Serial Measurment Board
FAN
Fan
SW
Keypin
Any number i.e. 66XX can be 6600, 6640, 6660 or 6650
Position switch
Location pin to avoid mismatch
Lab/Office:
Latest revision:
Status:
Legend
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX / 7600
= IRB66XX/7600
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 9
Next 10
Total 21
3HAC025744-001
02
BU Brake Release (Simplified)

-R1.MP
13
Brake Release
-X8
-X8
1
2
-X10
A
11
Brake PB
12
0V
-X10
R1.MP
R1.MP
R1.MP
R1.MP
R1.MP
10
R1.MP
-BU M1 / +Axis 1/30;2
Brake Bleed Circuit
-BU 0V M1 / +Axis 1/30;2
4
A
-BU M2 / +Axis 2/40;2
-BU 0V M2 / +Axis 2/40;2

-BU 0V M3 / +Axis 3/50;2
Brake Bleed Circuit

4
-BU 0V M4 / +Axis 4/60;2

A
-BU 0V M5 / =7600+Axis 5/70;2

=66XX+Axis 5/80;2
=66XX ID+Axis 5/90;2
-BU M3 / +Axis 3/50;2
Brake Bleed Circuit

6
Key Pin
-BU 0V M6 / =7600+Axis 6/100;2
=66XX+Axis 6/110;2
-X9
A
-X9
-BU M4 / +Axis 4/60;2
Brake Bleed Circuit

5
-BU M5 / =7600+Axis 5/70;2

=66XX+Axis 5/80;2
=66XX ID+Axis 5/90;2
Brake Bleed Circuit

9
10
10
-BU M6 / =7600+Axis 6/100;2

=66XX+Axis 6/110;2
=66XX ID+Axis 6/120;2
Brake Bleed Circuit

11
Key Pin
Lab/Office:
Latest revision:
Brake Release
Status:
Brake Release Unit
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX / 7600
= 66XX/7600
Plant:
+ BU
Location:
Sublocation: +
Rev. Ind Page 10
Next 20
Total 21
3HAC025744-001
02
SMB
+Axis 3/50;3 / -0V EXT.LAMP

R1.SMB
R2.SMB
R2.SMB
SDI
BK
SDI-N
WHBK
SDO
BN
SDO-N
WHBN
0V
RD
24V
WHRD
OG
L
M
KEYPIN
+Axis 3/50;3 / -24V EXT.LAMP

G
R2.G
+
-+
-+
R1.G(X3)
R1.G(X3)
0V
Lab/Office:
Latest revision:
Status:
Serial Measuring Board
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX / 7600
= 66XX/7600
Plant:
+ SMB
Location:
Sublocation: +
Rev. Ind Page 20
Next 30
Total 21
3HAC025744-001
02
MU1
R1.MP
-R2.MP1
-R2.MP1
17
M1R
RD
24
M1R
RD
R (U)
PE
M
~
T (W)
3
18
M1S
WH
25
M1S
WH
19
M1T
BK
26
M1T
10
10
BK
PE
GNYE
GNYE
PE
GNYE
12
12
GNYE
BU M1
BU +
BU 0V M1
10
BU -
PTC M
PTC M2
11
11
+BU/10;7 / -BU M1
S (V)
Brake
+BU/10;2 / -BU 0V M1
27
+Axis 2/40;2 / -PTC M2
SMB
-PTC1
FB1
R1.SMB1-3
R1.SMB1-3
BK
X1
14
14
WHBK
0V X1
-R2.FB1
-R2.FB1
RD
BK
Resolver
BN
Y1
BU
15
15
WHBN
0V Y1
YE
RD
0V EXC1
WHBK (WHYE)
18
18
WHRD
EXC1
WHRD
Lab/Office:
Latest revision:
Status:
Axis 1
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX / 7600
= 66XX/7600
Plant:
+ Axis 1
Location:
Sublocation: +
Rev. Ind Page 30
Next 40
Total 21
3HAC025744-001
02
MU2
R1.MP
-R2.MP2
-R2.MP2
23
M2R
RD
32
M2R
RD
22
M2S
WH
R (U)
PE
M
~
T (W)
3
31
M2S
WH
21
M2T
BK
30
M2T
10
10
BK
PE
GNYE
GNYE
PE
GNYE
12
12
GNYE
BU M2
BU +
BU 0V M2
10
BU -
+Axis 1/30;2 / -PTC M2
PTC M2
BU
+Axis 3/50;2 / -PTC M3
PTC M3
11
11
BK
+BU/10;7 / -BU M2
S (V)
Brake
+BU/10;2 / -BU 0V M2
SMB
-PTC2
FB2
R1.SMB1-3
R1.SMB1-3
BK
X2
16
16
WHBK
0V X2
-R2.FB2
-R2.FB2
RD
BK
Resolver
BN
Y2
BU
17
17
WHBN
0V Y2
YE
RD
0V EXC1
WHBK (WHYE)
19
19
WHRD
EXC1
WHRD
Lab/Office:
Latest revision:
Status:
Axis 2
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX / 7600
= 66XX/7600
Plant:
+ Axis 2
Location:
Sublocation: +
Rev. Ind Page 40
Next 50
Total 21
3HAC025744-001
02
MU3
R1.MP
-R2.MP3
-R2.MP3
M3R
RD
M3R
RD
R (U)
PE
M
~
T (W)
3
5
M3S
WH
M3S
WH
M3T
BK
14
M3T
10
10
BK
PE
GNYE
GNYE
PE
GNYE
12
12
GNYE
BU M3
BU +
BU 0V M3
10
BU -
+Axis 2/40;2 / -PTC M3
PTC M3
BU
+Axis 4/60;2 / -PTC M4
PTC M4
11
11
BK
+BU/10;7 / -BU M3
S (V)
Brake
+BU/10;2 / -BU 0V M3
-PTC3
B
A
KEYPIN
KEYPIN
SIGNAL LAMP (OPTIONAL)

R3.H
+SMB/20;4 / -24V EXT.LAMP
OG
R2.H1
R2.H1
+SMB/20;4 / -0V EXT.LAMP
R2.H2
R2.H2
2
SMB
FB3
R1.SMB1-3
R1.SMB1-3
BK
X3
21
21
WHBK
0V X3
-R2.FB3
-R2.FB3
RD
BK
Resolver
10
10
BN
Y3
BU
22
22
WHBN
0V Y3
YE
RD
0V EXC1
WHBK (WHYE)
20
20
WHRD
EXC1
WHRD
Lab/Office:
Latest revision:
Status:
Axis 3
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
Incl. optional signal lamp IRB 66XX / 7600
= 66XX/7600
Plant:
+ Axis 3
Location:
Sublocation: +
Rev. Ind Page 50
Next 60
Total 21
3HAC025744-001
02
MU4
R1.MP
-R2.MP4M4R
-R2.MP4-
RD
R (U)
PE
M
~
T (W)
3
2
M4S
WH
10
M4T
BK
PE
GNYE
GNYE
BU M4
BU +
BU 0V M4
BU -
+Axis 3/50;2 / -PTC M4
PTC M4
BU
=7600+Axis 5/70;2
=66XX+Axis 5/80;2
=66XX ID+Axis 5/90;2 / -PTC M5
PTC M5
11
11
BK
+BU/10;7 / -BU M4
S (V)
Brake
+BU/10;2 / -BU 0V M4
1 -PTC4
A Keypin
Keypin B
SMB
FB4
R1.SMB4-6
R1.SMB4-6
BK
X4
14
14
WHBK
0V X4
-R2.FB4
-R2.FB4-
RD
BK
Resolver
BN
Y4
BU
15
15
WHBN
0V Y4
YE
RD
0V EXC2
WHBK (WHYE)
18
18
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 4
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX / 7600
= 66XX/7600
Plant:
+ Axis 4
Location:
Sublocation: +
Rev. Ind Page 60
Next 70
Total 21
3HAC025744-001
02
MU5
R1.MP
R2.M5/6
M5R
20
C1
-R3.MP5
M5R
C1
-R3.MP5-
RD
R (U)
PE
M
~
T (W)
3
28
M5S
C2
C2
M5S
WH
29
M5T
C3
C3
M5T
BK
PE
GNYE
GND
PE
GNYE
GNYE
BU M5
B9
B9
BU M5
BU +
BU 0V M5
B1
B1
BU 0V M5
BU -
PTC M5
B7
B7
PTC M5
BU
B8
PTC M6
11
11
BK
=66XX/7600+BU/10;7 / -BU M5
GND
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M5
=66XX/7600+Axis 4/60;2 / -PTC M5

PTC 0V
15
1 -PTC5
-PTC 0V / +Axis 6/100;3
-PTC M6 / +Axis 6/100;5
SMB
FB5
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X5
A1
A1
BK
X5
16
16
WHBK
0V X5
A7
A7
WHBK
0V X5
-R3.FB5-
-R3.FB5-
RD
BK
Resolver
BN
Y5
A2
A2
BN
Y5
BU
17
17
WHBN
0V Y5
A8
A8
WHBN
0V Y5
YE
RD
0V EXC2
A3
A3
RD
0V EXC2
WHBK (WHYE)
19
19
WHRD
EXC2
A9
A9
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 5
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 7600
= 7600
Plant:
+ Axis 5
Location:
Sublocation: +
Rev. Ind Page 70
Next 80
Total 21
3HAC025744-001
02
MU5
R1.MP
R3.MP5
M5R
20
-R4.MP5M5R
-R4.MP5-
RD
R (U)
PE
M
~
T (W)
3
28
M5S
M5S
WH
29
M5T
M5T
BK
PE
GNYE
GND
PE
GNYE
GNYE
BU M5
BU M5
BU +
BU 0V M5
BU 0V M5
BU -
=66XX/7600+Axis 4/60;2 / -PTC M5
PTC M5
PTC M5
BU
+Axis 6/110;2 / -PTC M6.1
PTC M6
PTC M6
11
11
BK
=66XX/7600+BU/10;7 / -BU M5
GND
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M5
1 -PTC5
A Keypin
SMB
FB5
R1.SMB4-6
R1.SMB4-6
R3.FB5
BK
X5
BK
X5
16
16
WHBK
0V X5
WHBK
0V X5
-R4.FB5- -R4.FB56
6 RD
1
BK
Resolver
BN
Y5
BN
Y5
BU
17
17
WHBN
0V Y5
WHBN
0V Y5
YE
RD
0V EXC2
RD
0V EXC2
WHBK (WHYE)
19
19
WHRD
EXC2
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 5
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX
= 66XX
Plant:
+ Axis 5
Location:
Sublocation: +
Rev. Ind Page 80
Next 90
Total 21
3HAC025744-001
02
MU5
R1.MP
R2.M5/6
M5R
20
C1
C1
-R3.MP5
M5R
-R3.MP5-
RD
R (U)
PE
M
~
T (W)
3
28
M5S
C2
C2
M5S
WH
29
M5T
C3
C3
M5T
BK
PE
GNYE
GND
PE
GNYE
PE
GNYE
BU M5
B9
B9
BU M5
BU +
BU 0V M5
B1
B1
BU 0V M5
11
BU -
PTC M5
B7
B7
PTC M5
BU
BK
=66XX/7600+BU/10;7 / -BU M5
GND
PE
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M5
=66XX/7600+Axis 4/60;2 / -PTC M5
BU
PTC 0V 5
-PTC 0V.1 / +Axis 6/120;3
15
PTC M6
BU
1 -PTC5
-PTC M6.2 / +Axis 6/120;4

-BU 0V M6.1 / +Axis 6/120;4
SMB
FB5
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X5
A1
A1
BN
X5
16
16
WHBK
0V X5
A7
A7
WHBN
0V X5
-R3.FB5-
-R3.FB5-
RD
BK
Resolver
BN
Y5
A2
A2
RD
Y5
BU
17
17
WHBN
0V Y5
A8
A8
WHRD
0V Y5
YE
RD
0V EXC2
A3
A3
OG
0V EXC2
WHBK (WHYE)
19
19
WHRD
EXC2
A9
A9
WHOG
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 5
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX ID
= 66XX ID
Plant:
+ Axis 5
Location:
Sublocation: +
Rev. Ind Page 90
Next 100
Total 21
3HAC025744-001
02
R1.MP
9
MU6
-R3.MP6 -R3.MP6
-R2.M5/6M6R
C4
C4
M6R
RD
R (U)
PE
M
~
T (W)
3
8
M6S
C5
C5
M6S
WH
16
M6T
C6
C6
M6T
BK
PE
GNYE
GND
GND
PE
GNYE
GNYE
BU M6
B11
B11
BU M6
BU +
BU 0V M6
B12
B12
BU 0V M6
BU -
BU
11
11
BK
=66XX/7600+BU/10;7 / -BU M6
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M6
+Axis 5/70;5 / -PTC M6

+Axis 5/70;3 / -PTC 0V
B10
B10
PTC 0V
PTC M6
SMB
1 -PTC6
FB6
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X6
21
21
WHBK
0V X6
A4
A4
BK
X6
A10
A10
WHBK
0V X6
-R3.FB6
-R3.FB6
RD
BK
Resolver
10
10
BN
Y6
22
22
WHBN
0V Y6
RD
0V EXC2
20
20
WHRD
EXC2
A5
A5
BN
Y6
BU
A11
A11
WHBN
0V Y6
YE
A6
A6
RD
0V EXC2
WHBK (WHYE)
A12
A12
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 6
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 7600
= 7600
Plant:
+ Axis 6
Location:
Sublocation: +
Rev. Ind Page 100
Next 110
Total 21
3HAC025744-001
02
MU6
-R3.MP6- -R3.MP6-
R1.MP
M6R
RD
R (U)
PE
M
~
T (W)
3
8
M6S
WH
16
M6T
BK
PE
GNYE
GNYE
BU M6
BU +
BU 0V M6
BU -
=66XX/7600+BU/10;7 / -BU M6
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M6
+Axis 5/80;2 / -PTC M6.1

15
PTC M6
BU
PTC 0V
11
11
BK
SMB
1 -PTC6
FB6
R1.SMB4-6
R1.SMB4-6
BK
X6
21
21
WHBK
0V X6
-R3.FB6
-R3.FB6
RD
BK
Resolver
10
10
BN
Y6
BU
22
22
WHBN
0V Y6
YE
RD
0V EXC2
WHBK (WHYE)
20
20
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 6
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX
= 66XX
Plant:
+ Axis 6
Location:
Sublocation: +
Rev. Ind Page 110
Next 120
Total 21
3HAC025744-001
02
R1.MP
9
MU6
-R3.MP6 -R3.MP6
-R2.M5/6M6R
C4
M6R
C4
RD
R (U)
PE
M
~
T (W)
3
8
M6S
C5
C5
M6S
WH
16
M6T
C6
C6
M6T
BK
PE
GNYE
GND
GND
PE
GNYE
GNYE
BU M6
B11
B11
BU M6
BU +
BU 0V M6
BU -
PTC M6
BU
PTC 0V
11
11
BK
=66XX/7600+BU/10;7 / -BU M6
S (V)
Brake
+Axis 5/90;5 / -BU 0V M6.1
+Axis 5/90;5 / -PTC M6.2

+Axis 5/90;3 / -PTC 0V.1
B10
B10
SMB
1 -PTC6
FB6
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X6
21
21
WHBK
0V X6
A4
A4
BK
X6
A10
A10
WHBK
0V X6
-R3.FB6
-R3.FB6
RD
BK
Resolver
10
10
BN
Y6
22
22
WHBN
0V Y6
RD
0V EXC2
20
20
WHRD
EXC2
A5
A5
BN
Y6
BU
A11
A11
WHBN
0V Y6
YE
A6
A6
RD
0V EXC2
WHBK (WHYE)
A12
A12
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 6
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
IRB 66XX ID
= 66XX ID
Plant:
+ Axis 6
Location:
Sublocation: +
Rev. Ind Page 120
Next 130
Total 21
3HAC025744-001
02
-SW1.1
A
Power 1.1.1
21
22
Power 1.1.2
13
14
Signal 1.1.2
Signal 1.1.1
Location of position switches
SW1.6
-SW1.2
E
Power 1.2.1
21
22
Power 1.2.2
13
14
Signal 1.2.2
Signal 1.2.1
SW1.5
SW1.4
SW1.3
-SW1.3
SW1.2
J
Power 1.3.1
21
22
Power 1.3.2
10
13
14
Signal 1.3.2
12
Signal 1.3.1
11
-SW1.4
Power 1.4.1
13
21
22
Power 1.4.2
14
13
14
Signal 1.4.2
16
Signal 1.4.1
15
SW1.1
Position switches
Axis 1
-SW1.5
T
Power 1.5.1
17
21
22
Power 1.5.2
18
13
14
Signal 1.5.2
20
Signal 1.5.1
19
-SW1.6
Power 1.6.1
21
21
22
Power 1.6.2
22
13
14
Signal 1.6.2
24
Signal 1.6.1
23
Lab/Office:
Latest revision:
Status:
Pos. switch Axis 1
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
= 66XX/7600
Plant:
+ Option
Location:
Sublocation: +
Rev. Ind Page 130
Next 140
Total 21
3HAC025744-001
02
Location of position switches
Power 2.1.1
21
22
Power 2.1.2
Power 2.1.2
13
14
Signal 2.1.2
Signal 2.1.2
Signal 2.1.1
Signal 2.1.1
SW2.1
Power 2.1.1
SW2.2
SW2.4
R2.SW2
SW2.3
-SW2.1
R1.SW2/3
-SW2.2
E
Power 2.2.1
Power 2.2.1
21
22
Power 2.2.2
Power 2.2.2
13
14
Signal 2.2.2
Signal 2.2.2
Signal 2.2.1
Signal 2.2.1
Position switches
Axis 2
-SW2.3
J
Power 2.3.1
Power 2.3.1
21
22
Power 2.3.2
10
Power 2.3.2
10
13
14
Signal 2.3.2
12
Signal 2.3.2
12
Signal 2.3.1
11
Signal 2.3.1
11
13
24V FAN
+
15
ALARM FAN
-FAN
Fan axis 1 or 2
M
-
14
0V FAN
Lab/Office:
Latest revision:
Status:
Pos. switch Axis 2
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
= 66XX/7600
Plant:
+ Option
Location:
Sublocation: +
Rev. Ind Page 140
Next 150
Total 21
3HAC025744-001
02
Location of Position switches
-SW3.1
Power 3.1.1
Power 3.1.1
21
22
Power 3.1.2
Power 3.1.2
13
14
Signal 3.1.2
Signal 3.1.2
Signal 3.1.1
Signal 3.1.1
SW3.4
SW3.1
R2.SW3
SW3.2
R1.SW2/3
SW3.3
-SW3.2
X
Power 3.2.1
Power 3.2.1
21
22
Power 3.2.2
Power 3.2.2
13
14
Signal 3.2.2
Signal 3.2.2
Signal 3.2.1
Signal 3.2.1
Position switches
Axis 3
-SW3.3
b
Power 3.3.1
Power 3.3.1
21
22
Power 3.3.2
10
Power 3.3.2
10
13
14
Signal 3.3.2
12
Signal 3.3.2
12
Signal 3.3.1
11
Signal 3.3.1
11
13
24V FAN
+
15
ALARM FAN
-FAN
Fan axis 3
M
-
14
0V FAN
Lab/Office:
Latest revision:
Status:
Pos. switch Axis 3
2005-10-17
APPROVED
Document no.
Prepared by, date:
Approved by, date:
= 66XX/7600
Plant:
+ Option
Location:
Sublocation: +
Rev. Ind Page 150
Next
Total 21
3HAC025744-001
02
11 Circuit Diagram
11.3 Circuit diagram 3HAC 13347-1

Is this circuit diagram valid for your robot?
The validity of the circuit diagram depends on which cable harness is fitted to the robot.
Check the article number of the cable harness fitted to the robot.
Where to find the article number
Action
Label on the cable harness
The label is located at the connectors in the base.

Remove the rear cover plate to see the label.
WebConfig
This circuit diagram is valid for the following cable harness assemblies:
Robot
Cable harness
Revision
IRB 6600
3HAC 14940-1
all
IRB 6650, IRB 6650S
3HAC 16331-1
all
IRB 7600
3HAC 14940-1
revision 0-2
For remaining cable harness assemblies, see section Circuit diagram 3HAC 025744-001 on
page 486.
487
Circuit Diagram 3HAC 13347-1 / Rev. 02

CONTENTS
Sheet
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 6............................................................................................................................111
Switches axis 1 .............................................................................................................113
Switches/Fan axis 2 ......................................................................................................114
Switches/Fan axis 3 ......................................................................................................115
Axis 5 (IRB 6600) ........................................................................................................901
Design changes, note 1.1 ..............................................................................................905
Design changes, note 2.1-2.7 ........................................................................................906
sheet
Contents
101
02
Circuit Diagram 3HAC 13347-1
Revision
sheet
Connection Point Location

102
02
Revision
sheet
Legend
103
02
Revision
Brake Release Unit

104
sheet
02
Revision
sheet
Serial Measurement Board

105
02
Revision
sheet
Axis 1
106
02
Revision
sheet
Axis 2
107
02
Revision
sheet
Axis 3
108
02
Revision
Axis 4
109
sheet
02
Revision
Axis 5 (IRB 7600)

110
sheet
02
Revision
sheet
Axis 6
111
02
Revision
sheet
Switches axis 1
113
02
Revision
sheet
Switches/Fan axis 2
114
02
Revision
sheet
Switches/Fan axis 3
115
02
Revision
Axis 5 (IRB 6600)

Revision
901
02
sheet
Design changes, note 1.1

Revision
905
02
sheet
Design changes, note 2.1-2.7

Revision
906
02
sheet
11 Circuit Diagram
488
Index
A
Absolute Accuracy, calibration 411
gearbox axis 1, replacement

balancing device bearing, replacement 317

balancing device, replacement 322
brake release unit, replacement 313
brakes
testing function 29
requirements 54
cable harness axes 1-4, replacement 240

cable harness axes 1-6, replacement 228
cabling
position switches 111
cabling axis 5, replacement 259
cabling between robot and controller 122
cabling, robot 122
cabling, robot axes 1-4 241
cabling, robot axes 5-6 249
calibrating
roughly 415
calibration
Absolute Accuracy type 410
alternative method 411
Levelmeter calibration 411
marks/scales 412
rough 415
standard type 410
when to calibrate 409
calibration manuals 411
calibration position 415
checking 419
jogging to, FlexPendant 420
jogging to, TPU 420
scales 412
calibration, Absolute Accuracy 411
CalibWare 410
complete arm system, replacement 261
connecting the robot and controller, cabling 122
Connection of external safety devices 18
D
direction of axes 414
E
enlarged gear 427
ESD
damage elimination 40
sensitive equipment 40
wrist strap connection point 40
explanation, safety symbols 35
I
identification 427
installation
mechanical stop axis 1 105
installing
L
Levelmeter calibration 411
lifting of robot
with lifting slings 68
lifting robot
with fork lift 61
lifting slings, robot 68
lifting upper arm
attachment points for lifting device 286
loads on foundation 54
lower arm shaft, replacement 299
lower arm, replacement 292
M
mechanical stop
axis 1 105
axis 2 107
axis 3 109
motion of axes 59
motor axis 1, replacement
MoveAbsJ instruction
FlexPendant 419
TPU 419
337
343
350
357
364
374
N
negative directions, axes 414
O
oil change
safety risks 41
operating conditions, robot 54
FlexPendant
jogging to calibration position 420
MoveAbsJ instruction 419
updating revolution counters 417
fork lift 61
foundation
loads 54
position switches
cabling on robot 111
installing 111
position, robot 412
positive directions, axes 414
protection classes 55
383
391
399
405
489
Index
range of movement 59
replacement
balancing device 322
bearing, balancing device 317
brake release unit 313
cable harness axes 1-4 240
cable harness axes 1-6 228
cabling axis 5 259
complete arm system 261
gearbox axis 1 383
gearbox axis 2 391
gearbox axis 3 399
gearbox axis 6 405
lower arm 292
lower arm shaft 299
motor axis 1 337
motor axis 2 343
motor axis 3 350
motor axis 4 357
motor axis 5 364
motor axis 6 374
turning disk 274
upper arm 286
wrist unit 277
requirements on foundation 54
restricting
working range axis 2 107
revolution counters
storing on FlexPendant 417
storing on TPU 416
updating 415
risk of tipping 60
robot
operating conditions 54
protection class 55
storage conditions 54
weight 53
robot position 412
robot types 427
S
safety equipment
mechanical stop 105
signal lamp 173
Safety, service 18
safety, symbols 35
scales on robot 412
securing the robot to foundation, attachment screws 78
securing, base plate 74
securing, lower arm 305
securing, robot 78
securing, upper arm 352
serial measurement board unit, replacement 309
special tools 437
stability 60
490
storage conditions, robot 54

symbols, safety 35
sync marks 412
T
testing, brakes 29
tightening torque
tool set, balancing device bearing replacement 318
tools
calibration equipment, Levelmeter 438
Calibration Pendulum equipment 439
for service 437
oil exchange equipment 439
TPU
jogging to calibration position 420
MoveAbsJ instruction 419
turning disk replacement 274
type A 427
type B 427
type of motion 59
U
upper arm, replacement 286
V
Validity and responsibility 18
W
weight
balancing device 325, 327
base plate 73, 77
complete arm system 263, 264
gearbox 386, 387, 394, 395, 402
lower arm 295, 297
motor 339, 340, 353, 354
robot 65, 67, 69
upper arm 288, 290
wrist unit 279, 280, 283, 284
weight, robot 53
working range 56
restricting axis 1
restricting
restricting axis 2 107
restricting axis 3 109
wrist unit, replacement 277
3HAC023082-001, Revision E, en
ABB AB
Robotics Products
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592

IRB6600 6650 Typeb M2000 M2000A

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Product manual

Copyright 2004-2008 ABB. All rights reserved.

Copyright 2004-2008 ABB All right reserved.

1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Copyright 2004-2008 ABB. All rights reserved.

2 Installation and commissioning

2.4.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.5.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.6 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2.7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

2.7.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

2.8.1 Additional installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Type of oil in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

3.5.1 Lubrication of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Copyright 2004-2008 ABB. All rights reserved.

3.4 Replacement/changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.7.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

4.3.1 Replacement of cable harness, axes 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

4.5.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

6.1 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

7.1 Type A and type B of IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

9.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

Copyright 2004-2008 ABB. All rights reserved.

9.3 Part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485

11.2.1 Validity of circuit diagram 3HAC 025744-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

11.3.1 Validity of circuit diagram 3HAC 13347-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

Copyright 2004-2008 ABB. All rights reserved.

Copyright 2004-2008 ABB. All rights reserved.

mechanical and electrical installation of the robot

maintenance of the robot

mechanical and electrical repair of the robot.

Who should read this manual?

The manual is organized in the following chapters:

Safety information that must be read through before performing

Installation and commissioning

Required information about lifting and installation of the robot.

Step-by-step procedures that describe how to perform

Step-by-step procedures that describe how to perform repair

Procedures that does not require specific calibration equipment.

Environmental information about the robot and its components.

Continues on next page

Product specification - IRB 6600/6650/6650S 3HAC023933-001

Product specification - IRB 6600/6650/6650S 3HAC14064-1

Product manual - S4Cplus M2000

Product manual - S4Cplus M2000A