ABB - IRB 660 Robot M2004 Product Manual - 3HAC025755-001 - Revb - en

Product manual
Articulated robot
IRB 660 - 180/3.15

IRB 660 - 250/3.15
M2004
Product manual
IRB 660 - 180/3.15
IRB 660 - 250/3.15
M2004
Document ID: 3HAC025755-001

Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
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 2006-2008 ABB All rights reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 33
1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Installation and commissioning 37

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.3 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.4 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.3 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.4.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.4.5 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4.6 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4.7 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4.8 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4.9 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.5.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.5.3 Installation of position switch, axis 1 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3HAC025755-001 Revision: B 3
Table of Contents
2.6 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.6.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.7 Making robot ready for operation (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.7.1 Commissioning (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3 Maintenance 79
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3.2 Inspection, oil level gearbox axes 2 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.3.3 Inspection, oil level gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.3.4 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.5 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3.6 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3.7 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.3.8 Inspection, additional mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.3.9 Inspection, dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.3.10 Inspection, position switch axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3.11 Inspection, signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.4 Replacement/changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.4.1 Type of oil in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4.3 Oil change, gearbox axes 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.4.4 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.4.5 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5.1 Lubrication of bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4 Repair 129
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 © Copyright 2006-2008 ABB. All rights reserved.
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.3.1 Replacement of cable harness, lower end (axes 1-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.3.2 Replacement of cable harness, upper end (incl. axis 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.4.1 Replacement of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.4.2 Replacement of tilthouse unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.4.3 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.4.4 Replacement of linkage - upper rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.4.5 Replacement of linkage - lower rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.4.6 Replacement of linkage - link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.4.7 Replacement of parallel rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.4.8 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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4.4.9 Replacement of parallel arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

4.5 Frame and base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.5.1 Replacement of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.5.2 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.5.3 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.6.2 Replacement of motor, axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.6.3 Replacement of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.7.2 Replacement of gearbox, axes 2- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.7.3 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5 Calibration information 241

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6 Reference information 251

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
6.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
6.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
6.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
7 Spare parts and exploded views 263

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
7.2 Spare parts - frame to base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

7.3 Spare parts - cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.4 Spare parts - customer harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.5 Spare parts - lower arm system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
7.6 Spare parts - parallel rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.7 Spare parts - Balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
7.8 Spare parts - frame to lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7.9 Spare parts - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
7.10 Spare parts - tilthouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
7.11 Spare parts - upper arm front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7.12 Spare parts - Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
7.13 Spare parts - motor axis1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
7.14 Spare parts - SMB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
8 Circuit diagram 291

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Index 293
6
Table of Contents
3HAC025755-001 Revision: B
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 commis- Required information about lifting and installation of the robot.
sioning
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
Document name Document ID

Product specification - IRB 660 3HAC023932-001
Product manual - IRC5 3HAC021313-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC025709-001
Application manual - Additional axes and stand alone controller 3HAC021395-001
Technical reference manual - System parameters 3HAC17076-1
Revisions
Revision Description
- First edition
A Detailed illustrations added in some procedures.
Art. no. on tools added.
Chapter "Replacement of tilthouse unit" has been changed in order to make
it easier to follow the procedure.
B Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
Product documentation, M2004
General
The robot documentation is 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 that contains:
• 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)
• 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
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.
Application manuals
Specific applications (for example 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 (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software)
• How to use the application
• Examples of how to use the application

Continued
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
• Emergency safety information
• General safety information
• Getting started, IRC5
• IRC5 with FlexPendant
• RobotStudio
• Introduction to RAPID
• Trouble shooting, for the controller and robot
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.
Action Note/Illustration
8. 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, that is article number, dimensions.
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.
Action Note/Illustration
3. 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 13.
1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 29.
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, for example:
• 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
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.
Related information
Type of information Detailed in document Section
Installation of safety Product manual for the robot Installation and commissioning
devices
Changing operating Operating manual - IRC5 with Operating modes
modes FlexPendant
(RobotWare 5.0)
Restricting the working Product manual for the robot Installation and commissioning
space
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, chapter 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 must 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, that is, 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.
1 Safety
Continued
Complete robot
Safety risk Description

Hot components!
CAUTION!
Motors and gears are HOT after running the robot!
Touching motors and gears may result in burns!
With higher environment temperature more surfaces on
the robot are getting HOT and may result in burns too!
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

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

Gears may be damaged if
excessive force is used!
CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
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.
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.
Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools etc. from falling due to gravity.
1 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.
Qualified personnel
• 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.
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.
1 Safety
1.2.2.5. Risks associated with live electric parts
1.2.2.5. Risks associated with live electric parts
Voltage related risks, general

• Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
Voltage related risks, 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
OFFposition. Power supply cables which are in motion during the working process may be
damaged.
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 robot.
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 (robot
or controller)!
1 Safety
1.2.3.3. Emergency release of the robot’s arm
1.2.3.3. Emergency release of the robot’s 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 54.
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!
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 robot axis to a position where the combined weight of the robot 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 robot does not change position as the motors are switched off, then the brake
function is adequate.
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".
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.
Enabling device
The enabling device is a manually operated constant pressure push-button which, when
continuously activated in one position only, allows potentially hazardous functions but does
not initiate them. In any other position, hazardous functions are stopped safely.
The enabling device is of a specific type where you must press the push-button only half-way
to activate it. In the fully in and fully out positions, robot operation is impossible.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function is
actuated manually and immediately stops any movement when released. The hold-to-run
function can only be used in manual mode.
How to operate the hold-to-run function is detailed in Operating manual - IRC5 with
FlexPendant.
1 Safety
1.2.3.7. Work inside the robot's working range
1.2.3.7. Work inside the robot's working range
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position "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 robot! 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 robot or inside the cell.
• Test the motor brake on each axis, according to section Brake testing on page 24.
1 Safety
1.2.3.8. Translate the information on safety and information labels
1.2.3.8. 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, for example during installation, service or operation.
The labels are identified and located on the product as shown in section:
• Inspection, information labels on page 97
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
A 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,
danger 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
warning crushing, impact, fall from height etc.

ELECTRICAL The electrocution or electrical shock symbol
SHOCK indicates electrical hazards which could result in
severe personal injury or death.
Electrical shock
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
caution warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.

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

to find additional information or how to perform a
certain operation in an easier way.
Tip
1 Safety
1.3.2. DANGER - Moving robots are potentially lethal!
1.3.2. DANGER - Moving robots are potentially lethal!
Description
Any moving robot is a potentially lethal machine.
When running the robot, it may perform unexpected and sometimes irrational movements.
Moreover, all movements are performed with great force and may seriously injure any
personnel and/or damage any piece of equipment located within the working range of the
robot.
Elimination
Action Note
1. Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is tread mats, light curtains, etc.
correctly installed and connected.
2. Usually the hold-to-run function is active How to use the hold-to-run function in
only in manual full speed mode. To RobotWare 5.0 is detailed in section How
increase safety it is also possible to to use the hold-to-run function in the
activate hold-to-run for manual reduced Operating manual - IRC5 with Flex-
speed with a system parameter. Pendant.
The hold-to-run function is used in manual
mode, not in automatic mode.
3. Make sure no personnel are present within
the working range of the robot before
pressing the start button.
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, that is out of its
reach behind safety fences, etc!
4. Pay special attention to the function of the part previously serviced!
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!
1 Safety
1.3.5. WARNING - The unit is sensitive to ESD!
1.3.5. WARNING - The unit is sensitive to ESD!
Description
ESD (electrostatic 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 current-
limiting 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 right corner as shown in the illustration below.

xx0500002171
A 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!
Overfilling of gearbox oil can Make sure not to overfill the
lead to internal over-pressure gearbox when filling with oil!
inside the gearbox which in After filling, check the correct oil
turn may: level.
-
• damage seals and
Do not overfill! gaskets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the mix different types of oil unless
gearbox! specified in the instruction.

Always use the type of oil
-
specified by the manufacturer!
Do not mix types of oil!
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.
Heat up the oil!

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
Specified amount amount, depending on how
depends on drained much oil has previously been
volume! drained from the gearbox.
1 Safety
2 Installation and commissioning
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.
2.2. 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
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 mounted tool.
Continued
Action Note
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 mounted CAUTION!
tool. 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 on a mounted tool
page 54.
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 on
page 54
2.3.1. Pre-installation procedure
2.3 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:
Action
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 40.
4. If the robot is not installed directly, it must be stored as described in Storage conditions,
robot on page 41.
5. Make sure the expected operating environment of the robot conforms to the specifica-
tions as described in Operating conditions, robot on page 41.
6. Before taking the robot to its installation site, make sure the site conforms to Loads on
foundation, robot on page 40, Requirements, foundation on page 41 and Protection
classes, robot on page 41.
7. Before moving the robot, please observe Risk of tipping / stability on page 44 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 45.
Weight, robot

The table below shows the weights of the different models:
Robot model Weight

IRB 660 - 180/3.15 1750 kg
IRB 660 - 250/3.15 1750 kg
Loads on foundation, robot

The table below shows the various forces and torques working on the foundation 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 ± 8.0 kN ± 15.9 kN
Force z 17.0 ±3.3 kN 17.0 ±10.6 kN
Torque xy ± 23.2 kNm ± 40.6 kNm

Continued
Force Endurance load (operation) Max. load (emergency stop)

Torque z ± 10.1 kNm ± 14.4 kNm
Requirements, foundation
The table below shows the requirements for the foundation where the weight of the installed
robot is included:
Requirement Value Note
Min. levelity 0.5 mm
Max. tilt 5° The limit for the maximum load on the robot
is reduced if the robot is tilted.
Contact ABB for further information about
acceptable loads.
Min. resonance frequency 22 Hz
Storage conditions, robot

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

The table below shows the allowed operating conditions for the robot:
Parameter Value
Min. ambient temperature 0° C 1)
Max. ambient temperature +50° C
Max. ambient humidity Max. 95% at constant temperature
1)
At cold start (0° C - 5° C), see note in the product specification on how to warm up the robot.
Protection classes, robot

The table below shows the protection class of the robot:
Equipment Protection class
Robot IP 67
2.3.2. Working range and type of motion
Working range
The 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 660 - 180/3.15 and IRB 660 - 250/3.15

The illustration below shows the unrestricted working range of IRB 660 - 180/3.15 and IRB
660 - 250/3.15.
xx0500002274

H Mechanical stop
J Max working range
Angle axis 2 Angle axis 3

Position x (mm) Position z (mm)
(degrees) (degrees)
A 1910 1833 0 0
B 972 1966 -42 -20
C 895 870 -42 28
D 866 207 50 120
E 1160 -505 85 120
F 3139 315 85 15
G 2809 1837 50 -20
The table below specifies the types and ranges of the robot motion in every axis.
Axis Type of motion Range of motion
1 Rotation motion -180° to +180°

Continued
Axis Type of motion Range of motion

2 Arm motion -42° to +85°
3 Arm motion -20° to +120°
2-3 Arm motion 20° to 160°
6 Turn motion -300° to +300°
2.3.3. Risk of tipping / stability
2.3.3. 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.
xx0500002275
WARNING!
The robot is likely to be mechanically unstable while not secured to the foundation!
2.4.1. Lifting robot with fork lift
2.4 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.
xx0500002276
A Attachment points on adapter and horizontal attachment screws

B Attachment points, horizontal attachment screws

C Attachment points, vertical attachment screws
Required equipment
Equipment, etc. Art. no. Note

Fork lift set, incl. all required 3HAC023044-001 See the figure Fork lift set, 3HAC023044-
hardware 3HAC023044-001 001 on page 46.
Standard toolkit - The content is defined in section Standard
toolkit on page 258.

Continued
Fork lift set, 3HAC023044-001

The fork lift set 3HAC023044-001, is fitted to the robot as shown in the figure below.

xx0500002277
A Fork lift pocket (2 pcs, one long & one short)

B Adapter (1 + 1 pcs)
C Horizontal attachment screws (4 pcs/fork lift pocket)
D Attachment screws for adapter (1 pc/adapter)
E Vertical attachment screws (2 pcs)

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
1. 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 54.
xx0500002275
2. Fit the two adapters to the robot and secure. Attachment points on the robot are
shown in the figure Attachment points
on page 45.
Attachment screws, 2 pcs, M16 x 90.
Tightening torque: 60 Nm.
3. Strap up the axis 2 motor cable on the adapter.
xx0500002278
• A: Strap, velcro
Continued
Action Note
4.
CAUTION!
The fork lift pocket weighs 60 kg!
5. Secure the longer fork lift pocket to the adapter Make sure the original screws are
and frame with four of the horizontal always used (or replacements of
attachment screws and washers. equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
on page 45.
NOTE!
The vertically and the horizontally attached
screws are identical, but tightened with
different torques!
xx0500002279
• A: Horizontal attachment
screws, 4 pcs, M16 x 60.
• B: Adapter
6. Make sure the securing screw is removed from
the fork lift pocket! It is only used for robot
model IRB 6650S.
xx0700000655
• A: Securing screw must be

removed!

Continued
Action Note
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!
xx0500002284
• A: Vertical attachment screws, 2

pcs, M16x60.
• Tightening torque: 270 Nm.
Make sure the original screws are
always used (or replacements of
equivalent quality: M16, quality 12.9)!
on page 45.
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 Tightening torque: 60 Nm.
horizontal attachment screws. Make sure the original screws are
always used (or replacements of
equivalent quality: M16, quality 12.9)!
on page 45.
10. Double-check that the pockets are properly

secured to the robot! Insert the fork lift forks
into the pockets.
11. Carefully lift the robot and move it to its instal-
lation site.
12.
WARNING!
Personnel must not, under any circumstances,
be present under the suspended load!
2.4.2. 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 robot’s lower arm.
Attachment points
The figure below shows how to attach the roundslings to the robot.
xx0500002285
A Chain sling with shortener

Continued
B Roundsling, robot
C Roundsling, upper arm. Used to secure against rotation.
D Note! No sharp edges!
E Shackle
Sling specification
Sling type Qty Lifting capacity Length / Note

Chain sling with shortener 4 pcs 4 250 kg 0.605 m
0.8 m
1.0 m (2 pcs)
Roundsling, robot 4 pcs 2 000 kg 2m
Roundsling, upper arm 1 pc 2 000 kg 1m
2m
Secures against
rotation.
Lifting with roundslings
Action Note
1. Attach the roundslings to the robot according to
the figure Attachment points on page 50.
NOTE!
For Cleanroom robots it is important to
apply the roundslings:
• between robot harness and
lower arm
• behind the side bracket,
balancing cylinder.
2.
CAUTION!
The robot weighs 1750 kg! All lifting equipment
used must be sized accordingly!
3.
WARNING!
Personnel must not, under any circumstances,
be present under the suspended load!
2.4.3. 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.
NOTE!
Move the robot to the recommended 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!
Illustration, lifting slings

The figure below shows how to lift the complete robot with lifting slings.
xx0500002460
A Lifting device´s eye

B Swivelling lifting eyes, 3 pcs
C Chain
D Lifting sling, short. Secures against rotation.
E Lifting slings, long
F Hook
Required equipment
Equipment Art. no. Note

Lifting device, robot 3HAC15607-1 Includes
• user instructions (3HAC15971-2).

Continued
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
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 54.
xx0500002275
3. Shown in the figure Illustration, lifting

slings on page 52.
NOTE!
If the robot is equipped with forklift pockets, it
is necessary to remove these in order to reach
the lower holes in the frame. These are used
to attach the hooks of the lifting slings.
4. Fit the lifting device, robot to the robot as Art. no. is specified in Required
described in the enclosed instruction! equipment on page 52.
5.
CAUTION!
The robot weighs 1750 kg! All lifting
equipment used must be sized accordingly!
6.
WARNING!
Personnel must not, under any circum-
stances, be present under the suspended
load!
7. Raise the overhead crane to lift the robot. Make sure all hooks and attachments
maintain their correct positions while
lifting the robot!
Always move the robot at very low
speeds, making sure it does not tip.
2.4.4. 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.
Note! Buttons no. 4 and 5 are not used!
xx0500002286
- Internal brake release unit with push buttons
Releasing the brakes

The procedure below details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action Note
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 54.
NOTE!
Axes 4 and 5 does not exist on IRB 660!
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 55.

Continued
Action Note
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.
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
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
2.4.5. Lifting the base plate
2.4.5. Lifting the base plate
Required equipment

Lifting eye, M16 3HAC14457-4 3 pcs
Lifting slings 3 pcs
Length: approx. 2 m
Hole configuration
xx0200000096
A Attachment holes for lifting eyes (x3)

Lifting, base plate
Action Note
1.
CAUTION!
The base plate weighs 353 kg! All lifting equipment
2. Fit the lifting eyes in the three lifting holes. Shown in the figure Hole con-
figuration on page 56.
3. Fit the lifting slings to the eyes and to the lifting device.
2.4.6. Securing the base plate
General
This section details how to secure the base plate.
Base plate, dimensions

xx0100000105

Continued
xx0400000715
A Four holes for alternative clamping, 4x Ø18

Continued
Base plate, grooves and holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.
xx0300000045
A Guide sleeve holes (2 pcs)

B Orienting grooves (3 pcs)
C Levelling bolts, attachment holes (4 pcs)
Required equipment

Base plate 3HAC12937-9 Includes
• guide sleeves, 3HAC12937-3
• levelling screws, 9ADA120-79
• attachment screws and
washers for securing the robot
to the base plate.
A drawing of the base plate itself may
be ordered from ABB Robotics!
Standard toolkit - The content is defined in section
Standard toolkit on page 258.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.

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 ø10
mm steel bars, distance 140 mm, class K25, t=250
Recommended bolt quality and Hilti HDA-P, M20 x 250/50 (maximum thickness of
dimension 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
3. Orient the base plate in relation to the robot Shown in the figure Base plate, grooves
work location using the three grooves in the and holes on page 59.
base plate.
4. Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 56.
5. Use the base plate as a template and drill 16 If possible, observe the recommenda-
attachment holes as required by the selected tions specified in section Recommenda-
bolt dimension. tions, quality on page 60. ABB does not
assume any responsibility for other
foundation qualities, due to great
variations in the foundation properties. © Copyright 2006-2008 ABB. All rights reserved.
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 59.
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 Maximum 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.
2.4.7. Orienting and securing the robot
General
This section details how to orient and secure the robot to the base plate in order to run the
robot safely. The requirements made on the foundations are shown in the following tables and
figures.
Illustration, robot fitted to base plate

The illustration below shows the robot base fitted to the base plate.
xx0300000566
A Robot attachment bolts and washers, 8 pcs (M24 x 140)

B Orienting grooves in the robot base and in the base plate
C Levelling screws
D 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

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 Note
1. Lift the robot. Detailed in section Lifting robot with
lifting slings on page 52.
Detailed in section Lifting robot with
roundslings on page 50.
2. Move the robot to the vicinity of its installation
location.
3. Fit two guide sleeves to the guide sleeve holes
in the base plate.
NOTE!
One of the guide sleeve holes is
elongated!
4. Guide the robot gently using two M24 screws Make sure the robot base is correctly
while lowering it into its mounting position. fitted onto the guide sleeves!
5. Fit the bolts and washers in the base Specified inAttachment screws on
attachment holes. page 61.
Shown in the figure Illustration, robot
fitted to base plate on page 61.
NOTE!
Lightly lubricate the screws before
assembly!
6. Tighten the bolts in a criss-cross pattern to
ensure that the base is not distorted.

Continued
Hole configuration, base

The illustration below shows the hole configuration used when securing the robot.
xx0600002628
Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes.
xx0600002629
2.4.8. 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.
NOTE!
No extra equipment may be fitted on the lower arm of the robot.
Illustration, fitting of extra equipment on upper arm

The illustration below shows the mounting holes available for fitting extra equipment on the
upper arm.
For fitting of extra vacuum hose all holes shall be used (6 pcs). These holes can only be used
for extra vacuum hose!
The max. weight of the vacuum hose and fastening device on the upper arm, is calculated to
10 kg.
Max. extra weight on the upper arm:
• IRB 660 - 180/3.15 = 35 kg
• IRB 660 - 250/3.15 = 35 kg
Note! Extra weight on the upper arm, must be deducted from the max. handling capacity.
Example: If 35 extra kg is put on the upper arm, this means that the robot only can handle
180 - 35 = 145 kg or 250 - 35 = 215 kg (depending on model).
xx0500002289
A Fitting holes, M10 (2 pcs)

B Fitting holes, M10 (2 pcs)
C Fitting holes, M10 (2 pcs)

Continued
Illustration, fitting of extra equipment on frame

The illustration below shows the mounting holes available for fitting extra equipment on the
frame.
xx0500002505

Continued
Illustration, fitting on turning disk

The illustration below shows the mounting holes available for fitting equipment on the
turning disk.
xx0500002292
- Mounting flange.
Fastener quality
When fitting tools on the turning disk (see the figures above), only use screws with quality
12.9. When fitting other equipment standard screws with quality 8.8 may be used.
2.4.9. Loads
2.4.9. 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 motors, gears and structure.
CAUTION!
Incorrect defined loads may result in operational stops or major damage on the robot.
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 Operating
manual IRC5 with FlexPendant.
Stop time and braking distances

Robot motor brake performance depends on any loads attached. For further information about
brake performance, please contact ABB.
2.5.1. Introduction
2.5 Restricting the working range
2.5.1. 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 axis may be restricted:
• Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
As standard configuration, axis 1 is allowed to move ± 180º. The working range may however
be increased to ± 220º 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.
2.5.2. 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
A Additional mechanical stop

B Stop pin
Required equipment

Mechanical stop for axis 1, 7.5° 3HAC11076-1 Includes attachment screws
and an assembly drawing.
Mechanical stop for axis 1, 15° 3HAC11076-2 Includes attachment screws
and an assembly drawing.
Standard toolkit - The content is defined in
section Standard toolkit on
page 258.
Technical reference manual - System - Art. no. is specified in section
parameters (RobotWare 5.0) References on page 8.

Continued
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the additional mechanical stop to the Tightening torque: 120 Nm.
frame according to the figure Mechanical
stops, axis 1 on page 69.
3. The system parameters that must be
changed in RobotWare 5.0 (Upper joint
bound and Lower joint bound) are further
NOTE! detailed in Technical reference manual -
To utilize the option 561-1 "Extended working System parameters.
range axis 1" the software working range
limitations must be re-defined. The motion
configuration parameter "arm/rob1_1/Upper
Joint Bound" and "arm/rob1_1/Lower Joint
Bound" must be changed to 3.84 resp. -3.84.
The values are in radians that is 220 deg. =
3.84 rad.
4.
WARNING!
If the mechanical stop is deformed after a
hard collision, it must be replaced!
2.5.3. Installation of position switch, axis 1 (option)
General
Position switches can be installed on axis 1. The position switches include cams as shown in
the figure below.
The position switch sets may be delivered in one of two ways:
• Fitted by ABB 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 sets to be completely fitted to the robot and adjusted by the user.
Required equipment
Description Art.no. Note

Position switch, axis 1 3HAC 15715-1 Includes position switch and
plate for customer connec-
tions.
Connector kit R1.SW1 3HAC 17252-1
Plate for customer 3HAC 025778-001 An additional connection
connections plate must be fitted to the
robot base, if not already
installed.
Additional cabling to and -
inside the controller
Axis 1
The illustration below shows the position switch for axis 1. The switch is connected directly
to the connector in the base, R1.SW1.
xx0100000158
A Position switch, axis 1

B Cam

Continued
C Set screw, cam (cam stop)

D Protection sheet
E Rail
F Rail attachment
Specifications
Maximum voltage/current for the position switches:
Parameter Value
Voltage Max. 50 VDC
Current Max. 1 A
Connections
The position switch is 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 set is recommended. Art.no. is
specified in Required equipment on page 71.
Further information about cables and connection points, see section Robot cabling and
connection points on page 76.
Plate customer connections, at base
xx0500002301
A Plate for customer connections

B Attachment screws, 3 pcs, M6x16

Continued
Installation of cable harness for position switch

The procedure below details how to fit the complete cable harness for position switch axis 1
to the robot.
Action Note
1. Move the robot to its calibration position.
2.
DANGER!
3. Remove the rear cover (A) from the robot
base.
xx0500002306
4. Fit the position switch to the frame of the

robot.
5. Run the cabling through the notch in the base
of the robot next to the rear cover.
xx0600002625
• A: Notch for pos.switch cable

Continued
Action Note
6. Connect the connector R1.SW1 to the
position switch of axis 1 (D).
xx0600002626
• A: Cable, pos.switch axis 1

• B: Connection point R1.SW1
• C: Notch for cable
• D: Position switch, axis 1
7. Connect the connector R1.SW1 to the base See figure above!
of the robot (B).
8. Refit the rear cover to the robot base.
9. 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 241.
10.
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 32.
Fitting and adjusting cams and stops

The instruction below details how to fit and adjust the parts of the position switch:
Action Note
1. Cut the cam to a suitable length. Use a sharp knife and rubber hammer
or similair.
2. Cut the edge of the cam edge to max 30°! Shown in the figure Illustration, cutting
the cam on page 75.
If the angle is larger, this may damage
the position switch!

Continued
Action Note
3. Cut the part of the cam running in the profile to
90°!
Also see the figure Illustration, cutting the cam
on page 75.
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 Shown in the figure Illustration, adjust
the M5 screw to secure the cam. and secure cams on page 75.
Illustration, adjust and secure cams

The illustration below shows how to adjust and secure the position switch cams and profiles.
xx0100000113
A Cam stop, M5 nut and M5 x 6 set screw

B Adjustable cam
C Profile
Illustration, cutting the cam

The illustration below shows how to cut the position switch cam.
xx010000114
A Remove the gray section
2.6.1. Robot cabling and connection points
2.6 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 76.
Position switch cables Handles supply to and feedback from any position switches
(option) on the robot.
Specified in the table Position switch cables, robot base to
controller (option) on page 77.
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)1).
1)
Art. no. is specified in section References on page 8.
The cable categories are divided into sub-categories, specified below:

Robot cables
These cables are included in the standard delivery. They are completely pre-manufactured
and ready to plug in.
Connection Connection
Cable sub-category Description
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.
Robot cable, power
Cable Art. no.

Robot cable, power, 7 m 3HAC11818-1

Continued
Cable Art. no.

Robot cable, signals
Cable Art. no.

Robot cable, signal, shielded, 7 m 3HAC7998-1
Position switch 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 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 section Installation of position switch, axis
1 (option) on page 71.
Cabling between robot base and controller

In a M2004 robot system, the cables below are only used for position switch axis 1.
Connec- Connection
Cable Art. no. tion point, point,
robot cabinet
Position switch cable, axis 1, 7 m 3HAC13175-1 R1.SW XS8
Cabling inside control cabinet

Additional cabling must be connected inside the control cabinet when installing position
switches.
Connection Connection
Cable Art. no. point 1 inside point 2 inside
cabinet cabinet
Bracket in the cabinet wall (M2004) 3HAC020813-082 - -
Harness position switch axis 1 3HAC021117-001 XS8 XT8.1 and
(M2004) XT8.2
2.7.1. Commissioning (Foundry Prime)
2.7 Making robot ready for operation (Foundry Prime)
2.7.1. Commissioning (Foundry Prime)
General
The following should be taken in consideration when running a robot in a water jet
application cell:
CAUTION!
Never switch off the overpressure in motors and serial measurement compartment during
cooling down of robot after it has been switched off.
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.
NOTE!
When turning off a cleaning cell we recommend that the humid air is ventilated out from the
cell, to avoid that the humid air is sucked into gearboxes for example, due to the raised
vacuum when cooled down.
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, that is, required
tools and materials.
The procedures are gathered in different sections and 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 13 before performing any service work.
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.
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 83.
Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals.
Maintenance
Equipment Interval Detailed in section
activity
Cleaning Robot - Cleaning, robot on page
126
Inspection Axis 1 gear, oil level 12 mths 1) Inspection, oil level
gearbox axis 1 on page
84
Inspection Axes 2 and 3 gears, 12 mths 1) Inspection, oil level
oil level gearbox axes 2 - 3 on
page 86.
Inspection Axis 6 gear, oil level 12 mths 1) Oil change, gearbox
axis 6 on page 118.
Inspection Balancing device 12 mths Inspection, balancing
device on page 90
Inspection Cable harness 12 mths Inspection, cable
harness on page 94
Inspection Information labels 12 mths Inspection, information
labels on page 97
Inspection Mechanical stop, 12 mths Inspection, mechanical

axis 1 stop, axis 1 on page 99
Inspection Dampers 12 mths Inspection, dampers on
page 102.
Changing Axis 1 gear oil: First change: 6 000 h Do not mix with other
Kyodo Yushi TMO Second change: 24 000 h oils!
4)
150 Oil change, gearbox
axis 1 on page 112
Changing Axes 2 & 3 gear oil: First change: 6 000 h Do not mix with other
4)
axes 2-3 on page 115
Changing Axis 6 gear oil: First change: 6 000 h Do not mix with other
4)
axis 6 on page 118
Replacement Axis 1 gearbox As specified by SIS, or Replacement of
typically 96 mths. gearbox, axis 1 on page
225
3 Maintenance
Continued
Maintenance
activity
Replacement Axes 2 and 3 As specified by SIS, or Replacement of
gearboxes typically 96 mths. gearbox, axes 2- 3 on
page 232.
Replacement Axis 6 gearbox As specified by SIS, or Replacement of
typically 96 mths. gearbox, axis 6 on page
236.
Replacement Cable harness See note below 2) Replacement of cable
harness, lower end
(axes 1-3) on page 135.
Replacement of cable
harness, upper end
(incl. axis 6) on page
144.
Replacement SMB battery pack 36 mths Replacement of SMB
unit on page 205.
Lubrication Balancing device 12 000 h 3) Lubrication of bearing,
balancing device on
page 123
1)
• If the robot is run at ambient temperatures higher than 50°C, the equipment may
require maintenance more frequently.
2)
• Replace when damage is detected or when approaching life limit as specified in
Expected component life on page 83.
3)
• 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!
4)
• "24000 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
Inspection Signal lamp Inspection, signal lamp on
page 106
Inspection Additional mechanical stop 12 mths
axis 1
Inspection Position switches, axis 1 12 mths
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 4,000,000 cycles axis 1 ±180º See note 1)
2,000,000 cycles axis 1 ±220º
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.
See the note in the Product specification about warrenty, when running the robot in a cold
environment (0°C to 5°C).
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
application. Depending on the actual application, the life of individual gearboxes may vary
greatly from this specification. The Service Information System (SIS), integrated in the robot
software, keeps track of the gearbox life in each individual case and will notify the user when
a service is due.
The SIS for an M2004 system is described in the Operating manual - Service Information
System. Document number can be found in section References on page 8.
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.
xx0500002479
A Oil plug, inspection

B Gearbox, axis 1
C Oil plug filling
D Motor, axis 1

E Drain hose (Behind cover)
Required equipment

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
Note! Do not mix with other oil
types!
Other tools and procedures may These procedures include
be required. See references to references to the tools required.

3 Maintenance
Continued
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 35.
2.
DANGER!
3. Open the oil plug, inspection. Shown in the figure Location of
gearbox on page 84.
4. Required oil level: max. 10 mm below the oil plug
hole!
5. Add oil if required. Art. no. is specified in Required
equipment on page 84.
Further information about how to fill
the oil may be found in section Filling
oil, axis 1 on page 114.
6. Refit the oil plug, inspection. Tightening torque: 24 Nm.
3 Maintenance
3.3.2. Inspection, oil level gearbox axes 2 - 3
Location of gearbox, axes 2-3

The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor
attachment.
The figures below shows the position of gearbox axes 2 and 3.
xx0500002482
A Gearbox, axis 2
B Oil plug, draining
C Oil plug, filling
D Ventilation hole, gearbox axis 2
xx0500002483
A Gearbox, axis 3
C Oil plug, filling
3 Maintenance
Continued
Required equipment
Equipment etc. Art.no. Note

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
types!
page 258.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below
Inspection, oil level gearbox 2 - 3

The procedure below details how to inspect the oil level in gearbox axis 2 - 3.
Action Note
1.
WARNING!
safety information in section WARNING -
Safety risks during work with gearbox oil on
page 35.
2.
DANGER!
3. Open the oil plug, filling Shown in Location of gearbox, axes

2-3 on page 86.
4. Measure the oil level at the oil plug, filling.
Required oil level: max. 5 mm below the oil plug
hole.
5. Add oil if required. Art.no. is specified in Required
Filling of oil is detailed further in
section Oil change, gearbox axes 2-3
on page 115.
6. Refit the oil plug, filling. Tightening torque: 24 Nm
3 Maintenance
Location of gearbox
The axis 6 gearbox is located in the tilthouse unit as shown in the figure below.
xx0500002484
A Gearbox, axis 6
B Oil plug, filling
C Oil plug, draining
Required equipment

Lubricating oil, IRB 660 3HAC032140-001 Kyodo Yushi TMO 150
Do not mix with other oil types!

3 Maintenance
Continued
Inspection, oil level gearbox 6

The procedure below details how to inspect the oil level in gearbox axis 6.
Action Note
1.
WARNING!
safety information in section WARNING - Safety
risks during work with gearbox oil on page 35.
2.
DANGER!
3. Open the oil plug, filling. Shown in the figure Location of
gearbox on page 88.
4. Add oil if required. Art. no. is specified in Required
Further information about how to fill
the oil may be found in section Filling,
oil on page 119.
5. Refit the oil plug, filling. Tightening torque: 24 Nm.
3 Maintenance
3.3.4. Inspection, balancing device
Overview
The procedure below details how to inspect the bearings and piston rod of the balancing
device.
Location of balancing device

The figure below shows the location of the balancing device.
xx0500002495
A Balancing device

B Piston rod
C Guide ring (not visible in this figure)
Required equipment
Equipment Spare part no. Art.no Note

Balancing device 3HAC024779-001 White RAL 9003
3HAC024779-001
Grease 3HAB3537-1
Locking liquid Loctite 243
Auxiliary shaft, 3HAC5276-1
upper
Auxiliary shaft, lower 3HAC5275-1
page 258.

3 Maintenance
Continued
Equipment Spare part no. Art.no Note

Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step instruc-
tions below.
Inspection, bearings
The procedure below details how to inspect the bearings, balancing device.
Action Note
1. Move the axis 2 to calibration position.
2.
DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
3. Remove the locknuts (KM-8), sealing
rings and the outer support washers.
xx0500002496
• A: Ear (adjustable needle bearing

located inside)
• B: Support washer
• C: Lock nut (with sealing ring)
• D: Piston rod
• E: Guide ring (not visible in this view)
• F: Inner ring
4. Fit the auxiliary shafts on upper and Art.no. is specified in Required equipment on
lower axes of balancing device. page 90.
The shafts should be tightened to their
bottom position.

3 Maintenance
Continued
Action Note
5. Remove the protection hood from the
M12 hole on top of the balancing
device.
xx0600002687
• A: Attachment (seen from above)

• B: Protection hood
6. Unload the bearings using a M12x50
screw, in the hole for the protective
hood, at the cylinder top.
7. Pull out the cylinder a little, in order to Shown in the figure above in this procedure
be able to inspect the inner rings Inspection, bearings on page 91.
without removing the balancing
cylinder.
8. Wipe the inner rings clean and check
that there are no pressure marks or
other similar deformations.
NOTE!
It is quite normal for the bearing races to have
a darker color than the surrounding material.
9. Inspect the bearings, support washers Shown in the figure above in this procedure
and sealing rings. Inspection, bearings on page 91.
10. If any of the parts looks abnormal, Detailed in section Replacement of balancing
replace. device on page 200.
11. Lubricate the shafts, if needed.
12. Push the cylinder back in. Make sure that the inner support washers © Copyright 2006-2008 ABB. All rights reserved.
and sealing rings get in the correct position.
13. Remove the auxiliary shafts.
14. Remove the M12x50 screw.
Put back the protection hood in the
hole.
NOTE!
Don´t forget to remove the screw!
If the screw isn´t removed it may damage the
balancing device, when the robot starts
operating.
15. Apply locking liquid on the locknuts Tightening torque on the locknuts:
(KM-8) and refit them. • 120 Nm

3 Maintenance
Continued
Inspection, wear on the guide ring

The procedure below details how to inspect the piston rod for wear on the guide ring.
Action Note
1. Move axis 2 to a position where the
balancing device is in a horizontal
position.
2.
DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
3. Check the guide ring for wear.
Replace if necessary.
xx0600002689
• A: Guide ring
• B: Circlip
4.
NOTE!
If there is a risk of metallic contact
between the piston rod and the end
cover, the guide ring must be
replaced!
3 Maintenance
3.3.5. 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.

xx0500002497
A Cable harness robot, axes 1-6

B Connectors at base
C Motor cables
D Cable guide, axis 2
E Metal clamps
Required equipment
Equipment, etc. Art.no. Note

Standard toolkit - Detailed in section Standard

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

may be required. See references to the tools required.
references to these
Circuit diagram See chapter Circuit diagram.
Inspection cable harness, axes 1-6

The procedure below details how to inspect the cable harness of axes 1-6.
Action Note
1.
DANGER!
2. Make an overall inspection of the cable
harness, in order to detect wear and damage.
3. Check the connectors at the base. Shown in the figure Location of cable
harness, axes 1-6 on page 94
4. Check the motor cables. Shown in the figure Location of cable
harness, axes 1-6 on page 94.
5. If the robot is equipped with forklift device,
check that the velcro strap holding the
motorcable, is properly attached to the
adapter.
xx0600002691
• A: Velcro strap
6. Check the cable guide axis 2. Shown in the figure Location of cable
Replace if damaged. harness, axes 1-6 on page 94.
7. Check the metal clamps on the lower arm. Shown in the figure Location of cable
harness, axes 1-6 on page 94

3 Maintenance
Continued
Action Note
8. Check the metal clamps holding the cable
harness inside the upper arm, as shown in the
figure to the right.
xx0500002498
• A: Metal clamp inside upper arm

9. Check the metal clamp holding the motorcable Shown in the figure Location of cable
on axis 6. harness, axes 1-6 on page 94.
10. Replace the cable harness if wear or damage Detailed in section:
is detected! Replacement of cable harness, lower
end (axes 1-3) on page 135.
Replacement of cable harness, upper
end (incl. axis 6) on page 144.
3 Maintenance
3.3.6. Inspection, information labels
Location of labels
The figures below show the location of the information labels to be inspected.
xx0502499
A Warning label “High teperature”, (located on motor cover), 29454489-16 (4 pcs)

B Warning sign, symbol of flash (located on motor cover), 3HAC1589-1 (4 pcs)

D Warning label “Brake release”, 3HAC024985-001
G Warning label “Caught danger”, 3HAC4517-1
J Warning label “Shut off power”, 3HAC17804-1
K Warning label “Extended working range and pos switch” (option), 3HAC021761-
001
- Information labels about what oil is filled, on gearboxes and at the robot base.

3 Maintenance
Continued
xx0500002500
C Instruction label “Safety instructions”, 3HAC4591-1

E Instruction label “Lifting the robot”, 3HAC024629-001
F Warning label “Robot can tip forward...”, 3HAC9191-1
H Warning label “Stored energy”, 3HAC3981-1
L Information label at base, Kyodo Yushi TMO 150 in gearboxes, 3HAC024977-002
Required equipment

Labels and plate set 3HAC022897-001 Includes all labels specified in the two
previous figures! The labels are in english.
Label set, oil labels 3HAC024977-001 Includes only the oil labels at the
gearboxes and at the robot base.
Are fitted to the robot if the gearboxes © Copyright 2006-2008 ABB. All rights reserved.
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 97.
3. Replace any missing or damaged labels. Art. no. is specified in Required
3 Maintenance
3.3.7. 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.
xx0600002695
A Mechanical stop pin

B Fixed stop
Required equipment

Mechanical stop ax 1 3HAC17358-1 To be replaced when damaged.
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. Shown in the figure Location of
mechanical stop on page 99.
3. Make sure the mechanical stop can move in both
directions.

3 Maintenance
Continued
Action Note
4. If the stop pin is bent or damaged, it must be Art. no. is specified in Required
replaced! equipment on page 99.
NOTE!
The expected life of gearboxes can be reduced
as a result of collissions with the mechanical stop.

3 Maintenance
3.3.8. Inspection, additional mechanical stops
3.3.8. Inspection, additional mechanical stops
Location of mechanical stops

The figure below shows the location of the additional mechanical stops on axis 1. (The figure
shows IRB 7600 but the location on axis 1 is the same on IRB 660.) Additional mechanical
stops for axes 2-3 are not available for the IRB 660.
Required equipment
Equipment etc. Art. no. Note

Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1.
Action Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Check the additional stops on axis 1 for damage. Shown in the figure Location of
mechanical stops on page 101.
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 Art. no. is specified in Required
must be replaced! equipment on page 101.
Correct attachment screws (lubricated with Molycote
1000):
• Axis 3: M6 x 16

3 Maintenance
3.3.9. Inspection, dampers
Location of dampers
The figure below shows the location of the dampers.

xx0500002501
A Damper, lower arm, upper (2 pcs)

B Damper, lower arm, lower (1 pc)
C Damper, axis 2 (2 pcs)
- Damper, axis 3 (2 pcs) Not visible in this view,
Required equipment
Equipment Art.no Note

Damper axis 2, 3 3HAC 12991-1 To be replaced if damaged
Damper lower arm, 3HAC 022338-001 To be replaced if damaged
upper
Damper lower arm, 3HAC 022339-001 To be replaced if damaged
lower

3 Maintenance
Continued
Inspection, dampers
The procedure below details how to inspect the dampers.
Action Note
1.
DANGER!
2. Check all dampers for damage, cracks or Shown in the figure Location of
existing impressions larger than 1 mm. dampers on page 102.
3. Check attachment screws for deformation.
4. If any damage is detected, the damper must be Art.no. is specified in Required
replaced with a new one. equipment on page 102.

3 Maintenance
3.3.10. Inspection, position switch axis 1
Position switch, axes 1

The illustration below shows the position switch for axis 1.
xx0100000158
A Position switch, axis 1

B Cam
C Set screw, cam
D Protection sheet
E Rail
F Rail attachment
Required equipment
Equipment Art.no Note
Position switch, axis 1 3HAC 024854-001

3 Maintenance
Continued
Inspection, position switch

The procedure below details how to inspect the position switch, axis 1.
Action Note
1.
DANGER!
2. Check the position switch!
• Check that the rollers are easy to push in
and that they roll freely.
3. Check the rail!
• Check that the rail is firmly attached with
the attachment screws.
4. Check the cams!
• Check that the rollers have not caused
any impressions on the cams.
• Check that the cams are clean. Wipe
them if necessary!
• Check that the set screws holding the
cams in position are firmly attached.
5. Check the protection sheets on axis 1!
• Check that the three sheets are in
position and not damaged. Deformation
can result in rubbing against the cams!
• Check that the area inside of the sheets
is clean enough not to interfere with the
function of the position switch.
6. If any damage is detected, the position switch
must be replaced!

3 Maintenance
3.3.11. Inspection, signal lamp
Location of signal lamp

The signal lamp is located as shown in the figure below.
xx0500002466
A Signal lamp
B Cable straps, outdoor
C Cable
D Connection point to cable gland
Required equipment

Kit for UL lamp 3HAC023750-001 To be replaced in case of detected
damage.
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").

3 Maintenance
Continued
Action Note
2.
DANGER!
3. If the lamp is not lit, trace the fault by: Art. no. is specified in Required
• Checking whether the signal lamp is broken. equipment on page 106.
If so, replace it.
• Checking the cable connections.
• Measuring the voltage in connectors motor
axis 6 (=24V).
• Checking the cabling. Replace cabling if a
fault is detected.

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.
xx0500002467
A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 6
Type of oil - historically used

The 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
on page 110.
CAUTION! © Copyright 2006-2008 ABB. All rights reserved.
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 on page 110.
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 8,000 ml
Axis 6 Kyodo Yushi TMO 150 3HAC032140-001 250 ml

3 Maintenance
Continued
Labels next to oil plugs

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.
xx0800000230
Labels located next to oil plugs Currently used types of oils
xx0800000241
Historically used types of oil Need to be replaced, if currently used.
Labels at robot base

Label located at robot base show the types of oil in all gearboxes.
xx0500002477
- Label at robot base. Currently used types of oil.

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 on page 108. 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 on page 110.
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/Optigear RO 150
Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150
and Optimol Optigear RMO 150/Optigear RO 150 are mixed.
• 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.

3 Maintenance
Continued
Equipment

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.

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.
xx0500002479
A Oil plug, inspection

B Gearbox axis 1
C Oil plug, filling

D Motor, axis 1
E Drain hose
Required equipment
Equipment, etc. Art. no. Amount Note

Lubricating oil 3HAC032140-001 8,000 ml Kyodo Yushi TMO 150
types!
Oil collecting vessel - Capacity: 8,000 ml.
Oil exchange 3HAC021745-001 The content is defined in section
equipment Special tools on page 259.

3 Maintenance
Continued
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 112.
Action Note
1.
DANGER!
2.
WARNING!
page 35.
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
Required equipment on page 112.
6. Remove the oil plug, filling, in order to drain the Shown in the figure Location of oil
oil quicker! plugs on page 112.
7. Open the hose end and drain the oil into the
vessel.
NOTE!
The draining is time-consuming.
Elapsed time depends on the
temperature of the oil.
8. Close the oil drain hose, and put it back inside
the base.
9. Refit the rear cover by securing it with its
attachment screws.
3 Maintenance
Continued
Filling oil, axis 1

The procedure below details how to fill the oil in gearbox axis 1.
Action Note
1.
DANGER!
2.
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks during
work with gearbox oil on page 35.
3. Open the oil plug, filling. Shown in the figure Location of
oil plugs on page 112.
4. Refill the gearbox with lubricating oil. Art. no. and the total amount are
The amount of oil to be refilled depends on the specified in Required equipment
amount previously being drained. The correct oil level on page 112.
is detailed in section Inspection, oil level gearbox axis
1 on page 84.
5. Refit the oil plug, filling. Tightening torque: 24 Nm.

3 Maintenance
3.4.3. Oil change, gearbox axes 2-3
Location of oil plugs

The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor
attachment.
The figures below shows the position of gearbox axis 2 and 3.
xx0500002482
A Gearbox axis 2
C Oil plug, filling
xx0500002483
A Gearbox, axis 3
C Oil plug, filling

3 Maintenance
Continued
Required equipment
Equipment etc. Art.no Amount Note

Lubricating oil 3HAC032140-001 5,000 ml Kyodo Yushi TMO 150
Oil collecting vessel Capacity: 6,000 ml
Oil exchange 3HAC021745-001 The content is defined in
equipment section Special tools on page
259.
section Standard toolkit on page
258.
Draining
The procedure below details how to drain the oil in gearbox axis 2-3.
Action Note
1.
DANGER!
2.
WARNING!
page 35.
3. Remove the plug of the vent hole. Shown in Location of oil plugs on page
115.

4. Remove the oil plug, draining, and drain the Shown in Location of oil plugs on page
gearbox using a hose with a nipple and an oil 115.
collecting vessel. Vessel capacity is specified in
Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.
5. Refit the oil plug. Tightening torque: 24 Nm.

3 Maintenance
Continued
Filling
The procedure below details how to fill oil in the gearbox axes 2-3.
Action Note
1.
DANGER!
2.
WARNING!
page 35.
3. Refit the oil plug, draining. Shown in Location of oil plugs on page
115.
4.
NOTE!
Don´t mix Kyodo Yushi TMO 150 with other oil
types!
5. Refill the gearbox with lubricating oil. Art.no. and total amount are specified
The amount of oil to be filled depends on the in Required equipment on page 116.
amount previously being drained.
6. Refit the oil plug, filling and the plug in the Shown in Location of oil plugs on page
ventilation hole. 115.

3 Maintenance
Location of gearbox
The gearbox axis 6 is located in the center of the tilt house unit as shown in the figure below.
xx0500002484
A Gearbox, axis 6
B Oil plug, filling
Required equipment
Equipment, etc. Art.no. Amount Note

Lubrication oil 3HAC032140-001 250 ml Kyodo Yushi TMO 150
Do not mix with other oil types!
Oil exchange 3HAC021745-001

equipment
Oil collecting Vessel capacity: 300 ml.
vessel
Standard tollkit - The content is defined in section
Draining, oil
The procedure below details how to drain oil from the gearbox axis 6.
When using the oil change equipment, follow the instructions enclosed with the kit.
Action Note
1. Put the tilt house in a suitable position. Location of oil plugs are shown in
the figure Location of gearbox on
page 118.

3 Maintenance
Continued
Action Note
2.
DANGER!
3. Drain the oil from the gearbox into a vessel by Vessel capacity is specified in
removing the oil plug draining. Required equipment on page 118.
Also remove the oil plug, filling.
4. Refit the oil plugs, draining and filling.
Filling, oil
The procedure below details how to fill oil to the gearbox axis 6.
When using the oil change equipment, follow the instructions enclosed with the kit.
Action Note
1.
DANGER!
2. Remove the oil plug, filling. Shown in Location of gearbox on
page 118.
3. Refill the gearbox with lubricating oil. Art.no. and the total amount are
The amount of oil to be refilled on the amount specified in Required equipment
previously being drained. The correct oil level on page 118.
is detailed in section Inspection, oil level
gearbox 6 on page 89.
4. Refit the oil plug. Tightening torque: 24 Nm.

3 Maintenance
3.4.5. 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.
xx0500002486
A SMB battery cover

B SMB battery pack
C Battery cable
Required equipment
Equipment, etc. Spare part no. Note

Battery pack 3HAC16831-1 Battery includes protection circuits. Replace it
only with given spare part no. or an ABB
approved equivalent.
Circuit Diagram - See chapter Circuit diagram.
Removal, battery
The procedure below details how to remove the SMB battery.
Action Note
1. Move the robot to its calibration position. This is done in order to facilitate the
updating of the revolution counter.

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 34
4. Remove the SMB battery cover by unscrewing its Shown in the figure Location of SMB
attachment screws. battery on page 120.
5. Pull out the battery and disconnect the battery Shown in the figure Location of SMB
cable. battery on page 120.
6. Remove the SMB battery. Shown in the figure Location of SMB
Battery includes protection circuits. Replace it battery on page 120.
only with the specified spare part or with an ABB
approved equivalent.
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 34
3. Reconnect the battery cable to the SMB battery Art. no. is specified in Required
pack and fit it to the frame. equipment on page 120.
Shown in the figure Location of SMB
battery on page 120.
4. Secure the SMB battery cover with its Shown in the figure Location of SMB
attachment screws. battery on page 120.

3 Maintenance
Continued
Action Note
5. Update the revolution counter. Detailed in chapter Calibration -
section Updating revolution counters
on page 246.
6.
DANGER!
further detailed in section DANGER - First test
run may cause injury or damage! on page 32.

3 Maintenance
3.5.1. Lubrication of bearing, balancing device
3.5 Lubrication activities
NOTE!
This section is not applicable to the robot variant IRB 6660-205/1.9
Overview
The procedure below details how to lubricate the bearings and piston rod of the balancing
device.
Location of bearing and piston rod

The figure below shows the location of the bearings and piston rod.
Note! The balancing device must be fitted on the robot when lubricating the bearings!
xx0500002489
A Ear (adjustable needle bearing located inside)

B Support washer
3 Maintenance
Continued
C Lock nut
D Piston rod
E Guide ring (not visible in this view)
Required equipment
Equipment Art.no. Note

Lubrication tool 3HAC 5222-1
Bearing grease 3HAB 3537-1 Equivalent:
• Shell Alvania WR 2
Piston rod grease Castrol Spheerol SX2
Shell SRS 4000
OK Super Grease L2
Statoil Uniway 2X2N
page 258.
may be required. See references to the tools
references to these required.
Lubrication, bearings
The procedure below details how to lubricate the bearings, balancing device.
Action Note
1. Move axis 2 to the calibration position.
2.

DANGER!
3. Remove the locknut. Be careful not to loose the support washer
in the process.
4. Fit the lubricating tool.

The lubricating tool should be tightened to
the bottom, by hand only.
5. Grease through the nipple on the
lubricating tool.
6. Continue filling grease until the clean
grease exudes behind the inner sealing
ring.
Repeat this procedure for the other ring!
7. Remove the lubricating tool and clean the Also clean from old grease on the inner
threads on the shaft ends, free from side!
grease.

3 Maintenance
Continued
Action Note
8. Apply some grease on the support
washers.
9. Apply locking liquid on the locknuts (KM- Tightening torque on the locknuts:
8). • 120 Nm
NOTE!
Do not apply locking liquid on the shafts!
10. Check the play between support washer Minimum play:
and bearingseat at both bearings. • 0.1 mm
Lubrication, piston rod

The procedure below details how to lubricate the piston rod, balancing device.
Action Note
1. Move axis 2 to a position where the balancing
device is in the horizontal position and the
piston rod extended as much as possible.
2.
DANGER!
3. The piston rod must be lubricated. Type of grease is specified in
4. Clean the piston rod before applying new
grease.
5. Apply new grease, if necessary.

3 Maintenance
3.6.1. Cleaning, robot
3.6 Cleaning activities
General
The protection class is IP 67, that is 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
A Spiral cables to motor 6

B Inside of upper arm tube
C Rear of upper arm tube
D Inside of lower arm
E Inside of base/axis 1

3 Maintenance
Continued
xx0600002624
A Inside upper arm

B Inside lower arm
C Inside frame
D Inside base
Required equipment

Steam 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
High pressure water cleaner - • 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.

3 Maintenance
Continued
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, for example compressed air or solvents, other than
those specified above!
• Although the robot is watertight, avoid spraying connectors and similar items with a
high pressure cleaner!

4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter

This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate procedures, each detailing a specific repair activity. Each procedure
contains all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.

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 gearbox, the integrity of all seals enclosing the gearbox oil must
be tested. This is done in a leak-down test.
Required equipment

Leakdown tester 3HAC0207-1
Leak detection spray -
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 in Required
and replace it with the leakdown tester. equipment on page 130.
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.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is signifi-
be 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? © Copyright 2006-2008 ABB. All rights reserved.
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.

4 Repair
4.2.2. Mounting instructions for bearings
General
This section details how to mount and grease different types of bearings on the robot.
Equipment

Grease 3HAB3537-1 Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Follow the instructions below when mounting a bearing on the robot.
Action Note
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 cir-
cumstances 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.
Action Note
1. Tension the bearing gradually until the recommended pre-tension
is achieved.
NOTE!
The roller elements must be rotated at a specified number of turns
before pre-tensioning 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.

4 Repair
Continued
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.

4 Repair
4.2.3. Mounting instructions for seals
General
This sections details how to mount different types of seals to the robot.
Equipment

Grease 3HAB3537-1 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).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced, as it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page 133.
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.
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, Defective o-rings may not be used.
shape accuracy, etc.
3. Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct and
free from pores and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.

4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
4.3 Complete robot
Overview
The cable harness 1-6 is undivided.
Replacement of the cable harness is detailed in two steps - lower end (axes 1-3) and upper
end (axes 4-6). The procedure below details replacement of lower end of the cable harness.
The procedure for replacing the upper end is detailed in section Replacement of cable
harness, upper end.
Location of cable harness - lower end (axes 1-3)

The cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm
as shown in the figure below.
xx0600002608
A Cable harness, lower end

B Cable harness, upper end
C Connector R1.MP
D Connector R1.SMB
E Attachment point for earth lug
F Cover plate
G Rear cover plate
H Cable gland, SMB
I Cable guide, axis 2
J Metal clamp, frame
K Metal clamp, lower arm
L Metal clamp, upper arm
4 Repair
Continued
M Metal clamp, tilthouse
xx0700000070
A Cable guide, axis 2

B Metal clamp
C Connector at base
D Cable guide, axis 1
E Cable harness, axes 1-6
F Cover plate © Copyright 2006-2008 ABB. All rights reserved.
G Rear cover plate
H Attachment point for earth lug

4 Repair
Continued
The motors axes 2-3 are located on either side of the robot as shown in the figure below.
xx0600002599
A Motor, axis 2
B Motor, axis 3
C Motor attachment screws and washers
D Cable gland cover (located on the lower side of the motor)
E Motor cover
Required equipment
Equipment, etc. Spare part no. Art.no. Note

Cable harness 1-6 3HAC022544-001
Gasket 3HAC3537-1 Motor axes 1-5
section Standard toolkit
on page 258.
references to these
procedures in the
step-by-step
instructions below.
Circuit diagram 3HAC025690-001 See chapter Circuit
3HAC025691-001 diagram.
Removal, cable harness - lower end (axes 1-3)

The procedure below details how to remove the cable harness, lower end (axes 1-3).
Action Note
1. Move the robot to the calibration position. This is done in order to facilitate
updating of the revolution counter.

4 Repair
Continued
Action Note
2.
DANGER!
3. Remove the rear cover plate on the robot by Shown in Location of cable harness -
removing its attachment screws. lower end (axes 1-3) on page 135.
4. Disconnect the earth cable. Shown in Location of cable harness -
lower end (axes 1-3) on page 135.
5. Disconnect connectors R1.MP and R1.SMB. Shown in Location of cable harness -
6. Remove the cable guide axis 2.
xx0600002698
• A: Cable guide ax 2
7. Unscrew the screws in the metal clamps Shown in Location of cable harness - © Copyright 2006-2008 ABB. All rights reserved.
holding the cable harness in the frame and lower end (axes 1-3) on page 135
lower arm.
8. Remove the motor cover, axis 1, 2, 3 by
removing its attachment screws, in order to
reach the connectors.
9. Disconnect all connectors at motor 1, 2 and 3.

4 Repair
Continued
Action Note
10. Open the SMB cover carefully.
The cable (C) 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!
xx0600002700
• A: SMB battery cover

• B: SMB battery pack
• C: Battery cable
11. Disconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 from the brake
release unit.
12. Remove the cable gland, SMB by removing its
four attachment screws from inside the SMB
recess.
Perform this removal with care, in order not to
damage any of the components inside the SMB
recess.
xx0600002701
• A: Cable gland, SMB

• B: Attachment screws (4 pcs)

4 Repair
Continued
Action Note
13. Gently pull the cable harness out of base
through the cable guide, axis 1 and the frame.
xx0600002699

• B: Metal clamp, frame
• C: Cable guide, axis 1
14. Continue removal of the cable harness in the Detailed in Replacement of cable
upper arm. harness, upper end.

4 Repair
Continued
Refitting, cable harness - lower end (axes 1-3)

The procedure below details how to refit the cable harness, lower end (axes 1-3).
Action Note
1. Pull the cable and connectors down through the Make sure the cables are not twisted
cable guide axis 1 in the center of the frame. with each other or with eventual
customer harness!
xx0600002699

• B: Metal clamp, frame
• C: Cable guide, axis 1
2. Pull out the cables and connectors to the SMB
unit through the frame and refit the cable gland
with its four attachment screws from inside the

SMB recess.
Perform this refitting with care, in order not to
damage any of the components inside the SMB
recess.
xx0600002701

• B: Attachment screws, (4 pcs)
3. Reconnect connectors R1.MP and R1.SMB at Attachment points are shown in the
the robot base. figure Location of cable harness -

4 Repair
Continued
Action Note
4. Reconnect the earth cable. Attachment point is shown in the
figure Location of cable harness -
lower end (axes 1-3) on page 135
5. Refit the rear cover plate on the robot with its Shown in the figure Location of cable
attachment screws. harness - lower end (axes 1-3) on
page 135
6. Reconnect all connectors at motor 1, 2 and 3.
7. Refit the motor cover, axis 1, 2, 3.
Make sure the cabling is placed correctly when
refitting the cover and does not get jammed.
8. 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.
9. Secure the SMB cover with its attachment
screws.
10.
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 33!
11. Refit the cable guide, axis 2.
xx0600002698
• A: Cable guide axis 2

12. Pull the cable harness through the lower arm.
13. Continue refitting of the cable harness in the Detailed in section Replacement of
upper arm. cable harness, upper end.
14. Update the revolution counter! Detailed in section Updating
revolution counters on page 246.

4 Repair
Continued
Action Note
15.
DANGER!

4 Repair
4.3.2. Replacement of cable harness, upper end (incl. axis 6)
Overview
Replacement of the cable harness is detailed in two steps - lower end (axes 1-3) and upper
end. The procedure below details replacement of the cable harness in the upper end (incl. axis
6). The procedure for replacing the lower end (axis 1-3) is detailed in section Replacement of
cable harness, lower end (axes 1-3) on page 135.
Location of cable harness, upper arm

The cable harness, upper end is located as shown in the figure below.
xx0600002608
A Cable harness, lower end

B Cable harness, upper end
C Connector R1.MP
D Connector R1.SMB
E Attachment point for earth lug
F Cover plate
G Rear cover plate
H Cable gland, SMB
I Cable guide, axis 2
J Metal clamp, frame
K Metal clamp, lower arm
L Metal clamp, upper arm
M Metal clamp, tilthouse

4 Repair
Continued
The motor axis 6 is located as shown in the figure below.
xx0600002600
A Motor, axis 6
B Attachment screws and washers
C Cable gland cover
D Motor cover
Required equipment
Equipment, etc Spare part no. Art.no. Note

Cable harness, 1-6 3HAC 022544-001 Detailed in section
Spare parts - cable
harness on page 266.
Standard toolkit - The content is
defined in section
Standard toolkit on
page 258.
Other tools and These procedures
procedures may be include references to

required. See the tools required.
references to these
procedures in the step-
by-step instructions
below.
Circuit diagram 3HAC 025690-001 See chapter Circuit
3HAC 025691-001 diagram.
Removal, cable harness upper end (incl. axis 6)

The following procedure details how to remove the cable harness, upper arm (incl. axis 6).
Action Note
1. Move the robot to the calibration position. This is done in order to facilitate updating
of the revolution counter.

4 Repair
Continued
Action Note
2.
DANGER!
3. If the complete cable harness is being Detailed in section Replacement of cable
replaced, start removal by removing the harness, lower end (axes 1-3) on page
cable harness, lower end. 135
4. Remove the motor cover axis 6 by removing
its attachment screws, in order to reach the
connectors.
xx0600002696
• A: Motor cover
• B: Attachment screws
• C: Cable gland
5. Disconnect connectors at motor axis 6.
6. Remove the cable gland on motor axis 6 by
unscrewing the screw which is found after
removing the motor cover.
xx0600002694
• A: Screw holding the cable gland

4 Repair
Continued
Action Note
7. Remove the metal clamp holding the cable
at the tilt house, by removing its nuts.
xx0600002702
• A: Metal clamp, axis 6

8. Carefully pull the cable harness out of motor
axis 6.
9. Remove the cable clamps holding the
harness inside the upper arm by removing
its four nuts.
xx0500002498
• A: Metal clamp, upper arm

10. Carefully pull out the cable harness from the
upper and lower arm.
Refitting, cable harness upper arm

The following procedure details how to refit the cable harness, upper arm. It also details how
to refit the cable harness in axis 6.
Action Note
1. Start by fitting the cable harness, lower end Detailed in section Replacement of cable
if it has been removed. harness, lower end (axes 1-3) on page
135
2. Push the cable harness through the lower
and upper arm.

4 Repair
Continued
Action Note
3. Refit the cable harness inside the upper arm
by refitting the cable clamps with its four
nuts inside the upper arm.
xx0500002498
• A: Metal clamp, upper arm

4. Refit the metal clamp at the tilthouse with its
nuts.
xx0600002702
• A: Metal clamp, axis 6

5. Push the motor cables axis 6 carefully
through the cable gland.
6. Refit the cable gland with the screw which is

found under the motor cover.
xx0600002694

7. Reconnect the connectors in motor axis 6.
Put the cables in a way that they are not
twisted.
8. Refit the motor cover.
Make sure the cabling is placed correctly
when refitting the cover and does not get
jammed.
4 Repair
Continued
Action Note
9. Update the revolution counter! Detailed in section Updating revolution
counters on page 246.
10.
DANGER!
when performing the first test run. These
are further detailed in section DANGER -
First test run may cause injury or damage!
on page 32.

4 Repair
4.3.3. 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 Spare parts
and exploded views on page 263 .
xx0600002612
A Parallel rod
B Linkage
C Complete upper arm (incl. tilthouse) © Copyright 2006-2008 ABB. All rights reserved.
D Balancing device
E Frame
F Gearbox, axis 1
G Base
H Base attachment screws
Required equipment

Lifting device, robot 3HAC15607-1 Instruction 3HAC15971-2 is enclosed!

4 Repair
Continued

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.
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
Removal, arm system

The procedure below details how to lift and remove the complete arm system.
Action Note
1. Make sure the robot is positioned as Release the brakes if necessary, as detailed
shown in figure to the right. If it is not, in section Manually releasing the brakes on
position it that way. page 54.
xx0500002275
2.
DANGER!
3. Drain the oil from gearbox axis 1. Detailed in section Oil change, gearbox axis 1
on page 112.
4. Loosen the cable connectors from the Detailed in section Replacement of cable
base and pull up the cabling from the harness, axes 1-6.
base, through the hole in the center of the
frame.

4 Repair
Continued
Action Note
5. Remove the motor, axis 1. Detailed in section Removal, motor on page
213.
6. Run the overhead crane to a position
above the robot.
7. Fit the lifting device and adjust it as Art. no. is specified in Required equipment on
detailed in the enclosed instructions. page 150.
Make sure the lift is done completely level!
How to adjust the lift is described in the
enclosed instruction to the lifting device!
Read the instructions before lifting!
8. Remove the block for calibrationand
calibration plate axis 1 from the bottom of
the frame.
xx0600002734
• A: Block for calibration

• B: Calibration plate axis 1
9. Unfasten the arm system from the base Shown in the figure Location of arm system

by unscrewing its 24attachment screws. on page 150.
10. Fit the two guide pins in two opposite Art. no. is specified in section Required
screw holes. equipment on page 150.
11.
CAUTION!
The complete arm system weighs 1250
kg! All lifting equipment used must be
sized accordingly!
12. Lift the arm system carefully and secure Make sure all hooks and attachments stay in
it in a safe area. the correct position while lifting the arm
Always move the robot at very low system and that the lifting device does not
speeds, making sure it does not tip. wear against sharp edges.
Continue lifting even if the arm system
turns out to be unbalanced despite earlier
adjustments! The risk of damaging the
interfaces is bigger if the load is lowered
unbalanced!

4 Repair
Continued
Refitting, arm system

The procedure below details how to lift and refit the complete arm system.
Action Note
1.
DANGER!
2. Fit the lifting device as detailed in enclosed Art. no. is specified in Required
instruction. equipment on page 150.
Also fit a hoisting block to the frontchain, Make sure the lift is done completely
used to adjust the balance of the arm system level! How to adjust the lift is described in
in order to lift it completely level! the enclosed instruction to the lifting
device! Follow the instructions before
lifting!
3.
CAUTION!
The complete arm system weighs 1250 kg!
All lifting equipment used must be sized
accordingly!
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.
5. Fit the two guide pins to the frame
attachment holes, as shown in the figure to
the right.
x0600002632
The figure above shows the frame, view

from below.
• A: Attachment holes for the guide
pins, M12

4 Repair
Continued
Action Note
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!
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
NOTE!
The refitting must be made completely level!
Make sure the lifting device is adjusted prior
to refitting of arm system.
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 150.
screws and washers. M12 x 70, tightening torque: 115 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 254 before fitting.
9. Refit the block for calibrationandcalibration
plate axis 1 at the bottom of the frame.
xx060002734
• A: Block for calibration

• B: Calibration plate axis 1
10. Refit the motor axis 1. Detailed in section Refitting, motor on
page 215.
11. Refit the cabling in the base.
12. Perform a leak-down test of the gearbox axis Detailed in section Performing a leak-
1. down test on page 130.
13. Refill the gearbox axis 1 with lubricating oil. Detailed in section Oil change, gearbox
axis 1 on page 112.

4 Repair
Continued
Action Note
14. Recalibrate the robot. Calibration is detailed in a separate
calibration tools.
included in section Calibration information
on page 241.
15.
DANGER!
page 32.

4 Repair
4.4.1. Replacement of turning disk
4.4 Upper and lower arm
Location of turning disk

The turning disk is located in the front of the wrist housing, as shown in the figure below.
xx0600002627
A Turning disk
B Attachment screws (6 pcs) turning disk
C Tilthouse unit
D Gearbox, axis 6
E Attachment screws, axis 6
Required equipment
Equipment, etc. Spare part no. Art. no. Note

Turning disk, diam. 200 For robot version 180/3.15,
250/3.15
O-rings are not included!
O-ring 3HAB3772-65 For robot v. IRB 660 180/
(1 pc) 3.15, 250/3.15
21520431-20 (6 Must be replaced when
pcs) replacing the turning disk!
Grease 3HAB3537-1 Used to lubricate the o-rings.
page 258.

4 Repair
Continued

required. See references required.
to these procedures in
the step-by-step instruc-
tions below.
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 it is best to remove
the turning disk.
4. Drain the oil from gearbox 6. Detailed in section Draining, oil
on page 118.
5. Remove the turning disk by unscrewing its Shown in the figure Location of
attachment screws. turning disk on page 156.

4 Repair
Continued
Refitting, turning disk

The procedure below details how to refit the turning disk.
Action Note
1. Lubricate the turning disk o-ring with grease. Art. no. is specified in Required
Fit the o-ring to the rear of the turning disk. equipment on page 156.
Also fit the six o-rings, when refitting the
attachment screws.
xx0200000218
• A: Sealing surface, o-ring

2. Secure the turning disk with its attachment 6 pcs M14 x 25, 12.9 quality.
screws. Tightening torque: 175 Nm
they are lubricated as detailed in

section Screw joints on page 254
before fitting.
3. Perform a leak-down test of the gearbox axis 6. Detailed in section Performing a leak-
down test on page 130.
4. Refill the gearbox 6 with oil. Detailed in section Filling, oil on page
119.
5. Refit any equipment removed during disassem-
bly, to the turning disk.
6.
DANGER!

4 Repair
4.4.2. Replacement of tilthouse unit
Location of tilt house

The tilthouse unit is located as shown in the figure below.
xx0600002616
A Tilthouse unit
B Upper arm
C Upper rod
D Screw M6x10
E Washer 6.4x12x1.6
F Ballplug
G Protection cap

4 Repair
Continued
Location of axes 2 and 3 sides of the robot

The figure below shows the location of the axes 2 and 3 sides of the robot. See markings on
the lower arm (axis 2) and the parallel arm (axis 3).
xx0600002743
A Axis 2 side of the robot

B Axis 3 side of the robot
Cut away view of the assembly of the tilthouse unit

The figure below shows a cut away view of how the tilthouse unit is fitted to the upper arm.
The letters in the figure are being referred to in the step by step procedures below.
xx0600002742
A Axis 2 side
B Axis 3 side

4 Repair
Continued
C VK cover, VK 19 x 6, 2 pcs
D VK cover, VK 68 x 8, 2 pcs
E Screw M6 x 10 Steel 8.8-A2F + Washers, 4 + 4 pcs (for filling bearing grease)
F Retaining ring fore bores, 2 pcs
G Rust protection, Dinitrol 490
H Upper arm
I Tilthouse
J Bearing, 2 pcs (on the outside of the tilthouse)
K Bearing, 2 pcs (on the inside of the tilthouse)
L Ring
M Shaft, 2 pcs
N Radial seal with dustlip, 2 pcs
O Lock nut, KM7 2 pcs
P Screw M6x16 + washer (for locking the shafts), 2 + 2 pcs
Required equipment

Press tool, 3HAC 023075-001
premounting bearing
Press tool, mounting 3HAC 023080-001
axis 6
Shims Width = 3 mm
Grease 3HAB 3537-1
Rust protection Dinitrol 490
page 258.

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

4 Repair
Continued
Press tool premounting bearing

The press tool for premounting the bearing race, bearing complete, radial seal with dustlip
and ring in the tilthouse, is assembled with the parts shown in the figure below.
Note! The parts cannot be ordered separatly, but are inluded when ordering the complete tool.
The article numbers are given only for identification.
xx0600002750
A Hydraulic cylinder, 3HAC 11731-1

B Mounting washer, 3HAC 023075-004
C Bushing, 3HAC 023075-006
D Screw M6x25, 2 pcs (MC6S)
E Threaded washer, 3HAC 5507-1
F Press washer, 3HAC 023075-002
G Threaded bar, M16 L = 300 mm

4 Repair
Continued
Press tool mounting axis 6

The press tool for mounting the tilthouse on the upper arm, is assembled with the parts shown
in the figure below.
Note! The parts cannot be ordered separatly, but are included when ordering the complete
tool. The article numbers are given only for identification.
xx0600002751
A Hydraulic cylinder, 3HAC 11731-1

B Distance, 3HAC 023062-001

C Press housing, 3HAC 023080-004
D Support housing, 3HAC 023080-003
E Screw M6x14, 2pcs (MC6S)
F Flange lock nut, M16
G Threaded bar, M16 L=435 mm
H Nut M16
Removal, tilthouse
The procedure below details how to remove the tilthouse unit.
The item letters within paranthesis refer to the figure Cut away view of the assembly of the
tilthouse unit on page 160.
Action Note
1. Move the robot to a position where the tilthouse
rests on a table or similar.

4 Repair
Continued
Action Note
2.
DANGER!
3. Secure the tilthouse with a roundsling in an This is done in order to prevent the
overhead crane. tilthouse from falling down when the
shafts are removed.
4. Remove the upper rod. Detailed in section Replacement of
linkage - upper rod on page 177
5. Remove one of the M6 screws and washer at
the cover for filling grease.
xx0600002735
• A: Screw M6, grease filling

hole
6. Note! Do not remove the ball plug! Shown in the figure Location of tilt
Be careful not to damage the ball plug! house on page 159.
7. Remove the motor cable axis 6. Detailed in section Replacement of

cable harness, upper end (incl. axis 6)
on page 144
Put the motor cable in a way that is
isn´t damaged.
8. Remove one shaft at a time by following the
steps below.
9. Use compressed air in the M6 hole for filling Put a hand with some paper over the
grease (E), in order to remove the VK cover (D). VK cover in order to catch it.
Note! Only a very low air pressure is needed!

4 Repair
Continued
Action Note
10. Remove the screw that locks the shaft.
xx0600002703
• A: Screw M6x16
• B: Shaft
• C: Upper arm
11. Remove the small VK cover (C) from the inside Shown in the figure Cut away view of
with the help of a punch. the assembly of the tilthouse unit on
page 160.
12. Remove the lock nut (O). Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
13. Remove the shaft (M) with the press tool, Art.no is specified in Required
mounting axis 6. equipment on page 161
Note! A longer threaded bar M16 is needed
when removing the shaft than the one specified
when fitting.
14. Check that the tilthouse is secured in a
overhead crane or similar before proceeding
with the next shaft.
15. Remove the other shaft in the same way. Follow steps 9 through 13.
16. Lift the tilthouse to a safe place. Check that the bearings are kept
clean, if they are refitted.

17. Force away the sealing ring (N) with a The sealing must be replaced with a
screwdriver or similar. new one when refitting.
18. If needed change the bearings.
Premounting tilthouse bearings and other parts, axis 2 side

The procedure below details how to fit the bearings and other parts in the tilthouse on the axis
2 side, before fitting the tilthouse to the upper arm.
This work is best done on a workbench or similair.
Action Note
1. Lift the tilthouse to a workbench (or similair) with
a roundsling in an overhead crane.

4 Repair
Continued
Action Note
2. Apply some grease in the hole for the bearings Art.no. is specified in Required
(J) and (K). equipment on page 161.
Shown in the figure Cut away view of
page 160.
3. Fit two retaining rings for bores (F). Shown in the figure Cut away view of
page 160.
4. Fit the outer race of the bearing (J) facing the Shown in the figure Cut away view of
outside of the tilthouse. Use a plastic hammer or the assembly of the tilthouse unit on
similair. page 160.
5. Thread the radial seal with dustlip (N) and the Shown in the figure Cut away view of
inner bearing complete (K) on the presswasher the assembly of the tilthouse unit on
(F) of the pressing tool, premounting bearings. page 160.
Shown in the figure Press tool
premounting bearing on page 162.
Art.no. is specified in Required
6. Thread the race of the outer bearing (J) on the Shown in the figure Cut away view of
bushing (C) of the pressing tool, premounting the assembly of the tilthouse unit on
bearings. page 160.
7. Fit the pressing tool and press the parts
together.
Premounting tilthouse bearings and other parts, axis 3 side

The procedure below details how to fit the bearings and other parts in the tilthouse on the axis
3 side, before fitting the tilthouse to the upper arm.
This work is best done on a workbench or similair.
Action Note © Copyright 2006-2008 ABB. All rights reserved.
1. Apply some grease in the hole for the bearings Art.no. is specified in Required
(J) and (K). equipment on page 161.
page 160.
2. Fit the outer race of the bearing (J) facing the Shown in the figure Cut away view of
outside of the tilthouse. Use a plastic hammer or the assembly of the tilthouse unit on
similiar. page 160.
3. Thread the radial seal with dustlip (N), the inner Shown in the figure Cut away view of
bearing complete (K) and the ring (L) on the the assembly of the tilthouse unit on
press washer (F) of the pressing tool, page 160.
premounting bearings. Shown in the figure Press tool
Art.no. specified in Required

4 Repair
Continued
Action Note
4. Thread the race of the outer bearing (J) on the Shown in the figure Cut away view of
bushing (C) of the pressing tool, premounting the assembly of the tilthouse unit on
bearings. page 160.
5. Fit the pressing tool and press the parts
together.
Refitting, tilt house

The procedure below details how to refit the tilthouse unit.
Before starting this procedure, prepare the tilthouse as detailed in the procedures
Premounting tilthouse bearings and other parts, axis 2 side on page 165 and Premounting
tilthouse bearings and other parts, axis 3 side on page 166.
Action Note
1. Secure the tilthouse with a roundsling in an
overhead crane and lift it to its mounting
position on the upper arm.
2. Apply Dinitrol 490 (G) on the surfaces where Shown in the figure Cut away view of
the tilthouse faces the upper arm for rust the assembly of the tilthouse unit on
protection. page 160.
3. Apply some grease in the holes for the shafts Art. no. is specified in Required
(M) in the upper arm. equipment on page 161.
page 160.
4. Note! Fit the axis 2 side first. Shown in the figure Location of axes 2
and 3 sides of the robot on page 160.
5. Push the axis 2 shaft (M) into its hole, from the Shown in the figure Cut away view of
inside. the assembly of the tilthouse unit on
page 160.
6. Thread the race of the bearing (J) facing the Shown in the figure Cut away view of
outside of the tilthouse, on the press housing the assembly of the tilthouse unit on
(C) of the press tool, mounting axis 6 and fit it page 160.
on the shaft (M). Shown in the figure Press tool
mounting axis 6 on page 163.
Art. no. is specified in Required
7. Fit the rest of the press tool, mounting axis 6 Art. no. is specified in Required
from the outside of the tilthouse.Secure the equipment on page 161.
parts with the flange locknut (F). Shown in the figure Press tool
mounting axis 6 on page 163.

4 Repair
Continued
Action Note
8. Insert the shims in the space between the Art. no. is specified in Required
tilthouse and the upper arm on the axis 2 side. equipment on page 161.
xx0600002748
• Shims, width = 3 mm
• A: 68 mm
9. Press the parts together.
10. Fit the axis 3 side in the same way, by following
steps 4 through 6.
11. Insert the shims in the space between the
tilthouse and the upper arm on the axis 3 side.
12. Press the parts together.
13. Apply locking liquid on the lock nut, KM7 axis 2 Loctite 243.
side and fit it with the flat surface facing inside. Tightening torque: 90 Nm
14. Apply locking liquid on the lock nut, KM7 axis 3 Loctite 243.
side and fit it with the flat surface facing inside. Tightening torque: 90 Nm
15. Apply locking liquid in the holes for the screws
locking the shafts and fit screws and washers
on both sides, locking the shafts.
0600002703
• A: Screw M6x16
• B: Shaft
• C: Upper arm
16. Fit the inner VK cover (C) on both axes. Shown in the figure Cut away view of
page 160.
17. Fit the outer VK cover (D) on both axes. Shown in the figure Cut away view of
page 160.
18. Fill bearings with grease. Specified in Required equipment on
page 161.

4 Repair
Continued
Action Note
19. Refit the motor cable, axis 6. Detailed in section Replacement of
cable harness, upper end (incl. axis 6)
on page 144
20. Refit the M6 screw and washer at the cover for
filling grease.
xx0600002735
• A: Screw M6, grease filling

hole
21. Refit the upper rod. Detailed in section Replacement of
calibration tools.
23.
DANGER!

4 Repair
4.4.3. Replacement of upper arm
Location of upper arm

The upper arm is located as shown in the figure below.
xx0600002609
A Upper arm
B Motor axis 6
C Balancing device
D Lower arm
E Parallel rod © Copyright 2006-2008 ABB. All rights reserved.
F Linkage

4 Repair
Continued
View of the assembly of the upper arm components

The figure below show a cut away view how the upper arm is fitted to the lower arm. (Seen
from above) The letters in the figure are being referred to in the step by step procedures below.
xx0600002692
A Shaft, axis 2
B Shaft, axis 3
C Set screw, cup point ( M10 x 20)
D Lubricant paste (Molycote 1000)
E Sealing ring (V-ring)
F Sealing ring
G Taper roller bearing
H O-ring

4 Repair
Continued
I Sealing ring
J Sealing assembly
K Lock nut (KM 12)
L O-ring (Di = 54.2 mm, t = 5.7 mm)
Required equipment

Upper arm, axis 4 3HAC025525-001 White RAL 9003
3HAC026674-001
Adapter 3HAC023916-001
Grease filling tool -
Pressing tool, upper 3HAC023084-001
arm
KM12 socket 3HAC5347-1
page 258.
references to these
procedures in the
step-by-step
instructions below.
Circuit diagram - See chapter Circuit
diagram.
Removal, upper arm

The procedure below details how to remove the upper arm.
Action Note
1. Remove all equipment fitted to the turning © Copyright 2006-2008 ABB. All rights reserved.
disk.
2. Move the upper arm to a horizontal position.
3.
DANGER!
4. Secure the upper arm with roundslings in
an overhead crane.
5. Remove the cable harness in the upper Detailed in section
arm.
6. Raise the lifting equipment to take the
weight of the upper arm.
7. Remove the balancing device. Detailed in section Replacement of
balancing device on page 200

4 Repair
Continued
Action Note
8. Remove the linkage. Detailed in section Replacement of
Detailed in section Replacement of
linkage - lower rod on page 180
linkage - link on page 183
9. Remove the parallel rod. Detailed in section Replacement of
parallel rod on page 188
10. Remove the lock nut (K) on the shaft, axis Shown in the figure View of the assembly
3 (B). of the upper arm components on page
171.
11. Remove the set screw (C) holding the shaft. Shown in the figure View of the assembly
of the upper arm components on page
171.
12. Put the adapter on the shaft. Art.no. is specified in Required equipment
on page 172
13. Remove the shaft axis 3 (B). Shown in the figure View of the assembly
171.
Perform the removal with care. Threads
can otherwise be damaged!
14. Then remove the shaft, axis 2 (A) in the Shown in the figure View of the assembly
same order: of the upper arm components on page
1. Remove the lock nut (K) 171.
2. Remove the set screw (C) holding
the shaft
3. Remove the shaft axis 2.
NOTE!
The adapter is not needed on this shaft!
15. Put the shafts in a clean and safe place.
16. Remove the upper arm.
Preparations before refitting, upper arm

The procedure below details the preparations which must be done before refitting the upper
arm.
Action Note
1. Put the shafts (A & B) on a workbench and Shown in the figure View of the assembly
fit the sealing rings (E). of the upper arm components on page
171.
2. Apply some grease on the shafts and
sealing rings.
NOTE!
Don´t apply grease on the threads and
cones of the shafts!

4 Repair
Continued
Action Note
3. Fill the bearings (G) with bearing grease. Art. no. is specified Required equipment
Use grease filling tool. on page 172
Shown in the figure View of the assembly
171.
4. Apply lubricant paste (D) on the threads and Molycote 1000.
cones of the shafts. Shown in the figure View of the assembly
171
Refitting, upper arm

The procedure below details how to refit the upper arm.
Action Note
1. Secure the upper arm with roundslings in
an overhead crane.
2.
CAUTION!
The complete upper arm with weighs 170 kg
without any additional equipment fitted! Use
a suitable lifting device to avoid injury to
personnel!
3.
CAUTION!
The complete upper arm weighs 380 kg
without any additional equipment fitted!
Use a suitable lifting device to avoid injury to
personnel!
4. Lift the upper arm with an overhead crane
and move it to its mounting position. © Copyright 2006-2008 ABB. All rights reserved.
Make sure that the upper arm is placed in a
horizontal position.
5.
NOTE!
Refit the axis 3 side first!
6. Carefully refit the shaft, axis 3 (B) by hand Shown in the figure View of the assembly
only. of the upper arm components on page
Don´t use force since the threads can be 171.
damaged if fitting is not done in the correct
way.

4 Repair
Continued
Action Note
7. Put the adapter on the shaft and fit it. Art.no. is specified in Required equipment
Secure the shaft. on page 172
Tightening torque: 400 Nm. The adapter is used in order to be able to
use the same tool on both axis 2 and 3
shaft when refitting.
The adapter is only used on the shaft axis
3.
8. Refit the sealing ring (F) on the shaft. Shown in the figure View of the assembly
171.
9. Refit the bearing (G) on the shaft with the Shown in the figure View of the assembly
pressing tool, upper arm. of the upper arm components on page
171.
10. Fit an o-ring (H) on the sealing ring (I) and fit Shown in the figure View of the assembly
it on the shaft. of the upper arm components on page
171.
NOTE!
The o-ring shall be faced against the
bearing.
11. Fit the o-ring (L) on the sealing assembly (J) Shown in the figure View of the assembly
and refit the sealing assembly on the shaft. of the upper arm components on page
171.
12. Apply locking liquid on the lock nut (K) and Shown in the figure View of the assembly
refit it. of the upper arm components on page
171.
Loctite 243.
Tightening torque 90 Nm.
13. The refit the axis 2 side in the same order Follow the steps for refitting shaft axis 3
with the exception of the lock nut (K). above.
Shown in the figure View of the assembly
171.

4 Repair
Continued
Action Note
14. Apply locking liquid on the lock nut (K) and Shown in the figure View of the assembly
refit it. of the upper arm components on page
171.
Loctite 243.
Tightening torque the first time: 300 Nm
NOTE! Tightening torque the second time: 90
The order of the tightening torques is very Nm
important!
NOTE!
The fitting of the lock nut on axis 2 is
performed in three steps:
1. Fit the lock nut with a tightening
torque of 300 Nm.
2. Unscrew the lock nut.
3. Fit the lock nut once again. This time
with a tightening torque of 90 Nm.
15. Apply locking liquid in the holes for the set Shown in the figure View of the assembly
screws (C) and fit the screws. of the upper arm components on page
171
Loctite 243.
16. Wipe residual grease from the shafts.
17. Refit the parallel rod. Detailed in section Replacement of
18. Refit the cable harness, upper end. Detailed in section
19. Refit the linkage. Detailed in section Replacement of
20. (Not applicable to the robot variant IRB Detailed in section Replacement of
6660 - 205/1.9! ) balancing device on page 200
Refit the balancing device.
calibration tools.
on page 241.
22.
DANGER!
on page 32.

4 Repair
4.4.4. Replacement of linkage - upper rod
Overview
The link system consists of three basic parts - upper rod, lower rod and link. The procedures
below details how to remove and refit the upper rod.
Location of upper rod

The upper rod is located as shown in the figure below.
xx0600002592
A Lower rod
B Upper rod
C Link
Required equipment
Equipment Spare part no. Art no. Note

Upper rod 3HAC023744-003 White RAL 9003
Needle bearing 3HAC3311-1 Replace if damaged.
Bearing grease 3HAB3537-1 Used to lubricate the
bearings.
Locking liquid 3HAB7116-1 Loctite 243

4 Repair
Continued

page 258.
references to these
procedures in the
tions below.
Removal, upper rod

The procedure below details how to remove the upper rod of the linkage.
Action Note
1. Put the robot in a position where it is Check especially that it is possible to
possible to reach all parts that shall be remove the lock nut at the link.
removed.
2.
DANGER!
3. Let the tilthouse rest on something, (a table This is done in order to prevent the
for example). tilthouse from falling downwards when the
upper rod is removed.
4. Remove the lock nuts holding the upper rod
at each end.
5. Remove the support washers from the
upper rod.
6. Remove the upper rod. Note! The support washers on the inside
of the rod can stick to the grease of the
bearings when the rod is being removed. © Copyright 2006-2008 ABB. All rights reserved.
Remove them from the rod!
7. Remove the support washers and the
sealing rings.
8. Remove residual grease.
Refitting, upper rod

The procedure below details how to refit the upper rod of the linkage.
Action Note
1. If needed, replace the bearings in the rod. Spare part no. is specified in Required
Note! The bearings are sensitive for equipment on page 177.
pushes. Make sure they are not damaged!
2. Lubricate the bearings properly with bearing Specified in Required equipment on page
grease. 177.
3. Refit the sealing rings on the shaft ends of
the link and tilthouse.
4 Repair
Continued
Action Note
4. Refit the support washers on the shaft ends.
5. Refit the upper rod to its place on the shafts. Check that the rod is pushed in
completely.
6. Refit the support washers on the outside of
the upper rod, on the shaft ends.
7. Refit the lock nuts on the link and tilthouse, Tightening torque: 120 Nm.
using locking liquid.
8.
DANGER!
page 32.

4 Repair
4.4.5. Replacement of linkage - lower rod
Overview
The linkage consists of three basic parts - upper rod, lower rod and link. The procedures
below details how to remove and refit the lower rod.
Location of lower rod

The lower rod is located as shown in the figure below.
xx0600002592
A Lower rod
B Upper rod
C Link
Required equipment

Lower rod 3HAC023239-003 White RAL 9003
Needle bearing 3HAC3311-1 Replace if damaged.
Bearing grease 3HAB3537-1
Locking liquid 3HAB7116-1 Loctite 243

4 Repair
Continued

Standard toolkit The content is defined in
on page 258.
procedures may be include references to the
required. See tools required.
references to these
procedures in the
tions below.
Removal, lower rod

The procedure below details how to remove the lower rod of the linkage.
Action Note
1.
DANGER!
2. If the upper rod is removed, secure the link This is done in order to prevent the link
with a roundsling in a crane. Use the hole in from moving if both the upper and lower
the middle of the link. rod are removed.
3. Remove the lock nuts holding the lower rod
at each end.
4. Remove the support washers. These can stick to the grease and can
easy be forgotten and lost when removing
the lock nuts.
5. Remove the lower rod. Note! The support washers on the inside
of the rod can stick to the grease of the
bearings when the rod is being removed.
Remove them from the rod!
6. Remove the support washers and the

sealing rings and remove residual grease.
Refitting, lower rod

The procedure below details how to refit the lower rod of the linkage.
Action Note
1. If needed, replace the bearings. Spare part no. is specified in
Note! The bearings are sensitive for pushes. Required equipment on page 180.
Make sure they are not damaged!
2. Lubricate the bearings properly with bearing Specified in Required equipment on
grease. page 180.
3. Refit the sealing rings to the shaft ends on the
link and frame.
4. Refit the support washers to the shaft ends. Tip! Putting some grease on the
support washers will keep them in
position.

4 Repair
Continued
Action Note
5. Refit the lower rod on the shaft ends of the link Check that the lower rod is pushed
and frame. completely in.
6. Refit the support washers on the outside of the
lower rod, on the link and frame shafts.
7. Refit the lock nuts on the shaft ends, using Tightening torque: 120 Nm.
locking liquid. Locking liquid is specified in
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 32.

4 Repair
4.4.6. Replacement of linkage - link
Overview
The linkage consist of three basic parts - upper rod, lower rod and link. The procedures below
details how to remove and refit the link.
Location of link
The link is located as shown in the figure below.
xx0600002592
A Lower rod
B Upper rod
C Link
Required equipment

Link White RAL 9003
Auxiliary shaft 3HAC 023081-004
Pressing tool, link 3HAC 023081-001 Used to press the link on the
shaft
Pressing tool, link 3HAC 023079-001 Used to press the outer rings
of the bearings in the link

4 Repair
Continued

Lubrication tool 3HAC 5222-2
Sealing compound Permatex No. 3
Grease 3HAB 3537-1
Standard toolkit The contents are defined in
section Standard toolkit!
references to these
procedures in the
step-by-step
instructions below.
Removal, link
The procedure below details how to remove the link of the linkage.
Action Note
1.
DANGER!
2. Secure the link with a roundsling in a crane. This is done to prevent the link from
Use the hole in the middle of the link. moving when the upper and lower rods
are removed.
3. Remove the upper and lower rods. Detailed in section Replacement of
4. Fit the auxiliary shaft on the shaft. Art.no. is specified in Required equipment
on page 183 © Copyright 2006-2008 ABB. All rights reserved.

4 Repair
Continued
Action Note
5. Remove screw and washer in the hole for
filling grease.
xx0600002597
• A: Hole for filling grease

6. Use compressed air to remove the VK Put one hand with some paper on top of
cover. Blow with a very low air pressure into the VK cover in order to catch it when
the hole for filling grease. released.
Note! A very low air pressure is needed!
7. Remove the lock nut.
8. Put the end of the link facing the upper rod, Normally a not too hard knock is needed
downwards in order to find room to knock on to loosen the link.
it from the inside as close to its center as Note! Loosen the roundsling some before
possible. knocking! Otherwise the link may be
locked by the lifting power.
9. Use a pair of levers, to bend the link loose.
10. Remove the link.

11. Remove the support ring with the radial
seal.
12. Wipe off residual grease.
13. If needed, replace the bearings and radial
seal.
Refitting, link
The procedure below details how to refit the link of the linkage.
Action Note
1. Put the link on a bench. Place the outer
rings of the bearings in the link.
2. Use the pressing tool, link and fit the outer Art.no. is specified in Required equipment
rings. on page 183

4 Repair
Continued
Action Note
3. Secure the link with a roundsling in an
overhead crand. Lift it to the mounting
position.
4. Fit the auxiliary shaft on the shaft. Art.no. is specified in Required equipment
on page 183
5. Apply sealing compound on the support Permatex No. 3
ring.
6. Fit the support ring with the radial seal fitted. Replace the radial seal if needed!
7. Fit the bearings and link, in the following
order: bearing, link, bearing.
8. Use the pressing tool, link to fit the link. Art.no. is specified in Required equipment
on page 183
9. Apply locking liquid on the lock nut. Loctite 243
10. Fit the lock nut first with a tightening torque Tightening torque first time: 300 Nm
of 300 Nm. Then unscrew the lock nut and Tightening torque the second time: 90
fit it once again. This time with a tightening Nm
torque of 90 Nm.
Note the order of the two tightening torques!
11. Refit the VK cover.
12. Fill the link with grease. Use lubrication tool. Art.no. is specified in Required equipment
on page 183
xx0500002597
• A: Hole for filling grease

13. Refit the screw and washer in the hole for
filling grease.
14. Refit the upper rod to the link. Detailed in section Replacement of
15. Refit the lower rod to the link. Detailed in section Replacement of

4 Repair
Continued
Action Note
calibration tools.
on page 241.
17.
DANGER!
page 32.

4 Repair
4.4.7. Replacement of parallel rod
Location of parallel rod

The parallel rod is located as shown in the figure below.

xx0600002610
A Parallel rod
Required equipment

Parallel rod 3HAC021084-004 White RAL 9003
Mounting/ 3HAC5021-1
Demounting tool
on page 258.

4 Repair
Continued

references to these
procedures in the
step-by-step
instructions below.
Removal, parallel rod

The procedure below details how to remove the parallel rod. The procedure is the same in
both ends of the parallel rod.
Action Note
1.
DANGER!
2. Secure the upper arm with a roundsling in a
crane.
3. Remove the upper lock screw and washer,
locking the parallel rod in position.
xx0600002741
• A: Lock screw M6x16

4 Repair
Continued
Action Note
4. Remove the upper shaft (A) and cover
washer (B).
xx0700000065
Parts:
• A: Shaft
• B: Cover washer
• C: Parallel rod
• D: Sealed spherical bearing
• E: Bearing grease
• F: Thrust washer
5. Remove the thrust washer (F). See figure above!
6. Remove the parallel rod (C) backwards See figure above and Location of parallel
from its upper connection point and let it rest rod on page 188!
against frame and base.
7. Continue by removing the lower end of the See figure above!
parallel rod in the same way as the upper
end:
1. Remove the lower lock screw and
washer
2. Remove the lower shaft (A )and
cover washer (B)
3. Remove the thrust washer (F)
8. Remove the parallel rod from the robot.
9. Replace the bearings (D), if necessary. See figure above!
Refitting, parallel rod

The procedure below details how to refit the parallel rod. The procedure is the same in both
ends of the parallel rod.
Action Note
1. Lift the parallel rod to the mounting position.

4 Repair
Continued
Action Note
2. Put the thrust washer (F) on the axis 2 side
of the parallel rod (C).
xx0700000065
3. Put the cover washer (B) on the axis 3 side See figure above!
of the parallel rod.
4. Refit the shaft (A) by pushing it through the See figure above!
parallel bar.
Press the shaft in position.
5. Apply locking liquid in the hole of the lock Loctite 243
screw.
6. Refit the lock screw and plain washer.
xx0600002741
• A: Lock screw M6x16

calibration tools.
on page 241.
8.
DANGER!
page 32.

4 Repair
4.4.8. Replacement of complete lower arm
Location of lower arm

The complete lower arm is located as shown in the figure below.
xx0600002611
A Lower arm
B Parallel arm © Copyright 2006-2008 ABB. All rights reserved.
Required equipment

Lower arm 3HAC021464-004 White RAL 9003
3HAC021464-004
Crank 3HAC023132-001
Lock screw M16x90 -
Lifting tool, lower arm 3HAC8446-1
complete
page 258.

4 Repair
Continued

references to these
procedures in the
tions below.
diagram.
Removal, lower arm

The procedure below details how to remove the lower arm.
Action Note
1.
DANGER!
2. Secure the lower arm with a lock screw in the
hole as shown in the figure to the right.
xx0600002736
• A: Hole for lock screw,

M16x90
3. Remove the linkage. Detailed in section Replacement of
4. Remove the balancing device. Detailed in section Replacement of
balancing device on page 200
5. Remove the parallel rod. Detailed in sectionReplacement of
parallel rod on page 188 .

4 Repair
Continued
Action Note
6. Remove the upper part of the cable harness. Detailed in section Replacement of
Secure the cable harness in a way that it is cable harness, upper end (incl. axis
protected from getting damaged and from oil 6) on page 144.
spill.
7. Remove the complete upper arm. Detailed in section Replacement of
upper arm on page 170.
8. Remove the motors axes 2-3. Detailed in section Replacement of
motor, axes 2 and 3 on page 217.
9. Remove gearbox axes 2-3. Detailed in section Replacement of
gearbox, axes 2- 3 on page 232.
10.
CAUTION!
The lower arm weighs 160 kg! All lifting
11. Secure the complete lower arm (including the Art. no. is specified in Required
parallel arm) with the lifting tool, lower arm equipment on page 192.
complete in an overhead crane or similar.
12. Remove all M12 and M16 screws holding the
lower arm, on both sides.
13. Push the lower arm and parallel arm together If the parts are not pushed together, it
with the help of an iron bar or similar. will be difficult to remove the
complete lower arm.
14. Remove the complete lower arm (including the How to replace the parallel arm is
parallel arm). detailed in section Replacement of
parallel arm on page 197.
Refitting, lower arm

The procedure below details how to refit the lower arm.
Action Note
1. © Copyright 2006-2008 ABB. All rights reserved.
CAUTION!
The lower arm weighs 160 kg! All lifting
2. Fit the lifting tool lower arm complete, to the Art. no. is specified in Required
lower arm complete and lift it up. equipment on page 192.
3. Fit the two guide sleeves for the sealings axes 2/
3, to the lower arm and put the sealings on them.
4. Put the lower arm in the mounting position.
Use a crank to find the correct hole pattern.
5.
NOTE!
Refit the axis 2 side first!

4 Repair
Continued
Action Note
6. Refit all screws (both M12 and M16) with Tightening torque M16: 300 Nm
washers on the axis 2 side that are possible to fit Tightening torque M12: 120 Nm
at this stage.
7. Push the parallel arm against the axis 2 side.
8. Refit all screws with washers on the axis 3 side Tightening torque M12: 120 Nm
that are possible to fit.
NOTE!
The axis 3 side has no M16 screws!
9. Change the position of the lower arm in order to
reach the remaining attachment holes, and fit the
remaining screws.
10. Secure the lower arm by fitting a lock screw.
xx0600002736
• A: Hole for lock screw

M16x90
11. Refit gearbox axis 2-3. Detailed in section Replacement of

gearbox, axes 2- 3 on page 232.
12. Refit motor axes 2-3. Detailed in section Replacement of
motor, axes 2 and 3 on page 217.
13. Refit the complete upper arm. Detailed in section Replacement of
upper arm on page 170.
14. Refit the cable harness. Detailed in section Replacement of
cable harness, upper end (incl. axis
6) on page 144
15. Refit the parallel rod. Detailed in section Replacement of
16. Refit the balancing device. Detailed in section Replacement of
balancing device on page 200.

4 Repair
Continued
Action Note
17. Refit the linkage. Detailed in section Replacement of
18. Remove the lock screw.
calibration tools.
20.
DANGER!

4 Repair
4.4.9. Replacement of parallel arm
Location of parallel arm

The parallel arm is located as shown in the figure below.
0600002611
A Lower arm
B Parallel arm
Required equipment

Parallel arm 3HAC023026-003 White RAL 9003
3HAC023026-003
Bearing grease 3HAB 3537-1
Pressing tool, lower 3HAC023092-001
arm
Lifting device, parallel 3HAC023098-001
arm
Lifting tool, lower arm 3HAC8446-1
complete
Level -

4 Repair
Continued

on page 258.
procedures may be include references to
required. See the tools required.
references to these
procedures in the
tions below.
Removal, parallel arm

The procedure below details how to remove the parallel arm.
Action Note
1.
DANGER!
2. Remove the complete lower arm. Detailed in section Replacement
of complete lower arm on page
192.
3. Put the complete lower arm on a workbench.
Removal of the parallel arm is best perfomed on a
workbench.
4. Remove the two VK covers.
5. Fit the lifting device, parallel arm on the parallel arm. Art.no. is specified in Required
6. Disassemble the parallel arm from the lower arm by Art.no. is specified in Required
using the pressing tool, lower arm. equipment on page 197.

7.
CAUTION!
The parallel arm weighs 92 kg.
8. If necessary, change the bearings.
Refitting, parallel arm

The procedure below details how to refit the parallel arm.
Action Note
1. Refitting of the parallel arm is best performed on a
workbench.
2. Apply some grease on the shafts on the parallel
arm.
3. Refit a spacing sleeve on each shaft.

4 Repair
Continued
Action Note
4. Refit a bearing on each shaft with pressing tool, Art. no. is specified in Required
lower arm. equipment on page 197
5. Refit the protection washer on the inner shaft.
6. Refit the lock ring on the inner shaft.
7. Lift the lower arm onto the workbench with lifting Art. no. is specified in Required
tool, lower arm complete. equipment on page 197
8. Adjust the lower arm in a way that both holes are
parallel.
Use a level.
9. Apply some grease in the holes in the lower arm.
10. Fit the lifting device, parallel arm. Art. no. is specified in Required
11.
CAUTION!
The parallel arm weighs 92 kg.
12. Lift the parallel arm and put it in mounting position
with the lower arm.
13. Carefully press the parallel arm onto the lower arm Art. no. is specified in Required
with the pressing tool, lower arm. equipment on page 197.
14. Refit the big and small VK covers.
15. Refit the complete lower arm. Detailed in section Replacement
of complete lower arm on page
192.
16. Recalibrate the robot. Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
17.
DANGER!

4 Repair
4.5.1. Replacement of balancing device
4.5 Frame and base
Location, balancing device

The balancing device is located as shown in the figure below.
xx0600002604
A Balancing device
B Hole to neutralize the spring force. (M12)
C Hole on lifting ear
D Hole for lock screw

4 Repair
Continued
Required equipment

Balancing device 3HAC024779-001 White RAL 9003
3HAC024779-001
Auxiliary shaft 3HAC5281-1 For fitting the inner rings of the
bearings
Auxiliary shaft, long 3HAC5275-1
Auxiliary shaft, 3HAC5276-1
short
Lock screw - M16 x 90
For securing the lower arm.
Screw M12 x 50
For neutralizing the spring force
of the balancing cylinder.
Lubrication tool 3HAC5222-2
procedures may be references to the tools required.
required. See
references to these
procedures in the
step-by-step
instructions below.
Removal
The procedure below details how to remove the balancing device.
Action Note
1. Move the robot to a position close enough to its The balancing device must be placed
calibration position, to allow the lock screw to in a 90° angle from the floor, in order
be inserted into the hole for the lock screw. the be lifted in the most secure way.
Shown in section Location, balancing

device on page 200.

4 Repair
Continued
Action Note
2. Lock the lower arm by inserting the lock screw
into the hole.
xx0600002736
• A: Hole for lock screw M16x90

3.
DANGER!
4. Remove the protection hood in the upper end of
the balancing device.
5. Insert a long screw (M12x50) in the hole to The length of the cylinder is now
neutralize the spring force. locked.
6. Attach a roundsling to the balancing device. Use the hole in the lifting ear.
7. Remove the lock nuts. Note! Make sure that the shaft
between the upper and lower arm
does not rotate when unscrewing the
lock nuts! The lock nut is locked with
Loctite 243.
8. Fit the auxiliary shafts on the upper and lower Art.no. is specified in Required
pivot shaft. equipment on page 201
Fit the short auxiliary shaft on the upper shaft
and the longer on the lower shaft.
9. Stretch the roundsling.
10.
CAUTION!
The balancing device weighs 70 kg! All lifting
11. Carefully remove the balancing device from its
upper and lower attachment.
12. Remove the balancing device and put it in a
safe place.
13. Remove the inner rings of the bearings.

4 Repair
Continued
Action Note
14. Remove the sealing rings and support washers.
Refitting
The procedure below details how to refit the balancing device.
Action Note
1. Apply sealing compound on the surface for the
sealing ring.
2. Refit the inner sealing rings and support
washers.
3. Refit the inner ring of the bearings on the upper
and lower pivot shaft with the auxialiary shaft.
4. Fit the auxiliary shafts on the upper and lower Art.no. is specified in section Required
shafts. equipment on page 201
Fit the short auxiliary shaft on the upper shaft
and the longer on the lower shaft.
5. Attach a roundsling to the balancing device and
lift it on to the auxiliary shafts.
6. Adjust the length between the upper and lower This length should preferably be 0.5
bearings by means of the M12 screw, used to mm too short than 0.1 mm too long. If
neutralize the spring force. the distance is too long the bearings
may be damaged when erecting the
balancing device.
7.
CAUTION!
The balancing device weighs 70 kg! All lifting
8. Carefully refit the balancing device on the
upper and lower shafts.
9. Fit the lubricating tool. Art.no. is specified in section Required
The tool should be tightened to the bottom equipment on page 201.

position by hand power only.
10. Fill the bearings with grease through the nipple.
Continue until grease excudes behind the inner
sealing.
11. Remove the lubricating tool and wipe off
protruding grease.
12. Remove the auxiliary shafts.
13. Apply locking liquid on the lock nuts. Loctite 243
14. Refit the lock nuts and support washers. Tightening torque: 120 Nm
15. Check play (min. 0.1 mm) between support
washers and bearing seat at both bearings.
16. Remove the M12x50 screw to restore the
springforce.

4 Repair
Continued
Action Note
17. Remove the M16x90 lock screw.
xx0600002736
• A: Hole for lock screw M16x90

18.
DANGER!

4 Repair
4.5.2. Replacement of SMB unit
Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame
as shown in the figure below.
xx0600002621
A SMB cover
B SMB unit
C Battery cable
D SMB battery
E SMB battery, cover
Required equipment

SMB unit 3HAC022286-001

Battery pack 3HAC16831-1
3HAC16831-1
page 258.
Circuit Diagram - See chapter Circuit diagram.
Removal, SMB unit

The procedure below details how to remove the SMB unit.
Action Note
1. Move the robot to the calibration position.

4 Repair
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 34
4. Remove the SMB cover by unscrewing its Shown in the figure Location of
attachment screws. SMB unit on page 205.
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 205.
7. Gently disconnect the connectors from the SMB unit Connectors R1.SMB1-3,
when pulling the board out. R1.SMB4-6 and R2.SMB
8. Disconnect the battery cable from the SMB unit. Shown in the figure Location of
SMB unit on page 205.
Refitting, SMB unit

The procedure below details how to refit the SMB unit.
Action Note
1.
DANGER! © Copyright 2006-2008 ABB. All rights reserved.

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 34
3. Connect the battery cable to the SMB unit. Shown in the figure Location of SMB
unit on page 205.

4 Repair
Continued
Action Note
4. Connect all connectors to the SMB board and fit Art. no. is specified in Required
the SMB unit onto the pins. equipment on page 205.
Shown in the figure Location of SMB
unit on page 205.
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 Shown in the figure Location of SMB
screws. unit on page 205.
8. Update the revolution counter! Detailed in chapter Calibration -
section Updating revolution counters
on page 246.
9.
DANGER!

4 Repair
4.5.3. 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.
xx0600002621
A SMB cover
B SMB unit
C Battery cable
D SMB battery
E SMB battery, cover
Required equipment
Equipment, etc. Art. no. Note © Copyright 2006-2008 ABB. All rights reserved.
Brake release unit with buttons 3HAC16035-1 Located together with the SMB-unit at
the left hand side of the frame.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.

4 Repair
Continued
Removal, brake release unit

The procedure below details how to remove the brake release unit.
Action Note
1.
DANGER!
2.
esd
WARNING!
ESD! on page 34
3. Remove the push button guard from the SMB Shown in the figure Location of brake
cover. release unit on page 208.
The guard must be removed to ensure a
correct refitting of the brake release unit.
4. Open the SMB cover by unscrewing the Shown in the figure Location of brake
attachment screws. release unit on page 208.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
5. Remove the complete brake release unit
(including brake release unit and bracket)
from the SMB recess, by removing its two
attachment screws.
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 208.

4 Repair
Continued
Action Note
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
1.
DANGER!
2.
esd
WARNING!
ESD! on page 34
3. Fasten the brake release unit on the bracket Shown in the figure Location of brake
with the attachment screws. release unit on page 208.
Make sure the unit is positioned as straight as Art. no. is specified in Required
possible on the bracket! The push buttons can equipment on page 208.
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
5. Refit the complete brake release unit
(including brake release unit and bracket) to
the SMB recess with the two attachment
screws.

4 Repair
Continued
Action Note
6. Refit the SMB cover with its attachment Shown in the figure Location of brake
screws. release unit on page 208.
The push button guard must not be mounted
on the cover before the check described below
is made!
7.
WARNING!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 33!
8. Refit the push button guard to the SMB cover. Shown in the figure Location of brake
release unit on page 208.
9. If the battery has been disconnected the Detailed in the Calibration chapter -
revolution counter must be updated. section Updating revolution counters on
page 246.
10.
DANGER!

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 robot as shown in the figure below.
xx0600002598
A Motor axis 1
B Motor attachment screws and washers
C Cable gland cover (located on the lower side of the motor)
D Motor cover
Required equipment © Copyright 2006-2008 ABB. All rights reserved.

Motor axis 1 3HAC024775-001 Includes:
3HAC028861-001 • motor
• pinion
• o-ring (Old o-ring
must be replaced
when replacing the
motor)
Grease 3HAB3537-1 Used to lubricate the o-ring
Power supply - 24 VDC, max. 1,5 A
For releasing the brakes.
page 258.

4 Repair
Continued

references to these
procedures in the
step-by-step
instructions below.
diagram.
Removal, motor
The procedure below details how to remove motor, axis 1.
Action Note
1.
DANGER!
2. Remove the motor cover in order to get access Shown in the figure Location of motor
to the connectors on top of the motor by on page 212.
unscrewing its four attachment screws.
xx0600002696
• A: Motor cover
• C: Cable gland

4 Repair
Continued
Action Note
3. Remove the cable gland cover at the cable exit Shown in the figure Location of motor
by unscrewing its attachment screw which is on page 212.
found after removing the motor cover. Make sure the gasket is not damaged!
xx0600002694
• A: Screw holding the cable

gland
4. Disconnect all connectors beneath the motor
cover.
5. In order to release the brake, connect the 24 Connect to connector R2.MP1
VDC power supply. • + : pin 2
• - : pin 5
6. Remove the motor by unscrewing its four Shown in the figure Location of motor
attachment screws and plain washers. on page 212.
7. If required, press the motor out of position by Always use the removal screws in
fitting two screws in the holes on the motor for pairs!
pressing out the motor.
8.
CAUTION!
The motor weighs 29 kg! All lifting equipment
9. Lift the motor to get the pinion away from the
gear and disconnect the brake release voltage.
10. Remove the motor by gently lifting it straight up. © Copyright 2006-2008 ABB. All rights reserved.
11. Check the pinion. If there is any damage, the
pinion must be replaced.
NOTE!
If the gearbox is replaced, the motor pinion
must also be replaced!

4 Repair
Continued
Refitting, motor
The procedure below details how to refit motor, axis 1.
Action Note
1. Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.
NOTE!
The o-ring must be replaced when
replacing the motor.
2.
CAUTION!
• - : pin 5
4. Fit the motor, making sure the motor pinion is Make sure the motor is turned the right
properly mated to the gearbox of axis 1. way, that is connections on the left
hand side.
Make sure the motor pinion does not
get damaged!
5. Secure the motor with its four attachment M10 x 40
screws and plain washers. Shown in the figure Location of motor
on page 212.
6. Disconnect the brake release voltage.
7. Reconnect all connectors beneath the motor
cover.
8. Refit the cable gland cover at the cable exit with Make sure the cover is tightly sealed!
its attachment screw. Replace the gasket.
xx0600002694
• Screw holding the cable gland

4 Repair
Continued
Action Note
9. Refit the motor cover with its four attachment Make sure the cover is tightly sealed!
screws.
xx0600002696
• A: Motor cover
• C: Cable gland
calibration tools.
11.
DANGER!

4 Repair
4.6.2. Replacement of motor, axes 2 and 3
Location of motors, axes 2 and 3

The motors axes 2 and 3 are located on either side of the robot as shown in the figure below.
The procedure is the same for both motors.
xx0600002599
A Motor, axis 2
B Motor, axis 3
C Motor attachment screws and washers
D Cable gland cover (located on the lower side of the motor)
E Motor cover
F Hole for lock screw
Required equipment

Motor axis 2-3 3HAC024776-001 Includes
3HAC021030-001 • motor
• pinion
• o-ring (The o-ring
must be replaced
when the motor is
replaced)
Grease 3HAB3537-1 For lubricating the o-ring.
Guide pins M10 x 3HAC13120-2 For guiding the motor.
150 Guide pins are to be used
in pairs!
Lifting tool, motor 3HAC14586-1
axes 2-3
Power supply - 24 VDC, 1.5 A
Rotation tool Used to rotate the motor
pinion when mating it to the
gear, when brakes are
released with 24 VDC
power supply.

4 Repair
Continued

page 258.
references to these
procedures in the
tions below.
diagram.
Removal, motor
The procedure below details how to remove motors, axes 2 and 3.
Action Note
1. Run 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.
2. Secure the upper arm with roundslings in an This is done in order to secure axis 3
overhead crane. from collapsing when gearbox axis 3
is being removed.
3.
DANGER!
4. Lock the lower arm by inserting the lock screw Shown in the figure Location of
into the hole. motors, axes 2 and 3 on page 217.
5. Drain the oil from gearbox, axes 2- 3. Detailed in Oil change, gearbox axes
2-3 on page 115.
6. Remove the motor cover by unscrewing its four Shown in the figure Location of © Copyright 2006-2008 ABB. All rights reserved.
attachment screws. motors, axes 2 and 3 on page 217.
7. Remove the cable gland cover at the cable exit Shown in the figure Location of
by unscrewing its two attachment screws. motors, axes 2 and 3 on page 217.
Make sure the gasket is not damaged!
8. Disconnect all connectors beneath the motor
cover.
• - : pin 5
10. Remove the motor by unscrewing its four Shown in the figure Location of
attachment screws and plain washers. motors, axes 2 and 3 on page 217.
11. Fit the two guide pins in two of the motor Art. no. is specified in Required
attachment holes. equipment on page 217.
12. If required, press the motor out of position by Always use the removal tools in pairs!
fitting two screws in the motor attachment holes
diagonal to each other.

4 Repair
Continued
Action Note
13. Remove the two screws and fit the lifting toll, Art. no. is specified in Required
motor axes 2-3 to the motor. equipment on page 217.
14.
CAUTION!
15. Lift the motor to get the pinion away from the Make sure the pinion does not get
gear. damaged!
16. Remove the motor by gently lifting it straight out
and place it on a secure surface.
Disconnect the brake release voltage!
17. Check the pinion. If there is any damage, the
motor pinion must be replaced.
Note! If the gearbox is replaced, the motor
pinion must also be replaced!
Refitting, motor
The procedure below details how to refit motors, axes 2 and 3.
Action Note
1. Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
• - : pin 5
3. Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required
4. Fit the two guide pins in the two lower motor Art. no. is specified in Required

5.
CAUTION!
6. Lift the motor and guide it on to the guide pins, Make sure the motor is turned the right
as close to the correct position as possible way, that is connections for the cables
without pushing the motor pinion into the gear. facing downwards.
7. Remove the lifting tool and allow the motor to
rest on the guide pins.

4 Repair
Continued
Action Note
8. Use the rotation tool in order to rotate the motor
pinion when mating it to the gear (see figure
beside). Fit the motor, making sure the motor
pinion is properly mated to the gear of gearbox
axis 2-3 and that it doesn´t get damaged.
xx0200000165
The rotation tool is used beneath the

motor cover, directly on the motor
shaft as shown in figure above.
- A: Rotation tool
9. Remove the guide pins.
10. Secure the motor with its four attachment Shown in the figure Location of
screws and plain washers. motors, axes 2 and 3 on page 217.
M10 x 40, tightening torque: 50 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 254 before fitting.
12. Reconnect all connectors beneath the motor Connect in accordance with markings
cover. on connectors.
13. Refit the cable gland cover at the cable exit with Shown in the figure Location of
its two attachment screws. motors, axes 2 and 3 on page 217.
Replace the gasket.
14. Refit the motor cover with its four attachment Make sure the cover is tightly sealed!
screws and washers.
15. Remove the lock screw from the hole for lock Shown in the figure Location of
screw. motors, axes 2 and 3 on page 217.
16. Perform a leak-down test of the axis 2 (or 3)
gearbox.
17. Refill the gearbox with oil. Detailed in Oil change, gearbox axes
2-3 on page 115.
calibration tools.
19.
DANGER!

4 Repair
Location of motor axis 6

The motor axis 6 is located in the center of the tilthouse as shown in the figure below.
xx0600002595
A Motor, axis 6
C Cable gland cover
D Motor cover
Required equipment

Motor axis 6 3HAC 024777-001 Includes
• motor
• pinion
• o-ring (the o-ring
must be replaced
when the motor is
replaced)
Power supply - 24 VDC, 1.5 A
Grease 3HAB 3537-1 For lubricating the o-ring.
on page 258.
references to these
procedures in the
tions below.

4 Repair
Continued
Removal, motor
The procedure below details how to remove motor, axis 6.
Action Note
1. Run the robot to a position where it is The motor axis 6 can be replaced without
easiest to remove the motor axis 6 when draining the gear oil.
standing in front of the robot.
2.
DANGER!
3. Remove the motor cover, axis 6. Shown in the figure Location of motor axis
6 on page 221.
4. Remove the cable gland cover at the cable Make sure the gasket is not damaged!
exit by unscrewing its attachment screw.
xx0600002694

5. Disconnect all connectors beneath the
cover, motor axis 6.
Note! The connection to the UL lamp, if the
robot is equipped with it, must also be dis-
connected.
xx0500002466
• A: Signal lamp
• B: Cable straps, outdoor
• C: Cable
• D: Connection point to the cable
gland
• - : pin 5
7. Remove the motor by unscrewing its four
attachment screws and washers.
8. If required, press the motor out of position Always use the screws for removal in
by fitting two screws in the motor pairs!
attachment holes diagonal to each other
4 Repair
Continued
Action Note
9. Lift the motor carefully to get the pinion Make sure the pinion does not get
away from the gear. damaged!
Disconnect the brake release voltage.
10. Remove the motor by gently lifting it straight Make sure the pinion does not get
up and place it on a secure surface. damaged!
Refitting, motor
The procedure below details how to refit motor axis 6.
Action Note
1. Make sure the o-ring on the circumference of Note! The o-ring must be replaced
the motor is seated properly. Lightly lubricate when the motor is replaced.
• - : pin 5
3. Fit the two guide pins in two of the motor Art. no. is specified in Required
4. Lift the motor and carefully and refit it, with Make sure the motor is turned the
guidance from the pins. right way, i.e. connections for the
Make sure the motor pinion is properly mated to cables facing downwards.
the gearbox, axis 6.
5. Remove the guide pins.
6. Secure the motor with its four attachment M10 x 40
screws and washers. Tightening torque: 50 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 254 before fitting.
8. Reconnect all connectors in motor axis 6. Connect in accordance with markings

on connectors.
9. Refit the connections to the UL lamp, if the robot
is equipped with one.

4 Repair
Continued
Action Note
10. Refit the cable gland with its attachment screw.
xx0600002694
• A: Screw holding the cable

gland
Make sure the gasket is not damaged!
Replace if damaged.
11. Refit the cover, motor axis 6 with its four
attachment screws and washers.
xx0600002696
• A: Motor cover
• C: Cable gland
Make sure the cover is tightly sealed!
12. Recalibrate the robot! Calibration is detailed in a separate © Copyright 2006-2008 ABB. All rights reserved.
calibration tools.
13.
DANGER!

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.
xx0600002631
A Gearbox, axis 1
B Frame
C Base
Required equipment

Gearbox 3HAC022279-001 Includes:

3HAC10828-1 • gearbox
• all o-rings and
sealing rings
O-ring 3HAB3772-54 Replace only when
damaged!
O-ring 3HAB3772-55 Replace only when
damaged!
Sealing ring 3HAC11581-4 Replace only when
damaged!
Grease 3HAC3537-1 For lubricating the o-rings.
Support, base 3HAC15535-1
Lifting device, base 3HAC15560-1
Lifting tool (chain) 3HAC15556-1
page 258.

4 Repair
Continued

references to these
procedures in the
tions below.
Removal, gearbox axis 1

The procedure below details how to remove gearbox, axis 1.
Action Note
1. Move the robot to its most stable position,
shown in the figure to the right.
xx0500002275
2.
DANGER!
3. Drain the oil from gearbox 1. Detailed in section Oil change, gearbox

axis 1 on page 112.
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 151.
7. Remove the robot's attachment screws to
unfasten the base from the foundation.
8. Attach the lifting device, base and gear 1 Art. no. is specified in Required
and the lifting tool (chain), to the gearbox. equipment on page 225.

4 Repair
Continued
Action Note
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 Art. no. is specified in Required
support, base and gear 1 on each sides of equipment on page 225.
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
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

4 Repair
Continued
Action Note
14. Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
xx0200000256
• A: Location for attachment screws,

cable guide (cable guide removed
in the figure)
15.
CAUTION!
The gearbox weighs 160 kg! All lifting
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
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,
gearbox axis 1 on page 226.
2. Make sure the two o-rings (C, D) on the cir- Art no. is specified in Required
cumference of the gearbox are seated equipment on page 225.
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
4 Repair
Continued
Action Note
3. Refit the cable guide in the center of gearbox
1 with its attachment screws.
xx0200000256
• A: Location for attachment

screws, cable guide (cable
guide removed in figure)
4. Fit the lifting device, base and the lifting tool Art no. is specified in Required
(chain) to the gearbox. equipment on page 225.
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!
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. Reused screws may be used, providing
they are lubricated as detailed in
section Screw joints on page 254
before fitting.
xx0200000227
A view from below:

• A: Oil drain hose
• B: Attachment screws, gearbox
axis 1, 18 pcs
• C: Washers, 3 pcs

4 Repair
Continued
Action Note
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.
If removed, also refit the rear connector plate.
NOTE!
Direct the bends on the bottom plate
downwards!
xx0300000612
• 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 61.
13. Refit the complete arm system. Detailed in section Refitting, arm
system on page 153.
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.
15. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 130.
16. Refill the gearbox with oil. Detailed in section Oil change, gearbox
axis 1 on page 112.
calibration tools.

4 Repair
Continued
Action Note
18.
DANGER!

4 Repair
4.7.2. Replacement of gearbox, axes 2- 3
Location of gearbox, axes 2-3

The axes 2-3 gearbox is located on either side of the frame as shown in the figure below.
xx0500002467
A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 6
Required equipment
Equipment, etc. Spare part no. Art.no Note

Gearbox, axes 2-3 3HAC022644-001
3HAC022644-001
Sealing axes 2-3 3HAC022379-001
3HAC022379-001
Lock screw M16x90 -
Guide pins - Use guide pins in pairs. © Copyright 2006-2008 ABB. All rights reserved.
Lifting tool gearbox 3HAC023240-001

axes 2-3
page 258.
references to these
procedures in the
tions below.

4 Repair
Continued
Removal, gearbox axes 2-3

The procedure below details how to remove gearbox axes 2-3.
Action Note
1. Put the robot close to its calibration
position.
2. Fit the lock screw (M16x90) in the lower
arm.
xx0600002736
• A: Hole for lock screw, M16x90

3.
DANGER!
4. Drain the gearbox axis 2-3 from oil. Detailed in section Oil change, gearbox
axes 2-3 on page 115.
NOTE!
Time-consuming activity!
5. Remove the motor cables of motor axes 2-
3, and protect the cables from getting
damaged and from oil spill.
6. Remove one gearbox at a time!
7.
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!
8. Secure the upper arm with a roundsling in
an overhead crane.
4 Repair
Continued
Action Note
9. Remove motor axis 2-3. Detailed in section Replacement of motor,
axes 2 and 3 on page 217
10. Remove the gearbox cover by removing its
attachment screws.
11. Remove two of the attachment screws
holding the gearbox axis 2-3 and replace
them with two guide pins.
12. Remove the remaining attachment screws.
13. Fit the lifting tool, gearbox axes 2-3. Art. no. is specified in Required equipment
on page 232.
14.
CAUTION!
equipment used must be sized accord-
ingly!
15. If required, apply two M12 screws to the
holes in the gearbox, in order to press it
free.
16. Remove the gearbox axis 2-3 using an
overhead crane or similar, with guidance
from the fitted guide pins.
17. Remove the sealing from the lower arm
and clean it.
Refitting, gearbox axes 2-3

The procedure below details how to refit gearbox axes 2-3.
Action Note
1. Make sure that the o-ring is fitted to the
gearbox axis 2-3. Lightly lubricate it with
grease.
2. Fit the guide pins, axes 2-3 in the frame.
Use two of the attachment holes for the
screws holding the gearbox.
3.
CAUTION!
equipment used must be sized accord-
ingly!
4. Fit the lifting tool, gearbox axes 2-3 to the Art. no. is specified in Required equipment
gearbox. Use an overhead crane and put on page 232.
the gearbox onto the guide pins.
5. Slide the gearbox axis 2 on the guide pins,
through the attachment screw holes.

4 Repair
Continued
Action Note
6. Refit the gearbox axis 2 with its attachment Tightening torque: 120 Nm.
screws and washers.
Remove the guide pins and replace them
with the remaining attachment screws.
7. Refit the gearbox axis 3 in the same way. Tightening torque: 120 Nm
8. Clean the gearboxes of residual grease.
9. Apply locking liquid in the attachment holes Loctite 243.
of the cover in the frame.
10. Refit the cover with its attachment screws Tightening torque: 24 Nm
and washers.
11. Refit the motors axes 2-3. Detailed in section Replacement of motor,
axes 2 and 3 on page 217
12. Perform a leakdown test.
13. Refill the gearbox axes 2-3 with oil. Detailed in section Oil change, gearbox
axes 2-3 on page 115
14. Remove the locking screw, lower arm.
calibration tools.
General calibration information is included
in section Calibration information on page
241.
16.
DANGER!
on page 32.

4 Repair
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
xx0600002627
A Turning disk
B Attachment screws (6 pcs) turning disk
C Tilthouse unit
D Gearbox, axis 6
E Attachment screws and washers, gearbox axis 6
xx0200000219
A Gearbox, axis 6 (IRB 6620 Foundry Plus)

D Oil plug, filling

4 Repair
Continued
Required equipment

Gearbox Includes o-ring 3HAB3772-
58.
Turning disk, dia. 3HAC 9744-6
200
Washers 3HAA1001-172 Not included in gearbox!
Replace only when damaged!
O-ring 3HAB3772-58 Must be replaced when reas-
3HAB3772-64 sembling gearbox!
3HAB3772-61
Grease 3HAB3537-1 For lubricating the o-ring.
page 258.
Calibration 3HAC15716-1 Complete kit that also
Pendulum toolkit includes operating manual.
references to these
procedures in the
step-by-step
instructions below.
Removal, gearbox
The procedure below details how to remove gearbox, axis 6.
Action Note
1.
DANGER!
2. Drain the oil from gearbox, axis 6. Detailed in section Draining, oil on page
118.
3. Remove the turning disk. Detailed in section Removal, turning
disk on page 157.
4. Remove the gearbox by unscrewing its 8 Shown in the figure Location of gearbox
attachment screws. on page 236.

4 Repair
Continued
Action Note
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
6. Remove the gearbox axis 6 by lifting it out Be careful not to damage the motor
carefully. pinion!
7. Check the pinion. A damaged pinion must be
replaced!
Refitting, gearbox
The procedure below details how to refit gearbox, axis 6.
Action Note
1.
DANGER!


4 Repair
Continued
Action Note
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 237.
grease.
xx0100000132
• A: O-ring, gearbox axis 6

3. Release the holding brake of motor axis 6. Detailed in section Manually releasing the
brakes on page 54.
4. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in Required equipment
on page 237.
Shown in the figure Location of gearbox on
page 236.
Make sure the gears of the gearbox mate
with the gears of the motor!
5. Secure the gearbox with the attachment Shown in the figure Location of gearbox on
screws and washers. page 236.
8 pcs : M8 x 40, 12.9 quality UNBRAKO,

they are lubricated as detailed in section
Screw joints on page 254 before fitting.
6. Refit the turning disk. Detailed in section Refitting, turning disk on
page 158.
7. Perform a leak-down test. Detailed in section Performing a leak-down
test on page 130.
8. Refill the gearbox with oil. Detailed in section Filling, oil on page 119.
calibration tools.
General calibration information is included
in section Calibration information on page
241.

4 Repair
Continued
Action Note
10.
DANGER!
on page 32.

5 Calibration information
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 242, 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, for example motors, or parts 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 246. 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 is rebuilt, for example after a crash or when the robot is 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.

5.2. Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
Types of calibration
Type of calibra-
Description Calibration method
tion
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, that is the axes positions (angles) are (standard method)
set to 0º.
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.
Absolute Accuracy Based on standard calibration, and besides CalibWare
calibration positioning the robot at home position, the
(optional) 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-compensa-
tion 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 perfor-
mance, the robot must be recalibrated for
Absolute Accuracy!
xx0400001197

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.
CalibWare - Absolute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is further detailed in the application manual
Absolute Accuracy Calibware 2.0.
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 259.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including Operating manual - Calibration Pendulum, which describes the method and the
different routines further.

5.3. Calibration scales and correct axis position
5.3. Calibration scales and correct axis position
Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
Calibration scales/marks, IRB 660

The illustration below shows the positions of the calibration marks on the robot.
xx0500002487
A Calibration plate, axis 1

B Calibration tab on robot
C Calibration mark, axis 2
D Calibration mark, axis 3
E Calibration plate and marking, 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.

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, 4 axes

Note! The figure shows an IRB 260, but the positive direction is the same for all 4-axis robots
xx0500001927

5.5. Updating revolution counters
General
This section details how to perform a rough calibration of each robot axis, that is 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 Shown in section Calibration scales and
within the tolerance zone. correct axis position on page 244.
3. When all axes are positioned, store the Detailed in section:
revolution counter settings. Step 2 - Storing the revolution counter
setting with the FlexPendant on page 246
(RobotWare 5.0).
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.

Continued
Action
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.
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 248.

5.6. Checking the calibration position
5.6. Checking the calibration position
General
Check the calibration position before beginning any programming of the robot system. This
may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the teach pendant.
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! correct axis position on page 244.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 246.
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 axis 1-3 to jog axis 1, 2, or 3.
4. Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5. Check that the calibration marks for the The calibration marks are shown in section
axes align correctly. If they do not, update Calibration scales and correct axis position
the revolution counters! on page 244.
How to update the counters is detailed in
section Updating revolution counters on
page 246.

Overview
Overview
About this manual

This manual contains reference information for all procedures described in the Product
manual, procedures .
Usage
This manual should be used during
• installation
• 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
Reference information Useful information when performing installation, maintenance
or repair work (lists of necessary tools, reference documents,
safety standards).
Part list Complete list of manipulator parts, shown in the exploded
views or foldouts.
Exploded views / Foldouts Detailed illustrations of the manipulator with reference
numbers to the part list.
Circuit Diagram Circuit Diagram of the manipulator.
Revisions
Revision Description
- First edition.

250
Overview
3HAC025755-001 Revision: B
6 Reference information
6.1. Introduction
6.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.

6.2. Applicable Safety Standards
6.2. 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

The following standards are applicable when the robot is part of a robot cell:
• EN 953 - Fixed and moveable guards
• EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
• EN 349 - Minimum gaps to avoid crushing of parts of the human body.
• EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
• EN 1088 - Interlocking devices
• EN 999 - The positioning of protective equipment in respect of approach speeds of the
human body.
• ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing
systems. © Copyright 2006-2008 ABB. All rights reserved.

6.3. Unit conversion
6.3. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal

6.4. Screw joints
6.4. 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.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque on page 255 below. Screw
dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions © Copyright 2006-2008 ABB. All rights reserved.
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) 11712016-618

6.4. 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 descriptions. Any
special torque specified overrides the standard torque!
• 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, that is 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)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil-lubri- Class 10.9, oil-lubri- Class 12.9, oil-lubri-
cated cated cated
M5 6 - -
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 Molycote-
lubricated screws with Allen head screws.
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 35
M10 55 70
M12 96 120
6.4. Screw joints
Continued
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M16 235 280
M24 790 950
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

6.5. Weight specifications
6.5. 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!
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!

6.6. Standard toolkit
6.6. 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
Qty Tool Rem.

1 Ring-open-end spanner 8-19 mm
1 Socket head cap 5-17 mm
1 Torx socket no: 20-60
1 Box spanner set
1 Torque wrench 10-100 Nm
1 Torque wrench 75-400 Nm
1 Ratchet head for torque wrench 1/2
2 Hexagon-headed screw M10x100
1 Socket head cap no: 14, socket 40 mm bit L 100 mm
1 Socket head cap no: 14, socket 40 mm bit L 20 mm To be shortened to 12 mm

6.7. Special tools
6.7. 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 258,
and of special tools, listed directly in the instructions and also gathered in this section.
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.
Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.
Description Art. no. Note

Oil exchange equipment 3HAC021745-001 Includes
• vacuum pump with
regulator, hose and coupling
• couplings and adapters
• pump (manual) with hose
and coupling
• graduated measuring glass
• oil gun
• user instructions.
Basic tools
The table below specifies the tools in the basic toolkit 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.

Guide pins M10 x 100 2 3HAC15521-1
Guide pins M10 x 150 2 3HAC15521-2
Lifting tool, motor ax 1 1 3HAC14459-1
Lifting tool, motor ax 2, 3 1 3HAC15534-1
Removal tool, motor M12x Fits motors axes 1, 2 and 3.
Rotation tool 1 3HAC17105-1
Standard toolkit (content described in 1 -
section Standard toolkit on page 258)

6.7. Special tools
Continued
Lifting tools
The table below specifies the lifting 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 Article no.

Lifting tool, tilt house 3HAC023154-001
Lifting tool, motor 3HAC14586-1
Lifting tool, gear ax.2 3HAC023240-001
Lifting tool, frame 3HAC023308-001
Lifting tool, complete robot 3HAC15607-1
Lifting tool, parallel arm 3HAC023098-001
Lifting tool, turning device gearbox ax.1 3HAC14406-1
Lifting tool, base 3HAC14868-1
Guide pin, (short) 3HAC7601-086
Guide pin, (long) 3HAC7601-087
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.
Description Qty Article no.

Lower arm fixture 3HAC7035-1
Pressing, link 3HAC023081-001
Pressing, outer ring on link 3HAC023079-001
Pressing, innerring (nållager) 3HAC023112-008
KM-socket for link 3HAC5347-1
Pinion crank 3HAC023132-001
Pressing, lower arm/balancing weight 3HAC023092-001
Pressing, upper arm 3HAC023084-001 © Copyright 2006-2008 ABB. All rights reserved.
Pressing, tie rod 3HAC5021-1
Pressing, tilt house 3HAC023080-001
Pressing, outer ring, tilt house 3HAC023075-001
Auxiliary shaft, long 3HAC5275-1
Auxiliary shaft, short 3HAC5276-1
Support shaft/bearing race 3HAC5281-1
Axis 1 pinion 3HAC022436-001
Tool for lubrication 3HAC5222-1
Adapter for shaft axis 3 3HAC023916-001

6.8. 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.


7 Spare parts and exploded views
7.1. Introduction

7.1. Introduction
Definitions
This chapter specifies all spare parts and replacement articles of the robot.

7.2. Spare parts - frame to base
Parts list
Pos Article no. Description Qty

101 3HAC 17224-4 Base, machining 1
102 3HAC 021659-003 Frame, machining 1
103 3HAC 022279-001 RV 400C-224.26 1
104 3HAB 7700-73 Screw M12x70 24
105 3HAA 1001-134 Washer 13x19x1.5 24
106 3HAC 11732-2 Washer T = 3 3
107 3HAB 7700-5 Screw M16x70 18
108 3HAC 14453-1 Hose with flange 1
109 3HAC 11529-1 Rubber lined clip D = 28 1
110 9ADA 618-56 Screw M6x16 1
111 3HAC 4428-2 Hose clip 1
112 3HAC 14453-2 Plug 1
113 3HAC 12252-1 Bottom plate 1
114 3HAC 14131-1 Connection plate, base 1
115 9ADA 618-58 Screw M6x25 2
116 3HAC 11769-1 Cable guide, ax. 1 1
117 9ADA 618-56 Screw M6x16 2
118 3HAB 3537-1 Bearing grease 10 g
119 9ADA 618-53 Screw M6x8 1

Continued
Exploded view
xx0500002567

7.3. Spare parts - cable harness
Parts list
Item Article no. Description Qty

90.1 3HAC022544-001 Cable harness, man ax.1-6 1
90.2 3HAC022539-001 Metal clamp, manip. 1
90.3 3HAC 13416-1 Protection cover 1
90.4 3HAC 11774-3 Adapter, complete 1
90.5 3HAC 5172-1 Cable guide, ax.2 1
90.7 3HAC 022967-001 Bracket for cables 1
90.8 3HAC 022968-001 Distance 3
90.19 3HAC 12129-1 Cover plate 2
90.20 9ADA 267-6 Nut M6 1
90.21 9ADA 618-57 Screw M6x20 2
90.22 9ADA 183-24 Screw M6x16 12
90.24 9ADA 618-56 Screw M6x16 4
90.26 9ADA 183-37 Screw M8x25 3
90.29 9ADA 629-56 Screw M6x16 6
90.30 9ADA 183-25 Screw M6x20 4
90.31 3HAB7116-1 Locking liquid 1 ml
90.36 3HAC14222-1 Plate 1
90.37 9ADA 618-57 Screw M6x20 4

Continued
Exploded view
xx0500002568

7.4. Spare parts - customer harness
Parts list

1.1 3HAC022545-001 Cable harness, customer 1
1.2 3HAC023407-001 Attachment plate 1
1.3 3HAC 13416-1 Protection cover 1
1.4 3HAC 11774-3 Adapter, complete 1
1.5 9ADA 183-24 Screw M6x16 4
1.7 9ADA 618-57 Screw M6x20 4
1.8 3HAC 12625-1 Strap, Velco M5x300 1
1.9 9ADA 183-15 Screw M5x20 6
1.10 9ADA 267-6 Nut 10
1.12 9ADA 183-34 Screw M8x12 2
1.15 3HAC022969-001 Bracket 1
1.16 3HAC023100-001 Cover plate 1

Continued
Exploded view
xx0500002569

7.5. Spare parts - lower arm system
Parts list

301 3HAC021464-004 Lower arm (White RAL 9003) 1
302 3HAC023026-003 Parallel arm (White RAL 9003) 1
303 3HAA 2166-18 VK-Cover, VK 35x8 1
(Not visible in this figure.)
304 3HAB 3537-1 Bearing grease Shell Alvania WR2 10 g
305 3HAC 4435-1 Spacing sleeve 2
306 3HAB 4169-1 Sealed spherical bearing 2
310 3HAA 2166-23 VK-cover, VK 120x12 1
311 3HAC022338-001 Damper 2
312 9ADA 183-37 Screw M8x25 4
313 9ADA 312-7 Plain washer 8,4x16x1,6 4
314 3HAB7116-1 Locking liquid 1 ml
315 3HAC 12991-1 Damper ax.2 3
316 9ADA 618-57 Screw M6x20 3
317 3HAC 4836-8 Protection plug 1
318 3HAC022339-001 Damper 1

Continued
Exploded view
xx0500002570

7.6. Spare parts - parallel rod
Parts list

201 3HAC021084-004 Parallel rod (White RAL 9003) 1
202 3HAB 3537-1 Bearing grease Shell Alvania WR2 4g
203 3HAC 4331-1 Thrust washer 2
204 3HAC 3715-1 Sealed spherical bearing 2
205 3HAC 4332-1 Cover washer 2
206 3HAC 4330-1 Shaft 2

Continued
Exploded view
xx05000002571

7.7. Spare parts - Balancing device
Parts list

4 3HAC024779-001 Balancing device (White RAL 9003) 1
4.6 3HAC 3476-1 Guiding ring 1
4.10 3HAC 3530-1 Circlip 1
58 1236 0012-202 Sealing compound 4 ml
59 3HAC 7343-1 Sealing ring 2
60 3HAC 7253-1 Support washer 4
61 3HAC 3311-1 Adjust. Needle bearing 2
62 3HAB 3537-1 Bearing grease Shell Alvania RW2 10 g
63 3HAC 7349-1 Lock nut 2

Continued
Exploded view
xx0500002572

7.8. Spare parts - frame to lower arm
Parts list
Pos Article no. Description Qty.

11 3HAC022379-001 Sealing ax.2/3 1
12 3HAA 1001-134 Washer 13x19x1,5 24
13 3HAB 7700-71 Screw M12x60 24
14 3HAC022644-001 RV-450E 1
15 3HAB 3772-84 O-ring 1
17 9ADA 183-39 Screw M8x35 16
18 3HAC021663-003 Cover, machined 1
19 3HAB 4233-1 Washer 4
20 3HAB 3409-50 Screw M10x40 4
21 3HAC024776-001 Motor incl pinion ax.2 (White RAL 9003) 1
22 3HAC022379-001 Sealing ax.2/3 1
23 3HAC022644-001 RV-450E ax.3 1
24 3HAB 7700-71 Screw M12x60 24
25 3HAA 1001-134 Washer 13x19x1,5 24
26 3HAC021663-003 Cover, machined 1
27 9ADA 183-39 Screw M8x35 16
29 3HAB 3772-84 O-ring 1
30 3HAC024776-001 Motor inc. Pinion ax.3 (White RAL 9003) 1
31 3HAB 3409-50 Screw M10x40 4
32 3HAB 4233-1 Washer 4
33 3HAB 3409-86 Screw M16x60 6
34 3HAA 1001-186 Washer 17x25x3 6

35 3HAB 7700-69 Screw M12x50 21
36 3HAA 1001-134 Washer 13x19x1,5 21
37 3HAB 7700-69 Screw M12x50 21
38 3HAA 1001-134 Washer 13x19x1,5 21
39 3HAC032140-001 Lubricating oil Kyodo Yushi TMO 150 5000 ml
40 3HAC 16721-1 Magnetic plug 3
42 3HAC032140-001 Lubricating oil Kyodo Yushi TMO 150 5000 ml

Continued
Exploded view
xx0500002573

7.9. Spare parts - shafts
Parts list

501 3HAC 021113-003 Upper arm machining 1
502 3HAA 1001-124 Support ring 2
43 3HAC 4545-1 Shaft 1
44 3HAC 022446-001 Shaft 1
45 1171 2016-618 Lubricant, paste 5
46 3HAB 3772-29 O-ring 2
47 2216 264-16 Sealing ring 2
48 3HAC 022581-001 Sealing ring 2
50 2213 3802-8 Taper roller bearing 2
51 3HAC 7817-1 Nilos ring 2
52 3HAC 6627-1 Spacer 2
53 3HAA 1001-658 O-ring 2
54 3HAB 7116-1 Locking liquid, Loctite 243 4 ml
55 2126 2851-112 Lock nut 2
56 9ADA 205-75 Screw M10x20 2
57 3HAB 7116-1 Locking liquid, Loctite 243 4 ml

Continued
Exploded view
xx0500002574

7.10. Spare parts - tilthouse
Parts list

508 3HAC022764-003 Tilthouse complete (White RAL 9003) 1
508.1 3HAC022740-003 Tilthouse, machining 1
508.2 3HAC023533-001 Motor incl pinion 1
508.3 3HAC 10828-10 RV 40E-81 1
508.4 3HAB 7700-55 Screw M8x40 8
508.5 3HAA 1001-172 Washer 8,4x13x1,5 8
508.6 3HAC 9744-5 Turning disc 1
508.7 3HAC022977-001 Sync.plate 1
508.8 9ADA 618-32 Screw M4x8 2
508.9 2121 2518-577 Screw M14x25 6
508.10 2522 122-1 Magnetic plug 2
508.11 9ADA 624-69 Screw M8x20 2
508.12 3HAC 14263-1 Protection Cover 1
508.13 9ADA 183-37 Screw M8x25 4
508.14 9ADA 312-7 Plain washer 8,4x16x1,6 4
508.15 3HAB7116-1 Locking liquid 1 ml
508.16 2152 0431-20 O-ring 15,5x1,5 6
508.17 3HAC032160-001 Lubricating oil Kyodo Yushi TMO 150 250 ml
508.18 3HAB 3772-65 O-ring 131x2 1
508.19 2152 0441-1 Washer 2

Continued
Exploded view
xx0500002575

7.11. Spare parts - upper arm front
Parts list

501 3HAC025525-001 Upper arm machining (White RAL 9003) 1
503 9ADA 629-56 Screw M6x16 2
504 9ADA 327-4 Plain washer 6,4x17x3 2
506 3HAC022673-001 Ball plug 1
507 3HAC023027-001 Protection cap 1
508 3HAC022764-001 Tilt house 1
509 3HAA 2166-21 VK-Cover, VK 68x8 2
510 2126 2851-107 Lock nut 2
511 3HAC021158-001 Shaft upper arm 2
512 3HAA 2166-17 VK-Cover, VK 19x6 2
513 2213 3802-11 Taper roller bearing 4
515 3HAC022645-001 Ring 1
516 3HAB 3701-35 Radial seal w. dustlip 50x68x8 2
517 9ADA 183-22 Screw M6x10 4
518 3HAC020537-001 Washer 6,4x12x1,6 4
519 3HAC 8286-1 Dinitrol 490 30 ml
520 9ABA 137-28 Retaining ring, bore 2

Continued
Exploded view
xx0500002576

7.12. Spare parts - Linkage
Parts list
Pos Article no. Description Qty.

601 3HAC023744-003 Upper rod (White RAL 9003) 1
602 3HAC023239-003 Lower rod (White RAL 9003) 1
603 12360012-202 Sealing compound 2
604 3HAC7343-1 Ring 4
605 3HAC7253-1 Support washer 8
606 3HAC3311-1 Adjust. needel bearing 4
607 3HAB3537-1 Bearing grease 10
608 3HAC7349-1 Lock nut 4
609 3HAB7116-1 Locking liquid 2
701 3HAC021088-003 Link, machining 1
702 3HAA 2103-13 Taper roller bearing 2
704 1236 0012-202 Sealing compound Permatex No 3 2 ml
705 3HAB 3702-31 Radial seal 85x100x9 1
706 3HAC022521-001 Support Ring 1
707 2126 2851-108 Lock nut 1
709 3HAA 2166-13 VK-Cover 1

Continued
Exploded view
xx0500002577

7.13. Spare parts - motor axis1
Parts list

65 3HAC024775-001 Motor inc. pinion ax.1 (White RAL 9003) 1
66 3HAB 3409-50 Screw M10x40 4
67 3HAB 4233-1 Washer 4
68 2522 122-1 Magnetic plug 1
70 3HAC021469-001 Lubricating oil 8000 ml
71 3HAC 12671-6 Block for calibration 1
72 3HAC 14024-1 Protection screw 1
73 9ADA 618-57 Screw M6x20 3
74 3HAC021287-001 Sync.plate 1
75 9ADA 618-56 Screw M6x16 2
76 3HAC 17358-1 Mech.stop 1
77 3HAC 18306-1 Cover sheet 1
78 3HAB 7700-89 Screw M16x90 1

Continued
Exploded view
xx0500002578

7.14. Spare parts - SMB
Parts list

90.9 3HAC 11526-1 Stud screw 2
90.10 3HAC022204-001 Bracket 1
90.11 3HAC 2744-1 Push button guard 1
90.12 3HAC 4813-1 Cover, push button guard 1
90.13 3HAC 16035-1 BU w.buttons DSQC 563 1
90.14 3HAC 14791-3 Cover battery box 1
90.15 3HAC 13151-1 Cable battery/SMB 1
90.16 3HAC 15619-1 Cable, FB7-SMB 1.7 1
90.17 3HAC022286-001 Serial measurement unit 1
90.18 3HAC 16831-1 Battery pack 1
90.20 9ADA 267-6 Nut M6 3
90.23 9ADA 183-25 Screw M6x20 10
90.25 9ADA 183-13 Screw M5x12 6
90.27 9ADA 312-6 Plain washer 6.4x12x1.6 2
90.28 3HAC 021349-003 Cover SMB 1
90.35 9ADA 618-45 Screw M5x16 6

Continued
Exploded view
xx0500002579


8 Circuit diagram
8.1. Introduction
8 Circuit diagram
8.1. Introduction
Overview
This chapter includes the circuit diagram for the robot.

8 Circuit diagram
8.1. Introduction

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.
In no event shall ABB be liable for incidental or consequential damages arising from use of this document.
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
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
Sweden
Latest revision: Lab/Office: Status: Plant: = IRB660, CC

2000-03-03
Location: + Manipulator
Approved Sublocation: +
COPYRIGHT PAGE Document no. Rev. Ind Page 1
Next 2
Prepared by, date: Approved by, date: Title page/cover sheet 3HAC025690-001 01 Total 7
Customer :
Robot serial number(s) :
Drawing number : 3HAC025690-001
Drawing version :
Manufacture : 2008-03-03
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :
Project start : 2005-08-30

Project manager :
Last revision :
Designed by : sethsta
Designed date : 2008-03-03
Number of pages : 7
:

2000-03-03
TITLE PAGE Document no. Rev. Ind Page 2
Next 3
Prepared by, date: Approved by, date: Title page/cover sheet 3HAC025690-001 01 Total 7
Table of contents ABB_table_of_contents
Plant Location Page Page description Page supplementary field Date Editor
IRB660, CC Manipulator 1 COPYRIGHT PAGE Approved 2008-03-03 sethsta
IRB660, CC Manipulator 2 TITLE PAGE Approved 2008-03-03 sethsta
IRB660, CC Manipulator 3 Table of contents: (1 - 22) Approved 2008-03-03 sethsta
IRB660, CC Manipulator 4 Revision information Approved 2008-03-03 sethsta
IRB660, CC Manipulator 11 Connection point location Approved 2008-03-03 sethsta
IRB660, CC CP/CS 21 Customer power/Customer signal Approved 2008-03-03 sethsta
IRB660, CC CBUS 22 Customer bus Approved 2008-03-03 sethsta

Table of contents: (1 - 22) Document no. Rev. Ind Page 3
Next 4
Prepared by, date: Approved by, date: Table of contents 3HAC025690-001 01 Total 7
1 2 3 4 5 6 7 8
Revision 01
Sheet 3 new table of contents.
Sheet 4 new, revision information
Sheet 21 One of the parallel earth wire was removed, coordinate column 3,4 and 5
Sheet 21 Two twisted symbol removed at coordinate column 4.
Sheet 21 Shield symbol changed, the shield include wire D1,D3, D4 and D6.
Latest revision: Lab/Office: Status: 2008-03-03 Plant: = IRB660, CC

Revision information Approved
Sublocation: +
Document no. Rev. Ind Page 4
Next 11
Prepared by, date: EM 080303 Approved by, date: ER 080303 3HAC025690-001 01 Total 7
1 2 3 4 5 6 7 8
R2.CP/CS
R1.CP/CS

Connection point location Approved
Sublocation: +
Next 21
1 2 3 4 5 6 7 8
-R1.CP/CS -R2.CP/CS
4
D1
24V
C4
5
D6
0V
C5
6
D3
24V
C6
7
D4
0V
C7
GN/YE PE
WH/BK
B1
CS1
B18
BK
B2
CS2
B19
WH/BN
B3
CS3
B20
BN
B4
CS4
B21
WH/RD
CS5
B5 B22
RD
B6
CS6
B23
WH/OG
B7
CS7/KSR
B24
OG
B8
CS8/KSR
B25
WH/YE
B9
CS9
B16
YE
B10
CS10
B17
WH/GN
B11
CS11
B1
GN
B12
CS12
B2
WH/BU
B13
CS13
B3
BU
B14
CS14
B4
WH/VT
B15
CS15
B5
VT
B16
CS16
B6
WH/GY
B18
CS17
B7
GY
B19
CS18
B8
WH/BK
B20
CS19
B9
BK
B21
CS20
B10
WH/OG
C16
CS25
B11
OG
C17
CS26
B12
WH/BN
C18
CS27
B13
BN
C19
CS28
B14
WH/RD
C20
CS29
B15
RD
C21
CS30
C8

Location: + CP/CS
Customer power/Customer signal Approved
Sublocation: +
Next 22
1 2 3 4 5 6 7 8
-R1.CP/CS -R2.CP/CS
WH/BK
B22 A1
BK
B23 A2
WH/BN
B24 A3
2
B25 A4
5 YE
A3 A7
6 YE
A4 A8
7 VT
A5 A9
8 VT
A6 A10
1 GN
A9 A5
2 GN
A10 A6
3 GN
A11 A11
4 GN
A12 A12

Location: + CBUS
Customer bus Approved
Sublocation: +
Next
1 2 3 4 5 6 7 8
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.
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
Sweden
Latest revision: Lab/Office: Status: 2008-06-03 Plant: = IRB660

Approved Sublocation:+
COPYRIGHT PAGE Document no. Rev. Ind Page 1
Prepared by, date: EM 2008-06-02 Approved by, date: JM 080603 3HAC025691-001 02 Next 2
Total 12
1 2 3 4 5 6 7 8
Customer :
Robot serial number(s) :
Drawing number : Manipulator
Drawing version :
Manufacture : 2008-06-04
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction : RMM
Project start : 2005-08-31

Project manager :
Last revision :
Designed by : seermes
Designed date : 2008-06-04
Number of pages : 12
:

TITLE PAGE Document no. Rev. Ind Page 2
Total 12
1 2 3 4 5 6 7 8
Table of contents ABB_table_of_contents
Plant Location Page Page description Page supplementary field Date Editor
IRB660 Manipulator 1 COPYRIGHT PAGE Approved 2008-06-04 seermes
IRB660 Manipulator 2 TITLE PAGE Approved 2008-06-04 seermes
IRB660 Manipulator 3 Table of contents: Approved 2008-02-27 sethsta
IRB660 Manipulator 4 Revision information Approved 2008-06-04 seermes
IRB660 Manipulator 11 Connection point location Approved 2008-06-04 seermes
IRB660 BU 21 Brake Release Unit Approved 2008-06-04 seermes
IRB660 SMB 22 Serial Measuring Board Approved 2008-06-04 seermes
IRB660 Axis 1 23 Axis 1 Approved 2008-06-04 seermes

IRB660 Switches 27 Switches axis 1 Approved 2008-06-03 seermes

Table of contents: Document no. Rev. Ind Page 3
Total 12
1 2 3 4 5 6 7 8
080228 rev.01
Sh.3 New sheet, Table of contents.

Sh.4 New sheet . Revision information.
Sh.11 R1.SW1 add.
Sh.27 New sheet, Switches axis 1
080602 rev.02
Sh.23 The page description has been changed.

Revision information Document no. Rev. Ind Page 4
Total 12
1 2 3 4 5 6 7 8
R3.H1
R3.H2
R2.MP6
R2.FB6
R2.H1
R2.H2
R2.MP3
R2.MP2 R2.FB3
R2.FB2
R1.G
R2.SMB
R1.SMB1-3
R1.SMB6
R1.MP
X8
R1.SMB
X9
R1.SW1
X10
R2.MP1
R2.FB1

Connection point location Document no. Rev. Ind Page 11
Prepared by, date: EM 2008-06-02 Approved by, date: JM 080603 3HAC025691-001 02 Next +BU/21
Total 12
1 2 3 4 5 6 7 8
-BU Brake Release (Simplified)
-R1.MP -X8 -X8

13 Brake Release 2 1 1
2 -X10 -X10 R1.MP

A K 1 1 5 =+-BU M1 / +Axis 1/23.2
11 Brake PB 1 5 5
Brake Bleed Circuit

12 0V 4 3 3 2
=+-BU 0V M1 / +Axis 1/23.2 4

A K 6 R1.MP
3 3 =+-BU M2 / +Axis 2/24.2
=+-BU 0V M2 / +Axis 2/24.2
=+-BU 0V M3 / +Axis 3/25.2 Brake Bleed Circuit

4
A K 7 R1.MP
5 5 =+-BU M3 / +Axis 3/25.2
=+-BU 0V M6 / +Axis 6/26.2

Brake Bleed Circuit
6
Key Pin 9
-X9
A K 4
Brake Bleed Circuit

5
A K 8
Brake Bleed Circuit

9
-X9 R1.MP
A K 10 10 10 =+-BU M6 / +Axis 6/26.2
Brake Bleed Circuit

11
Key Pin 1

Location: + BU
Brake Release Unit Document no. Rev. Ind Page 21
2 Prepared by, date: EM 2008-06-02 Approved by, date: JM 080603 3HAC025691-001 02 Next +SMB/22
Total 12
1 2 3 4 5 6 7 8
-SMB
-R1.SMB -R2.SMB -R2.SMB

A SDI BK 9 9
B SDI-N WHBK 5 5
C SDO BN 8 8
D SDO-N WHBN 4 4
E 0V RD 3 3
F 24V WHRD 7 7
L 24V EXT.LAMP OG
0V EXT.LAMP WHOG
M
+Axis 6/26.3 /=-0V EXT.LAMP

+Axis 6/26.3 /=-24V EXT.LAMP
G -R1.G(X3) -R1.G(X3)
+ -+ -+ - 0V 2 2
+ 1 1

Location: + SMB
Serial Measuring Board Document no. Rev. Ind Page 22
Prepared by, date: EM 2008-06-02 Approved by, date: JM 080603 3HAC025691-001 02 Next +Axis 1/2
Total 12
1 2 3 4 5 6 7 8
-MU1
-R1.MP -R2.MP1 -R2.MP1
17 M1R 1 1 1 RD
24 M1R 2 4 4 RD R (U) PE
18 M1S 3 6 6 WH M T (W)
3~
25 M1S 4 3 3 WH S (V)
19 M1T 5 7 7 BK
26 M1T 6 10 10 BK
PE GNYE 9 9 GNYE
PE GNYE 12 12 GNYE
-PTC
27 PTC M 7 8 8 BU
+Axis 2/24.2 / +-PTC M2 PTC M2 8 11 11 BK

+BU/21.7 / =+-BU M1 BU M1 9 2 2 BU +
Brake
+BU/21.2 / =+-BU 0V M1 BU 0V M1 10 5 5 BU -
-SMB -FB1
-R1.SMB1-3 -R1.SMB1-3 -R2.FB1 -R2.FB1

2 2 BK X1 6 6 RD
14 14 WHBK 0V X1 1 1 BK
Resolver
3 3 BN Y1 7 7 BU
15 15 WHBN 0V Y1 2 2 YE
6 6 RD 0V EXC1 8 8 WHBK (WHYE)

18 18 WHRD EXC1 3 3 WHRD

Location: + Axis 1
Axis 1 Document no. Rev. Ind Page 23
Total 12
1 2 3 4 5 6 7 8
-MU2
23 M2R 1 1 1 RD
32 M2R 2 4 4 RD R (U) PE
22 M2S 3 6 6 WH M T (W)
3~
31 M2S 4 3 3 WH S (V)
21 M2T 5 7 7 BK
30 M2T 6 10 10 BK
PE GNYE 9 9 GNYE
PE GNYE 12 12 GNYE
+Axis 1-PTC
+Axis 1/23.2 / +-PTC M2 PTC M2 7 8 8 BU
+Axis 3/25.2 / +-PTC M3 PTC M3 8 11 11 BK

+BU/21.7 / =+-BU M2 BU M2 9 2 2 BU +
Brake
+BU/21.2 / =+-BU 0V M2 BU 0V M2 10 5 5 BU -
-SMB -FB2
-R1.SMB1-3 -R1.SMB1-3 -R2.FB2 -R2.FB2

4 4 BK X2 6 6 RD
16 16 WHBK 0V X2 1 1 BK
Resolver
5 5 BN Y2 7 7 BU
17 17 WHBN 0V Y2 2 2 YE


Location: + Axis 2
Total 12
1 2 3 4 5 6 7 8
-MU3
3 M3R 1 1 1 RD
4 M3R 2 4 4 RD R (U) PE
5 M3S 3 6 6 WH M T (W)
3~
6 M3S 4 3 3 WH S (V)
7 M3T 5 7 7 BK
14 M3T 6 10 10 BK
PE GNYE 9 9 GNYE
PE GNYE 12 12 GNYE
+Axis 1-PTC
+Axis 2/24.2 / +-PTC M3 PTC M3 7 8 8 BU
+Axis 6/26.2 / +-PTC M6 PTC M6 8 11 11 BK

+BU/21.7 / =+-BU M3 BU M3 9 2 2 BU +
Brake
+BU/21.2 / =+-BU 0V M3 BU 0V M3 10 5 5 BU -
-SMB -FB3
-R1.SMB1-3 -R1.SMB1-3 -R2.FB3 -R2.FB3

9 BK X3 6 6 RD
21 21 WHBK 0V X3 1 1 BK
Resolver
10 10 BN Y3 7 7 BU
22 22 WHBN 0V Y3 2 2 YE


Location: + Axis 3
Total 12
1 2 3 4 5 6 7 8
-MU6
9 M6R 1 1 1 RD R (U) PE
M T (W)
3~
8 M6S 2 3 3 WH S (V)
16 M6T 3 7 7 BK
PE GNYE 9 9 GNYE
+Axis 1-PTC
+Axis 3/25.2 / +-PTC M6 PTC M6 4 8 8 BU
15 PTC 0v 5 11 11 BK
+BU/21.7 / =+-BU M6 BU M6 6 2 2 BU +
Brake
+BU/21.2 / =+-BU 0V M6 BU 0V M6 7 5 5 BU -
-SIGNAL LAMP (OPTIONAL)

R3.H
+SMB/22.2 =+SMB-24V
/ EXT.LAMP OG R2.H1 R2.H1 A K
1
+SMB/22.2 =+SMB-0V
/ EXT.LAMP R2.H2 R2.H2
2
-SMB -FB6
-R1.SMB6 -R1.SMB6 -R2.FB6 -R2.FB6

9 9 BK X6 6 6 RD
21 21 WHBK 0V X6 1 1 BK
Resolver
10 10 BN Y6 7 7 BU
22 22 WHBN 0V Y6 2 2 YE


Location: + Axis 6
Prepared by, date: EM 2008-06-02 Approved by, date: JM 080603 3HAC025691-001 02 Next +Switche
Total 12
1 2 3 4 5 6 7 8
LOCATION OF SWITCHES
PLACERING AV BRYTARE
-SW1.1
-R1.SW
B POWER 1.1.2 2 13 14
D SIGNAL 1.1.2 4 SW1.6
A POWER 1.1.1 1 21 22
C SIGNAL 1.1.1 3 SW1.5
-SW1.2 SW1.4
F POWER 1.2.2 6 13 14 SW1.3

H SIGNAL 1.2.2 8
E POWER 1.2.1 5 21 22 SW1.2
G SIGNAL 1.2.1 7
SW1.1
-SW1.3
K POWER 1.3.2 10 13 14
M SIGNAL 1.3.2 12
J POWER 1.3.1 9 21 22
L SIGNAL 1.3.1 11 SWITCHES AXIS 1
BRYTARE AXEL 1
-SW1.4
P POWER 1.4.2 14 13 14
S SIGNAL 1.4.2 16
N POWER 1.4.1 13 21 22
R SIGNAL 1.4.1 15
-SW1.5
U POWER 1.5.2 18 13 14
W SIGNAL 1.5.2 20
T POWER 1.5.1 17 21 22
V SIGNAL 1.5.1 19
-SW1.6
Y POWER 1.6.2 22 13 14
a SIGNAL 1.6.2 24
X POWER 1.6.1 21 21 22
Z SIGNAL 1.6.1 23

Location: + Switches
Switches axis 1 Document no. Rev. Ind Page 27
Prepared by, date: EM 2008-06-02 Approved by, date: JM 080603 3HAC025691-001 02 Next
Total 12
Index
A L
Absolute Accuracy, calibration 243 lifting equipment 257
lifting of robot
B
with lifting slings 52
brake release unit, replacement 208 lifting robot
brakes with fork lift 45
testing function 24 lifting slings, robot 52
C linkage
replacing lower rod 180
cabling between robot and controller 76 replacing upper rod 177
cabling, robot 76 loads on foundation 40
calibrating
roughly 246 M
calibration mechanical stop
Absolute Accuracy type 242 axis 1 69
marks/scales 244 MoveAbsJ instruction
rough 246 FlexPendant 248
standard type 242
when to calibrate 241 N
calibration manuals 243 negative directions, axes 245
calibration position 246
O
checking 248
jogging to, FlexPendant 248 oil change
scales 244 safety risks 35
calibration, Absolute Accuracy 243 operating conditions, robot 41
CalibWare 242 P
complete arm system, replacement 150
connecting the robot and controller, cabling 76 position, robot 244
Connection of external safety devices 14 positive directions, axes 245
protection classes 41
D
R
direction of axes 245
replacement
E brake release unit 208
enabling device 26 complete arm system 150
ESD gearbox axis 1 225
damage elimination 34 gearbox axis 6 236
sensitive equipment 34 turning disk 156
wrist strap connection point 34 replacing
explanation, safety symbols 29 lower rod, linkage 180
upper rod, linkage 177

F requirements on foundation 41
FlexPendant restricting
jogging to calibration position 248 working range axis 1 69
MoveAbsJ instruction 248 revolution counters
updating revolution counters 246 storing on FlexPendant 246
fork lift 45 updating 246
foundation risk of tipping 44
loads 40 robot
requirements 41 operating conditions 41
protection class 41
G
storage conditions 41
gearbox axis 1, replacement 225 weight 40
gearbox axis 6, replacement 236 robot position 244
H S
hold-to-run 26 safety equipment
I mechanical stop 69
signal lamp 106
installation Safety, service 14
mechanical stop axis 1 69 safety, symbols 29

Index
scales on robot 244

securing the robot to foundation, attachment screws 61
securing, base plate 57
securing, robot 61
serial measurement board unit, replacement 205
special tools 259
stability 44
storage conditions, robot 41
symbols, safety 29
sync marks 244
T
testing, brakes 24
tightening torque
mechanical stop axis 1 70
tools
Calibration Pendulum equipment 259
for service 259
oil exchange equipment 259
turning disk replacement 156
U
updating revolution counters 246
V
Validity and responsibility 14
W
weight
base plate 56, 60
complete arm system 152, 153
gearbox 228, 229, 234
lower arm 194
motor 214, 215
robot 51, 53
upper arm 174
weight, robot 40
working range 42
restricting axis 1 69

3HAC025755-001, Revision B, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

ABB - IRB 660 Robot M2004 Product Manual - 3HAC025755-001 - Revb - en

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Product manual

IRB 660 - 180/3.15

Document ID: 3HAC025755-001

© Copyright 2006-2008 ABB. All rights reserved.

© Copyright 2006-2008 ABB All rights reserved.

2 Installation and commissioning 37

2.3.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.6 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.4.9 Replacement of parallel arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

5 Calibration information 241

6 Reference information 251

7 Spare parts and exploded views 263

7.2 Spare parts - frame to base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

8 Circuit diagram 291

About this manual

Who should read this manual?

Continues on next page

Document name Document ID

© Copyright 2006-2008 ABB. All rights reserved.

Product documentation, M2004

Technical reference manuals

• RAPID Overview: An overview of the RAPID programming language.

Continues on next page

© Copyright 2006-2008 ABB. All rights reserved.

How to read the product manual

Reading the procedures

References to required equipment

© Copyright 2006-2008 ABB. All rights reserved.

1.2 General safety information

1.2.1. Safety in the robot system

Validity and responsibility

Connection of external safety devices

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on robot

General risks during installation and service

Nation/region specific regulations

Non-voltage related risks

To be observed by the supplier of the complete system

Safety risk Description

Safety risk Description

Gearboxes and motors

Safety risk Description

1.2.2.2. Safety risks related to tools/workpieces

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

© Copyright 2006-2008 ABB. All rights reserved.

1.2.2.4. Safety risks during operational disturbances

1.2.2.5. Risks associated with live electric parts

Voltage related risks, general

Voltage related risks, IRC5 controller

© Copyright 2006-2008 ABB. All rights reserved.

Voltage related risks, robot

Voltage related risks, tools, material handling devices, etc

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

1.2.3.2. Fire extinguishing

© Copyright 2006-2008 ABB. All rights reserved.

1.2.3.3. Emergency release of the robot’s arm

1.2.3.4. Brake testing

© Copyright 2006-2008 ABB. All rights reserved.

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

1.2.3.6. Safe use of the FlexPendant

1.2.3.7. Work inside the robot's working range