3HAC022033 PM IRB 7600-En (Replace Gearbox)

ROBOTICS
Product manual
IRB 7600
Trace back information:
Workspace 23B version a11
Checked in 2023-06-20
Skribenta version 5.5.019
Product manual
IRB 7600 - 500/2.55
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
IRB 7600 - 325/3.1
IRB 7600 - 150/3.5
M2000, M2000A, IRC5
Document ID: 3HAC022033-001

Revision: AG
© Copyright 2007 - 2023 ABB. All rights reserved.

Specifications subject to change without notice.
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, damage 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.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation, M2000/M2000A ......................................................................................... 18
Product documentation, IRC5 .......................................................................................................... 19
How to read the product manual ...................................................................................................... 21
1 Safety 23
1.1 Safety information ............................................................................................. 23
1.1.1 Limitation of liability ................................................................................. 23
1.1.2 Requirements on personnel ...................................................................... 24
1.2 Safety signals and symbols ................................................................................. 25
1.2.1 Safety signals in the manual ...................................................................... 25
1.2.2 Safety symbols on manipulator labels ......................................................... 27
1.3 Robot stopping functions .................................................................................... 33
1.4 Safety during installation and commissioning ......................................................... 34
1.5 Safety during operation ...................................................................................... 37
1.6 Safety during maintenance and repair ................................................................... 38
1.6.1 Safety during maintenance and repair ......................................................... 38
1.6.2 Emergency release of the robot axes .......................................................... 41
1.6.3 Brake testing .......................................................................................... 42
1.7 Safety during troubleshooting .............................................................................. 43
1.8 Safety during decommissioning ........................................................................... 44
2 Installation and commissioning 45

2.1 Introduction to installation and commissioning ....................................................... 45
2.2 Robot transportation precautions ......................................................................... 46
2.3 Securing the robot with a transport support ........................................................... 50
2.4 Unpacking ....................................................................................................... 52
2.4.1 Pre-installation procedure ......................................................................... 52
2.4.2 Technical data ........................................................................................ 53
2.4.3 Working range, IRB 7600 - 150/3.5 .............................................................. 57
2.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ................................ 59
2.4.7 Risk of tipping/stability ............................................................................. 61
2.4.8 The unit is sensitive to ESD ....................................................................... 62
2.5 On-site installation ............................................................................................ 63
2.5.1 Lifting robot with fork lift ........................................................................... 63
2.5.2 Lifting robot with lifting accessory (recommended lifting method) ..................... 69
2.5.3 Lifting robot with roundslings .................................................................... 71
2.5.4 Manually releasing the brakes ................................................................... 73
2.5.5 Lifting the base plate ................................................................................ 75
2.5.6 Securing the base plate ............................................................................ 76
2.5.7 Orienting and securing the robot ................................................................ 81
2.5.8 Fitting equipment on robot ....................................................................... 84
2.5.9 Installation of base spacers (option) ........................................................... 89
2.5.10 Installation of cooling fan for motors (option) ................................................ 91
2.5.11 Installation of Foundry Plus Cable guard (option) .......................................... 98
2.5.12 Loads fitted to the robot, stopping time and braking distances ......................... 99
2.5.13 Safety lamp (option for IRC5) ..................................................................... 100
2.5.14 Extended working range, axis 1 (option) ..................................................... 101
2.6 Restricting the working range .............................................................................. 103
2.6.1 Axes with restricted working range ............................................................. 103
2.6.2 Mechanically restricting the working range of axis 1 ...................................... 104
Product manual - IRB 7600 5

3HAC022033-001 Revision: AG
Table of contents
2.7 Electrical connections ........................................................................................ 111

2.7.1 Robot cabling and connection points .......................................................... 111
2.8 Start of robot in cold environments ...................................................................... 115
2.9 Test run after installation, maintenance, or repair .................................................... 116
3 Maintenance 117
3.1 Introduction ...................................................................................................... 117
3.2 Maintenance schedule and expected life ............................................................... 118
3.2.1 Specification of maintenance intervals ........................................................ 118
3.2.2 Maintenance schedule ............................................................................. 119
3.2.3 Expected component life ......................................................................... 123
3.3 Inspection activities ........................................................................................... 124
3.3.1 Inspecting the motor seal ......................................................................... 124
3.3.2 Inspecting the oil level in axis-1 gearbox ..................................................... 126
3.3.8 Inspecting the balancing device ................................................................. 144
3.3.9 Inspecting the cable harness ..................................................................... 150
3.3.10 Inspecting the axis-1 mechanical stop pin ................................................... 153
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3 ...................................... 155
3.3.12 Inspecting the damper on axes 2 to 5 .......................................................... 157
3.3.13 Inspecting the information labels ................................................................ 159
3.3.14 Inspecting the UL lamp ............................................................................. 161
3.4 Changing/replacement activities .......................................................................... 163
3.4.1 Type of lubrication in gearboxes ................................................................ 163
3.4.2 Changing oil, axis-1 gearbox ..................................................................... 165
3.4.8 Replacing the SMB battery ........................................................................ 185
3.5 Lubrication activities .......................................................................................... 190
3.5.1 Lubrication of spherical roller bearing, balancing device ................................. 190
3.6 Cleaning activities ............................................................................................. 192
3.6.1 Flushing a contaminated gearbox ............................................................... 192
3.6.2 Cleaning the IRB 7600 .............................................................................. 194
3.7 Service Information System, M2000 ...................................................................... 197
3.7.1 Using the SIS system ............................................................................... 197
3.7.2 Description of Service Information System (SIS) ........................................... 198
3.7.3 SIS system parameters ............................................................................ 201
3.7.4 Setting the SIS parameters ....................................................................... 202
3.7.5 Reading the SIS output logs ...................................................................... 203
3.7.6 Exporting the SIS data ............................................................................. 204
4 Repair 205
4.1 Introduction ...................................................................................................... 205
4.2 General procedures ........................................................................................... 206
4.2.1 Performing a leak-down test ...................................................................... 206
4.2.2 Mounting instructions for bearings ............................................................. 207
4.2.3 Mounting instructions for sealings .............................................................. 209
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 212
4.2.5 The brake release buttons may be jammed after service work ......................... 213
4.3 Complete robot ................................................................................................. 214
4.3.1 Replacement of cable harness, axes 1-4 ..................................................... 214
4.3.2 Replacement of cable harness, axes 5-6 ...................................................... 224
6 Product manual - IRB 7600

Table of contents
4.3.3 Replacement of complete arm system ......................................................... 227

4.4 Upper and lower arm ......................................................................................... 232
4.4.1 Replacing turning disk .............................................................................. 232
4.4.2 Replacement of complete wrist unit ............................................................ 236
4.4.3 Replacement of complete upper arm ........................................................... 241
4.4.4 Replacement of complete lower arm ........................................................... 246
4.4.5 Replacement of lower arm shaft ................................................................. 256
4.5 Frame and base ................................................................................................ 264
4.5.1 Replacing the SMB unit ............................................................................ 264
4.5.2 Replacement of brake release board ........................................................... 268
4.5.3 Replacement of spherical roller bearing, balancing device .............................. 274
4.5.4 Replacing the balancing device .................................................................. 279
4.6 Motors ............................................................................................................ 291
4.6.1 Replacement of motor, axis 1 .................................................................... 291
4.6.2 Replacement of motor axis 2 ..................................................................... 296
4.7 Gearboxes ....................................................................................................... 328
4.7.1 Replacing the axis 1 gearbox ..................................................................... 328
4.7.2 Replacement of gearbox, axis 2 ................................................................. 340
5 Calibration 373
5.1 Introduction to calibration ................................................................................... 373
5.1.1 Introduction and calibration terminology ...................................................... 373
5.1.2 Calibration methods ................................................................................. 374
5.1.3 When to calibrate ................................................................................... 377
5.2 Synchronization marks and axis movement directions ............................................. 378
5.2.1 Synchronization marks and synchronization position for axes ......................... 378
5.2.2 Calibration movement directions for all axes ................................................ 379
5.3 Updating revolution counters ............................................................................... 380
5.3.1 Updating revolution counters on IRC5 robots ............................................... 380
5.4 Calibrating with Axis Calibration method ............................................................... 385
5.4.1 Description of Axis Calibration .................................................................. 385
5.4.2 Calibration tools for Axis Calibration ........................................................... 388
5.4.3 Installation locations for the calibration tools ............................................... 390
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 391
5.4.5 Reference calibration ............................................................................... 395
5.5 Calibrating with Calibration Pendulum method ....................................................... 397
5.6 Calibrating with Wrist Optimization method ........................................................... 398
5.7 Verifying the calibration ...................................................................................... 400
5.8 Checking the synchronization position .................................................................. 401
6 Decommissioning 403
6.1 Introduction to decommissioning ......................................................................... 403
6.2 Environmental information .................................................................................. 404
6.3 Scrapping of robot ............................................................................................. 406
6.4 Decommissioning of balancing device ................................................................... 407
7 Robot description 411

7.1 Type A vs type B motors .................................................................................... 411

Table of contents
8 Reference information 413

8.1 Introduction ...................................................................................................... 413
8.2 Applicable standards ......................................................................................... 414
8.3 Unit conversion ................................................................................................. 416
8.4 Screw joints .................................................................................................... 417
8.5 Weight specifications ......................................................................................... 420
8.6 Standard tools .................................................................................................. 421
8.7 Special tools .................................................................................................... 422
8.8 Lifting accessories and lifting instructions .............................................................. 426
9 Spare part lists 427

9.1 Spare part lists and illustrations ........................................................................... 427
10 Circuit diagram 429

10.1 Circuit diagrams ................................................................................................ 429
10.2 Validity of circuit diagram 3HAC025744-1 .............................................................. 431
10.3 Validity of circuit diagram 3HAC13347-1 ................................................................ 432
Index 433

Overview of this manual

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.
The manual also contains reference information for all procedures detailed in the
manual.
The robot described in this manual has the protection type Standard and Foundry
Plus.
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
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope

The manual covers covers all variants and designs of the IRB 7600. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
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 the robot. Contains general
safety aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Continues on next page

Continued
Chapter Contents
Maintenance Step-by-step procedures that describe how to perform maintenance
of the robot. Based on a maintenance schedule that may be used
to plan periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts, tools, etc.
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional documents,
safety standards etc.
Spare part list Complete spare part list shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot.
References
Procedures in this product manual contain references to the following manuals:
Document name Document ID Note
Product manual - IRB 7600 Foundry Prime 3HAC044350-001
Product manual, spare parts - IRB 7600 3HAC049113-001
Product specification - IRB 7600 3HAC023934-001
Product specification - IRB 7600 M2000/M2000A 3HAC13491-1
Circuit diagram - IRB 7600 3HAC13347-1
3HAC025744-001
Safety manual for robot - Manipulator and IRC5 or 3HAC031045-001 M2004
OmniCore controller i
Product manual - IRC5 3HAC021313-001
IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Product manual - S4Cplus M2000 3HAC021333-001
Product manual - S4Cplus M2000A 3HAC022419-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
User’s guide - S4Cplus (BaseWare OS 4.0) 3HAC7793-1
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC050944-001 M2004
Operating manual - Levelmeter Calibration 3HAC022907-001 M2000/M2000A
Technical reference manual - Lubrication in gear- 3HAC042927-001
boxes
Technical reference manual - System parameters 3HAC050948-001
Application manual - Additional axes and standalone 3HAC051016-001 M2004
controller

Continued
Document name Document ID Note

Application manual - External axes 3HAC9299-1 M2000
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Additional document references
Document name Document ID

Application manual - CalibWare Field 3HAC030421-001
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commissioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Various corrections due to technical revisions, changes in the toolkits
etc.
A Chapter Calibration replaced with chapter Calibration information.
Following corrections are made:
• In chapter 3: Maintenance in section Exporting the SIS data, the unit
seconds for different SIS parameters is replaced by the unit hours.
The change is only valid for RobotWare release 5.0.
Following updates are made:
• In chapter 4: Repair, the sections Removal of complete lower arm and
Refitting of complete lower arm are completed with more detailed in-
formation about how to use the glycerin pump.
• Section Document references is completed with article numbers for
calibration manuals.
• Section Part list is completed with the spare part number for a variant
of the cable harness/brake release unit.
B New lubricating oil in the gearboxes. Changes made in the chapter Mainten-
ance on page 117 and Part list.
C • New variant of the robot (IRB 7600 - 500/2.55) implemented throughout
the manual.
• Wrist unit updated, new spare part number is specified in Replacement
of complete wrist unit on page 236 and Spare part list.
• Insulated wrist unit implemented, new spare part number is specified
in Replacement of complete wrist unit on page 236 and Spare part list.
Amount of oil differs from non-insulated wrist unit, changes made in
sections Type of oil in gearboxes and Changing oil, axis-6 gearbox on
page 182.
• New section that describes how to replace the bearing at the front eye
of the balancing device, Replacement of spherical roller bearing, balan-
cing device on page 274.
• Incorrect article numbers for position switches are corrected.
• New section: Installation of cooling fan for motors (option) on page 91.
• New section: Installation of base spacers (option) on page 89
• New section that specifies all the recommended spare parts: Spare
part list.

Continued
• Repair sections for removal/refitting are restructured into replacement
sections.
• Various corrections made, due to technical revisions etc.
D Foundry Prime option included.
E • New variant of the robot (IRB 7600 - 325/3.1) implemented throughout
the manual.
• In chapter 3 Maintenance section Oil in gearboxes type of oil and art.
no. in gearbox axes 1 has been added.
• New product name has been implemented throughout the manual:
"Mobilgear 600 XP 320". Replaces "Mobil Gearlube X320".
• Interval for change of Shell Tivela S 150 has been changed in section
Maintenance schedule.
• Section Service Information System has been removed from the
manual. There is a specific manual for SIS. See References.
• Section Chip and dust protection has been removed from the manual.
This option is no longer available.
• Standard tightening torque for M24 Allen head screws has been added
in section Screw joints.
• Prerequisites in section Overview
F This revision includes the following additions and/or changes:
• Section "WARNING! - Mixed oils may cause severe damage to gear-
boxes" in chapter Safety, has been integrated in section "Type of oil in
gearboxes" in the Maintenance chapter.
• The oil Shell Tivela S150 in gearboxes 1, 2, 3 and 6 has been replaced
by Kyodo Yushi TMO 150. Changes made in chapters Maintenance and
Spare Parts.
• The section "Type of oil in gearboxes" in chapter Maintenance has been
updated according to changes made in oil types and intervals for oil
change.
• Sections "Robot transportation precaution" and "Securing the robot"
are added to the Installation chapter.
• Modified maintenance intervals for oil change in gearboxes.
• Chapter Maintenance, section "Maintenance Schedule": interval for
replacement of battery pack changed.
• Section "Type of oil" changed.
G This revision include the following addition:
• New WARNING! added in Safety chapter section Work inside the robot´s
working range.
• New WARNING! added in Safety chapter section WARNING! - Safety
risks during work with gearbox oil.
• The text in the introduction to chapters Installation, Maintenance and
Repair has been uppdated concerning the robot being connected to
earth when power connected.
• Section Expected component life in chapter Maintenance: The lifetime
of certain parts has been updated.
• Section Type of oil in chapter Maintenance has been updated.
• Section Foundry Plus,Cable guard added to Installation chapter.
H This revision includes the following additions and/or changes:
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 429.
• List of standards updated, see Applicable standards on page 414.
• Interval changed for inspection and lubrication of balancing device
(Foundry Prime). See chapter Maintenance section Maintenance
schedule on page 119.

Continued
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 25.
• New safety labels on the manipulators, see Safety symbols on manipu-
lator labels on page 27.
• Revised terminology: robot replaced with manipulator.
J This revision includes the following updates:
• Maximum deviation changed, see Securing the base plate on page 76.
• Corrected part numbers, see Wrist, 3HAC16628-4.
• Corrected exploded view, see Wrist complete.
• Added inspection of oil level in gearboxes and inspection of surface
treatment in maintenance schedule for Foundry Prime. See section
Activities and intervals, Foundry Prime.
• Text in maintenance schedules concerning lubrication of balancing
device bearing changed into concerning all bearings of the balancing
device, see Maintenance schedule on page 119.
• Replacement of cable harness in Foundry Prime robots added to
maintenance schedule, see Activities and intervals, Foundry Prime.
K This revision includes the following updates:
• Removed incorrect article number for fork lift, see Lifting robot with fork
lift on page 63.
• Information about restricting and extending the working range of axis
1 is now separated, see Mechanically restricting the working range of
axis 1 on page 104 and the new section Extended working range, axis
1 (option) on page 101. Also added signal about option 561-1 in section
Inspecting the axis-1 mechanical stop pin on page 153.
L This revision includes the following updates:
• A new block, about general illustrations, added in section How to read
the product manual on page 21.
• Made minor corrections and improvements in the complete instruction
for how to replace the axis 1 gearbox, see Replacing the axis 1 gearbox
on page 328.
• Robot designations are adjusted in sub-headings in section Robot
transportation precautions on page 46.
• Added new mechanical structure of the lower arm attachment point for
robots with protection Foundry Plus and Foundry Prime, see Replace-
ment of complete lower arm on page 246, the new section Replacement
of lower arm shaft on page 256 and the exploded view Frame-Lower arm
2 in Product manual, spare parts - IRB 7600.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 417.
• Added information about batteries.
• The maximum allowed deviation in levelness of the base plate is
changed, see Securing the base plate on page 76.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 76.
• Added attachment plate for axis-2 switch to equipment list for installation
of position switch.
• Friction washer added to the instruction for replacing axis-2 gearbox
and to the exploded view, see Replacement of gearbox, axis 2 on
page 340 and Exploded view.
• Moved all information about Foundry Prime to a separate Product
manual, see References on page 10 for document number.

Continued
• Corrected article numbers for the o-rings and removed the removal tool
from the equipment list and from the procedure, see Replacement of
gearbox, axis 6 on page 368.
• Corrected article number for axis-2-3 sealing, see Replacement of
complete lower arm on page 246 and Replacement of complete upper
arm on page 241.
M This revision includes the following updates:
• A new SMB unit and battery is introduced, with longer battery lifetime.
N This revision includes the following updates:
• Instruction for inspection of oil level updated.
• Spare part number, motor axis 2 corrected.
• Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 406.
• Added information in draining instructions and in Safety chapter about
draining oil from gearboxes.
• Information regarding fork lift set 3HAC0604-2 deleted from manual.
• Information regarding oil types added to maintenance schedule.
• New illustrations, and updated repair instructions regarding brake unit
cover.
• Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 7600
P This revision includes the following updates:
• Information about maintenance kit (3HAC15834-1), and upgrade kit
(3HAC14965-1), deleted from manual.
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 76.
• Added tightening torque for R1.SMB and 7th axis connector, see Re-
placement of cable harness, axes 1-4 on page 214.
• Minor corrections.
Q This revision includes the following updates:
• The inspection of oil level in gearboxes is removed from the mainten-
ance schedule and moved to the cleaning section.
• The instructions for inspection of oil level in gearboxes are updated,
see Inspection activities on page 124.
• Illustrations of SMB battery RMU improved.
R This revision includes the following updates:
• Article number changed for Fork lift accessory (from 3HAC0604-1 to
3HAC0604-2)
• New standard calibration method introduced (Axis Calibration). See
Calibration on page 373.
• Tightening torque for securing screw in piston shaft front eye changed,
see Replacing the balancing device on page 279.
• External brake release unit section removed from the manual.
• Turning disk fixture is removed from special tools for Levelmeter calib-
ration.
S This revision includes the following updates:
• Oil types in maintenance schedule table removed and a reference to
the Tech. manual added.
• Maintenance table splitted into several tables.
• Edited information regarding deciding calibration routine in each repair
section.
• Added a warning that calibration pin must be inserted in the calibration
bushing until it snaps, see Description of Axis Calibration on page 385.

Continued
• Added warning regarding risk of pinching, in Description of Axis Calib-
ration on page 385.
• Added information about inspection of calibration tool prior to usage,
see Examining the calibration tool on page 388.
• Added information about the calibration procedure, see Overview of
the calibration procedure on the FlexPendant on page 391, Restarting
an interrupted calibration procedure on page 393.
• Added information about Axis Calibration when SafeMove is installed,
see Axis Calibration with SafeMove option on page 393.
T Published in release R16.2. The following updates are done in this revision:
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 76.
• Corrections due to updates in terminology.
• Drawing of tool flange for LeanID added.
U Published in release R17.2. The following updates are done in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Note regarding VK cover on axis 3 (lower arm) due to removal of hole
in new design of the lower arm.
• Cooling fans (option) is available for axes 1 and 2.
• Applicable standards updated
• Added text regarding overhaul in section specification of maintenance
intervals.
• Section Start of robot in cold environments on page 115 added.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Updated information regarding lubrication of gearbox oil for all axis.
• Definition of reference calibration clarified.
V Published in release R18.1. The following updates are made in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 388.
• Updated information about locking liquid in replacement of cable har-
ness, axes 1-4.
• Added sections in General procedures on page 206.
• Safety restructured.
• Updated spare part number brake release unit (was DSQC561, is
DSQC1052).
• Type B motors are introduced throughout the manual.
- New periodic maintenance activity regarding inspection of the
type B motor oil seal.
- New gasket at axis-6 motor cable inlet.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calibra-
tion values.
• Information about myABB Business Portal added.
• Revised tightening torque for gearbox axis 2.
• Added Nickel in Environmental information.
• Changed direction of installed cooling fan on axis-2 motor and removed
a faulty image showing the design of the cooling fan. Also added de-
tailed images to installation procedure for the fan.

Continued
W Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or sur-
face on the robot before replacing parts on page 212.
• Levelmeter 2000 kit (6369901-347) no longer available.
• Updated oil plug torque on axis 6 gearbox to 20 Nm.
X Published in release 19C. The following updates are made in this revision:
• Added three velcro straps to the cable harness in the lower arm.
Y Published in release 19D. The following updates are made in this revision:
• Added references to DressPack manual in Robot cabling and connection
points on page 111.
Z Published in release 20B. The following updates are made in this revision:
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 209.
• Clarified text about position of robot and added table with dependencies
between axes during Axis Calibration.
• Added information about Wrist Optimization in calibration chapter.
• Replaced article number and name of grease, previously 3HAB3537-1.
AA Published in release 20C. The following updates are made in this revision:
• New press equipment for unloading balancing device introduced. New
article number. User instructions for the equipment are enclosed with
the tool and removed from this manual.
• New press equipment for replacing the lower arm shaft introduced. New
article numbers. User instructions for the equipment are enclosed with
the tools and removed from this manual.
• New press equipment introduced for following repair procedures. New
article numbers added. User instructions for the equipment are enclosed
with the tool and removed from this manual.
- unloading balancing device
- replacing lower arm shaft
- replacing balancing device shaft
AB Published in release 20D. The following updates are made in this revision:
• Recommended fastener quality is replaced with a general text, see
Fitting equipment on robot on page 84.
AC Published in release 21A. The following updates are made in this revision:
• Changed lifting accessory for lifting axis-2 and axis-3 gearboxes.
• Tool number for Press device, axis 2 shaft and axis 2 bearing changed,
see Required equipment on page 257
• New tool/adapter added to required equipment, see Replacing the bal-
ancing device on page 279.
AD Published in release 21B. The following updates are made in this revision:
• Oil name Optimol PD0 is changed to Tribol GR 100-0-PD in Lubrication
of spherical roller bearing, balancing device and Replacement of balan-
cing device.
• Information regarding documentation of Installation of Foundry Plus
Cable guard (option no. 908-1) is changed since DVDs are removed.
See Installation of Foundry Plus Cable guard (option) on page 98.
• Text regarding fastener quality is updated, see Fastener quality on
page 88.
• The information about extended working range for axis 1 is updated,
see Extended working range, axis 1 (option) on page 101.
AE Published in release 22A. The following updates are done in this revision:
• Updated information about Gleitmo treated screws, see Screw joints
on page 417.

Continued
• Removed information about position switches as they are no longer
available.
AF Published in release 22C. The following updates are made in this revision:
• Corrected article numbers for axis-6 gearbox o-ring and turning disk o-
ring.
AG Published in release 23B. The following updates are done in this revision:
• Added a step for overall inspection of cabling after cable harness has
been replaced.
• Corrected the section Lubrication of spherical roller bearing, balancing
device on page 190.
• Added note about oscillations in section about reference calibration.
• Updated the torque value for transparent plug.

Product documentation, M2000/M2000A
Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including
controller, robot and any hardware option, consists of the manuals listed below:
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools ).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Software manuals
The software documentation consists of a wide range of manuals, ranging from
manuals for basic understanding of the operating system to manuals for entering
parameters during operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation.
Each document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.

Product documentation, IRC5

Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Troubleshooting.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
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, software).
• How to install included or required hardware.
• How to use the application.

Continued
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/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 and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
3. 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 the chapter Safety on page 23.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

This page is intentionally left blank
1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 Safety information
1.1.1 Limitation of liability
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.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed as
intended.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved for their intended use. The installation and/or use of non-original spare
parts and equipment can negatively affect the safety, function, performance, and
structural properties of the robot. ABB is not liable for damages caused by the use
of non-original spare parts and equipment.

1 Safety
1.1.2 Requirements on personnel
1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Personal protective equipment

Use personal protective equipment, as stated in the instructions.

1 Safety
1.2.1 Safety signals in the manual
1.2 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.
ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.
CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.
ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.
NOTE Signal word used to indicate important facts and

conditions.

1 Safety
Continued
Symbol Designation Significance

TIP Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.

1 Safety
1.2.2 Safety symbols on manipulator labels
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 27.
The information labels can contain information in text.
Symbols on safety labels
Symbol Description
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
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
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, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839

1 Safety
Continued
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
Before disassembly, see product manual
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

1 Safety
Continued
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817

1 Safety
Continued
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Adjustable chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
Shut off with handle

Use the power switch on the controller.
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648

1 Safety
1.3 Robot stopping functions
1.3 Robot stopping functions
Protective stop and emergency stop

The protective stops and emergency stops are described in the product manual
for the controller.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller

1 Safety
1.4 Safety during installation and commissioning
National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform a risk assessment.
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working space.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 404 for specification of allergenic materials
in the product, if any.
Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
respective product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.

1 Safety
Continued
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.

1 Safety
Continued
Pneumatic or hydraulic related hazards
Note
The pressure in the complete pneumatic or hydraulic systems must be released

before service and maintenance.
All components in the robot system that remain pressurized after switching off
the power to the robot must be marked with clearly visible drain facilities and a
warning sign that indicates the hazard of stored energy.
Loss of pressure in the robot system may cause parts or objects 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.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Verify the safety functions

Before the robot system is put into operation, verify that the safety functions are
working as intended and that any remaining hazards identified in the risk
assessment are mitigated to an acceptable level.

1 Safety
1.5 Safety during operation
1.5 Safety during operation
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
Unexpected movement of robot arm
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
WARNING
equipment.

1 Safety
1.6.1 Safety during maintenance and repair
1.6 Safety during maintenance and repair
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
Gearbox lubricants (oil or grease)

When handling oil, grease, or other chemical substances the safety information of
the respective manufacturer must be observed.
Note
Take special care when handling hot lubricants.

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease

1 Safety
Continued

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• 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 gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
for the product.
Do not mix types of oil
Oil residues might be present in Make sure that protective gear
a drained gearbox and spilled like goggles/protective visor,
when separating a motor and gloves and arm protection are
gearbox during repair. always worn during this activity.
Put oil absorbent cloth or paper
Oil residues
at appropriate locations to catch
any oil residues.
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.
Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume

1 Safety
Continued

For lifetime reasons always drain
as much oil as possible from the
gearbox. The magnetic oil plugs
will gather residual metal chips.
Contaminated oil in
gearboxes
Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads
to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions, robot on page 55.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation and operation.

1 Safety
1.6.2 Emergency release of the robot axes
1.6.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 73.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the manipulator does
not result in additional hazards, for example, even more severe injuries on a trapped
person.
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.

1 Safety
1.6.3 Brake testing
1.6.3 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
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 verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the manipulator does not change position as the motors are switched off,
then the brake function is adequate.
Note
It is recommended to run the service routine BrakeCheck as part of the regular

maintenance, see the operating manual for the robot controller.
For robots with the option SafeMove, the Cyclic Brake Check routine is
recommended. See the manual for SafeMove in References on page 10.

1 Safety
1.7 Safety during troubleshooting
1.7 Safety during troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Troubleshooting on the controller while powered on must be performed by

personnel trained by ABB or by ABB field engineers.
A risk assessment must be done to address both robot and robot system specific
hazards.
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.

1 Safety
1.8 Safety during decommissioning
1.8 Safety during decommissioning
General
See section Decommissioning on page 403.
If the robot is decommissioned for storage, take extra precaution to reset safety
devices to delivery status.
WARNING
WARNING
equipment.

2 Installation and commissioning
2.1 Introduction to installation and commissioning

2.1 Introduction to installation and commissioning
General
This chapter contains assembly instructions and information for installing the IRB
7600 at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
The technical data is detailed in section Technical data on page 53.
Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 23 before performing any installation
work.
Note
Always connect the IRB 7600 and the robot to protective earth and residual
current device (RCD) before connecting to power and starting any installation
work.

2.2 Robot transportation precautions
General
This section describes ABB approved transportation precautions for ABB robots.
CAUTION
All transportation in or outside the plant, must be carried out according to the
method described in this section.
Transportation in any other way can seriously damage the robot. If the robot
is incorrectly transported and the instructions are not followed, the robot is
not covered by the warranty and ABB will not accept any compensation claim.
Method 1 - recommended method

Transportation according to method 1 is strongly recommended by ABB.
xx0800000030
Always follow these instructions when transporting an ABB robot according to

method 1:
• Always remove the tool before transportation of the robot.
• Always place the robot in the ABB recommended transport position, described
in section Risk of tipping/stability on page 61.
• Always read and follow the instructions in section Pre-installation procedure
on page 52
Method 2 - transportation with a tool mounted to the robot

Transportation according to method 2 is approved by ABB, only if use of method
1 is not possible.

Continued
Always follow these instructions when transporting an ABB robot according to

method 2:
• Always read and follow the instructions in section Securing the robot with a
transport support on page 50
• Always place the robot in the ABB recommended transport position for robot
with tool, described in sub section Transport position with a transport support
on page 48.
• Always use the recommended transport support described in sub section
Recommended transport support on page 49.
IRB 7600
C
D
xx0800000037
A Transport Support
B Hexagon socket head cap screw M16x140
C Threaded bar M10x200
D Nut M10

Continued
Transport position with a transport support

All transportation of the robot with tool must follow these instructions.
IRB 7600
xx0800000040

Continued
Recommended transport support

Always use the recommended transport support when transporting a robot with
tool.
IRB 7600
xx0800000039

2.3 Securing the robot with a transport support
General
This section describes how to fit the transport support to the robot in order to
secure the robot for transportation. The transport support is required if the robot
must be transported with mounted tools.
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.
Fitting the transport support

Illustration for fitting the transport support
xx0800000062

Continued
Fitting the transport support
Action Note
1 Fit the transport support’s lower end to the Do not tighten the screw.
robot using the recommended screw joint, See attachment point for the specific ro-
(A) in figure. bot in the section Transport position with
a transport support on page 48.
2 Jog the robot into a position as near above
as possible to the recommended transport CAUTION
position for the specific robot, as specified
in section Transport position with a transport Do not try to jog the robot to the exact
support on page 48. position (max distance 1mm).
3 Use the brake release for axis 3 to reach the See attachment point for the specific ro-
final resting position on the transport support, bot in the section Transport position with
see the section Manually releasing the brakes a transport support on page 48
on page 73.
4 Tighten all the attachment screws, (A) and
(B), in the figure with the brake release for CAUTION
axis 3 still activated starting with the lower
attachment screw. Do not attempt to tighten any attachment
screws without first releasing 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 the section Manually releasing the brakes
on page 73

2.4.1 Pre-installation procedure
2.4 Unpacking
2.4.1 Pre-installation procedure
Introduction
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.
Prerequisites for installation personnel

Installation personnel working with an ABB product must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/maintenance/repair work
• conform to all national and local codes.
Checking the pre-requisites for installation
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 53
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 55
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 55
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 54
• Protection classes, robot on page 56
• Requirements, foundation on page 55
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 61
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 63
11 Install required equipment, if any.
• Safety lamp (option for IRC5) on page 100
• Installation of base spacers (option) on page 89

2.4.2 Technical data
Weight, robot
The table shows the weight of the robot.
The weight does not include the weight of the DressPack.
Robot model Weight
IRB 7600 2500 kg
Note
The weight does not include tools and other equipment fitted on the robot.
The weight does not include the weight of the DressPack.
Mounting positions
The table shows valid mounting options for the manipulator.
Mounting option Installation angle Note
Floor mounted 0° i
i A tilt of up to 5° does not affect the payload or reach, but it can have a negative impact on
performance and lifetime. The actual value must be set in the system parameters.
Note
The actual mounting angle must always be configured in the system parameters,
otherwise the performance and lifetime is affected.

Continued
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
Floor mounted
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ± 14 kN ± 31 kN
Force z +32 ± 10 kN +39 ± 16 kN
Torque xy ± 42 kNm ± 72 kNm
Torque z ± 11 kNm ± 19.5 kNm

Continued
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.3 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
Minimum resonance 22 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see the application manual of the
time to have a controller software, section Motion Process
lower resonance Mode.
frequency than
recommended.
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated frequency. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Storage conditions, robot

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

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5° C
Maximum ambient temperature +50° C
Maximum ambient humidity Max. 95% at constant temperat-
ure

Continued
Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class i
Manipulator, protection type Standard IP 67
Manipulator, protection type Foundry Plus IP 67
i According to IEC 60529.

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

Illustration
xx0300000296

2.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55
2.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 400/2.55
and IRB 7600 - 500/2.55:
xx0100000100

Illustration
en0100000099

2.4.7 Risk of tipping/stability
2.4.7 Risk of tipping/stability
Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The transportation position is the most stable position.
Do not change the robot position before securing it to the foundation!
Transportation position
This figure shows the robot in its transportation position.
xx0100000103
Note
The robot might be positioned in a different position at delivery, due to actual

configurations and options (for example DressPack).
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.

2.4.8 The unit is sensitive to ESD
2.4.8 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.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.

2.5.1 Lifting robot with fork lift
2.5 On-site installation
General
The robot may be moved using a fork lift, provided that available special aids are
used.
This section describes how to attach the fork lift equipment to the robot.
Attachment points on robot

The attachment points for the fork lift equipment are shown in this figure.
xx0400000707
A Attachment points, spacer and horizontal attachment screws

B Attachment points, horizontal attachment screws
C Attachment points, vertical attachment screws
D Attachment points, horizontal attachment screws

Continued
Required equipment
Equipment, etc. Art. no. Note

Fork lift accessory, incl. all 3HAC0604-2
required hardware
Standard toolkit - Content is defined in section Standard
tools on page 421.
Fork lift accessory, 3HAC0604-2

The Fork lift accessory, 3HAC0604-2, is fitted to the robot as shown in the figure
below.
xx0200000379
A Fork lift pocket (2 pcs, 3HAC15766-1 , 3HAC11264-1)

B Spacer (2 pcs)
C Horizontal attachment screws (4 pcs/ fork lift pocket)
D Vertical attachment screws (2 pcs)

Continued
Lifting robot with fork lift

This section 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 If a cooling fan for the axis 1 motor is used, it
must be removed in order to use the fork lift
device!
2 Position the robot as shown in the figure to the Release the brakes if required as de-
right! tailed in section Manually releasing the
brakes on page 73.
Note
50°
No load is permitted on the robot if the fork lift
set 3HAC0604-2 is used!
10°
m
xx0200000079
When using fork lift set 3HAC0604-2,

no load is permitted on the robot!
xx0200000387
3 Fit the two spacers to the robot and secure. Attachment points are shown in figure
Attachment points on robot on page 63.
4
CAUTION
The fork lift pocket weighs 60 kg!

Continued
Action Note
5 Secure the longer fork lift pocket to the spacers Always use original screws (or replace-
with four of the horizontal attachment screws ments of equivalent quality: M16, qual-
and washers. ity 12.9)!
Attachment points on the robot are
Note
shown in figure Attachment points on
robot on page 63.
The screws, which are attached horizontally
and vertically, are identical. However, they are
tightened with different torque!
xx0400001068
A Horizontal attachment screws, 4

pcs, M16 x 60. Tightening torque:
60 Nm.
B Spacers, 2 pcs.
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

Continued
Action Note
7 Secure fork lift pocket to robot with two vertical
attachment screws and washers.
(only valid for the Fork lift accessory
3HAC0604-2)
Note
Vertically and the horizontally attached screws

are identical, but tightened with different
torques!
xx0300000464
A Vertical attachment screws, 2

pcs, M16x60. Tightening torque:
270 Nm.
Always use original screws (or replace-
ments of equivalent quality: M16, qual-
ity 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on
page 63.
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 hori- Tightening torque: 60 Nm.
zontal attachment screws.
Always use original screws (or replace-
ments of equivalent quality: M16, qual-
ity 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on
page 63.
10 Double-check that pockets are properly se-
cured to the robot! Insert fork lift forks into the
pockets.
xx0200000380
Reposition harness, if any, before using

a fork lift!

Continued
Action Note
11
CAUTION
The IRB 7600 robot weighs 2500 kg.

All lifting accessories used must be sized ac-
cordingly!
12 Carefully lift the robot and move it to its install-

ation site.
13
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
14 Refit the cooling fan to the motor, if any. Detailed in section Installation of cool-
ing fan for motors (option) on page 91.

2.5.2 Lifting robot with lifting accessory (recommended lifting method)
General
This section contains a general overview of how to lift the complete robot using
special lifting accessory.
Illustration, lifting accessory

The following figure shows the principle for how to use and lift the entire robot with
lifting accessory. For a more detailed instruction, see the user instructions enclosed
with the accessory.
Note
The user manual may be out of date. The latest revision is available for download
via myABB Business Portal, www.abb.com/myABB.
xx0200000153
Required equipment
Equipment Article number Note

Lifting accessory, robot 3HAC15607-1 Includes user instructions 3HAC15971-2

Continued
Slings attached directly onto robot

This section details how to lift and move the robot using lifting slings when these
are attached directly onto the robot.
Note
Please refer to the enclosed user instruction for instruction how to place the
manipulator in an correct position. Attempting to lift a manipulator in any other
position may result in the robot tipping over, causing severe damage or injury!
Action Note
1 Run the overhead crane to a position above
the robot.
2 Position the robot as detailed in enclosed in- Article number is specified in Required
struction! equipment on page 69.
Release the brakes, if required, as de-
tailed in section Manually releasing the
brakes on page 73.
3 Fit the lifting accessory to the robot as de- Article number is specified in Required
scribed in the enclosed instruction! equipment on page 69.
Go to the user instructions enclosed with the
lifting accessory.
DANGER
Handling the tool incorrectly will cause serious

injury.
Read and follow enclosed user instructions
for the tool.
4
CAUTION

cordingly!
5
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
6 Raise 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.

2.5.3 Lifting robot with roundslings
General
The figure below shows how to lift the complete robot with roundslings.
Notice the recommended robot position shown in the figure below!
Roundslings attached to the robot
xx0200000315
A Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m)
B Roundsling, 1000 kg, 2 pcs
C Roundsling, 2000 kg, 3 pcs (4 m)

Continued
Required equipment
Equipment Note
Chain sling with shortener, 4250 kg, 3 pcs Lengths: 0.5 m (2 pcs), 0.265 m (1 pc).
Roundslings, 1000 kg, 2 pcs
Roundslings, 2000 kg, 3 pcs Lengths: 4 m (3 pcs).
Slings attached directly on to robot

The section below details how to attach roundslings to the robot in order to lift the
complete robot.
Action Note
1 Recommended robot position is de-
CAUTION scribed in section Risk of tipping/sta-
bility on page 61.
Attempting to lift the robot in any other position
than that recommended may result in the robot
tipping over and causing severe damage or in-
jury!
2
CAUTION

cordingly!
3 Run the overhead crane to a position above the

robot.
4 Attach the three chain slings with shorteners Shown in the figure Roundslings at-
to the overhead crane hook. tached to the robot on page 71.
Lengths are specified in Required
equipment on page 72.
5 Fit the three roundslings, 2000 kg to the robot. Shown in the figure Roundslings at-
Attach the roundslings to the chain slings tached to the robot on page 71.
hanging from the overhead crane. Lengths are specified in Required
6 Attach the two roundslings, 1000 kg to the up- Shown in the figure Roundslings at-
per arm and the overhead crane hook! tached to the robot on page 71.
7 Raise the overhead crane to lift the robot. Make sure all hooks and attachments
maintain correct position while lifting
the robot!

2.5.4 Manually releasing the brakes
General
This section details how to release the holding brakes of each axis motor.
The brakes may be released by:
• Internal brake release unit: using push buttons on the robot. This requires
either the controller to be connected or that power is supplied to the R1.MP
connector, according to the section Supplying power to connector R1.MP
on page 74.
Location of brake release unit

The internal brake release unit is located as shown in the figure.
Brake release at base

The figure below shows the unit located at the base.
xx0200000375
- Internal brake release unit with push buttons, located on the robot base
Brake release at frame

The figure below shows the unit located at the frame.
xx0200000376
- Internal brake release unit with push buttons, located on the robot frame

Continued
Releasing the brakes

This procedure 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 Buttons are shown in figure Location of
with buttons for controlling the axes brakes. brake release unit on page 73.
The buttons are numbered according to the
numbers of the axes.
If the robot is not connected to the control-
ler, power must be supplied to the connect-
or R1.MP according to the section Supply-
ing power to connector R1.MP on page 74.
2
DANGER
When releasing the holding brakes, the ro-

bot axes may move very quickly and
sometimes in unexpected ways!
Make sure no personnel is near or beneath
the robot arm!
3 Release the holding brake on a particular

robot axis by pressing the corresponding
button on the internal brake release unit.
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 on the robot in order to enable the brake release buttons.
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.
xx0600002937

2.5.5 Lifting the base plate
2.5.5 Lifting the base plate
Required equipment

Lifting eye, M16 3HAC14457-4 3 pcs
Lifting slings 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 accessories

used must be sized accordingly.
2 Fit lifting eyes in specified holes. Shown in figure Hole configur-

ation on page 75.
3 Fit lifting slings to the eyes and to the lifting accessory.
CAUTION
Lift and move the base plate very slowly. If the base
plate starts to swing it is a risk for injuries or damage.

2.5.6 Securing the base plate
Base plate, dimensions

D G H
2x R525
598,31
560,85
B 487,01
(Ø 8 455
00)
950
243,5
F 2x 450
12x M24 A E
Ø1 A
A
0
73,84
231,5
111,30
C C
560,85
634,68
502,04
73,84
0
132,64
317,3
2x 50x45º
857,3
1020
48
4x
(4x)
6,3
)
(48
(2 3x
) 45
º
0.3 Common Zone
E, F, G, H
13
1,6
A
(2)
1,6
)
(2
13
3x
A-A 45
Ø 45P7 º B-B
Ø1.5
47 +0
0 ,5
c
K7
3x R1
45
52,
0,25 c
5º
(2
) (2x R22,5)
4
3x
3x 90º 1,6
C-C D
xx1000001053
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)

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

Continued
Base plate, orienting grooves and leveling bolts

The illustration below shows the orienting grooves and attachment holes for leveling
bolts in the base plate.
B A
B
B
A
xx1500000312
A Orienting grooves (3 pcs)

B Levelling bolts, attachment holes (4 pcs)

Continued
Base plate, guide sleeve holes

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

Base plate 3HAC12937-7 Includes
• guide sleeves, 3HAC12937-3
• levelling screws, 9ADA120-79
• attachment screws and washers
for securing the robot to the
base plate.
tools on page 421.
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.
Base plate
This section details how to secure the base plate to the foundation.
Action Note
1 Make sure the foundation is levelled.

Continued
Action Note
2
CAUTION
The base plate weighs 353 kg! All lifting

equipment used must be sized accordingly!
3 Position base plate in relation to the robot Shown in figure Base plate, orienting
work location using the grooves in the base grooves and leveling bolts on page 78.
plate.
4 Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 75.
5 Use the base plate as a template and drill at- Attachment holes: 16 pcs.
tachment holes as required by the selected
bolt dimension.
6 Fit the base plate and use the levelling bolts Shown in figure Base plate, orienting
to level the base plate. grooves and leveling bolts on page 78.
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 contact surfaces on the Maximum allowed deviation all over the
base plate to make sure the base plate is base plate, from one contact surface to
levelled and flat. the other: 0.3 mm.
If it is not, use pieces of sheet metal or similar
to bring the base plate to a levelled position.

2.5.7 Orienting and securing the robot
General
This section details how to orient and secure the robot to the base plate in order
to run the robot safely.
Illustration, robot fitted to base plate

This illustration shows the robot base fitted to the base plate.
xx0100000107
A Robot attachment bolts and washers, 12 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

Use this procedure to secure robot to base plate after fitting plate to the foundation.
Action Note
1 Lift the robot. See section Lifting robot with lifting
accessory (recommended lifting
method) on page 69.
See section Lifting robot with round-
slings on page 71.
2 Move robot to the vicinity of its installation loca-
tion.
3 Fit two guide sleeves to the guide sleeve holes Shown in figure Base plate, guide
in the base plate. sleeve holes on page 79.
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 attach- Specified in Attachment screws on
ment holes. page 81.
Shown in figure Illustration, robot fitted
to base plate on page 81.
Note
Lightly lubricate screws before as-

sembly!
6 Tighten bolts in a criss-cross pattern to ensure

that the base is not distorted.

Continued
Hole configuration, base

This illustration shows the hole configuration used when securing the robot.
xx0300000046
Cross section, guide sleeve hole

This illustration shows the cross section of the guide sleeve holes.
xx0100000109

2.5.8 Fitting equipment on robot
General
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional
cabling, equipment, etc., fitted by the robot user. Make sure the required mounting
holes are accessible when planning the robot cell.
Note
All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.
Illustration, fitting of extra equipment on lower arm

The illustration below shows the mounting holes available for fitting extra equipment
on the lower arm.
Make sure not to damage the robot cabling on the inside of the lower arm when
fitting extra equipment. Always use appropriate attachment screws!
xx0700000722
Robot variant A
IRB 7600 - 500/2.55 2442 mm
IRB 7600 - 500/2.3 2192 mm
IRB 7600 - 400/2.55 2442 mm
IRB 7600 - 340/2.8 2692 mm
IRB 7600 - 325/3.1 2942 mm

Continued
Robot variant A
IRB 7600 - 130/3.5 3398 mm
xx0100000120
Illustration, fitting of extra equipment on upper arm

The illustration below shows the mounting holes available for fitting extra equipment
on the upper arm.
xx0100000116

Continued
xx0300000299
Robot variant A
IRB 7600 - 500/2.55 1056 mm
IRB 7600 - 500/2.3 806 mm
IRB 7600 - 400/2.55 1056 mm
IRB 7600 - 340/2.8 1306 mm
IRB 7600 - 325/3.1 1556 mm
IRB 7600 - 150/3.5 2012 mm
Illustration, fitting of extra equipment on frame

The mounting holes available for fitting extra equipment on the frame are shown
below.
xx0100000117

Continued
xx0100000118
Tool flange, standard

The illustration below shows the mounting holes available for fitting equipment on
the turning disc.
xx0100000119

Continued
Tool flange, LID (LeanID)

The illustration below shows the tool flange for option LID (LeanID).
30°
12x I 15°
2,5
12 H7
15min 16max
0,07 A B 3,2
1,6
2 X
2,5
8min
G
12x M16 min 24
250 h8
Drill max 25,5
227
125 H7
flat bottom hole
0,3 A B
1x45
0,04 A
200
1 x 45
12 H7
0,08 CD A
15min 30max
0,07 A I
5° SECTION I-I
xx1600000980
Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.

2.5.9 Installation of base spacers (option)
Illustration, installation of base spacers
xx0500001570
A Base spacer (4 pcs)

B Guide sleeve (4 pcs)
C Attachment screws and washers (12 pcs)
Required equipment
Equipment Art. no. Note

Base spacers 3HAC021899-002 Includes mounting set with at-
tachment screws and mount-
ing instruction.
Base plate 3HAC12937-7
Standard toolkit - Content is defined in section
Standard tools on page 421.

Continued

Other tools and procedures These procedures include ref-
may be required. See refer- erences to the tools required.
ences to these procedures in
the step-by-step instructions
below.
Installation, base spacers

The procedure below details how to fit the base spacers between the robot and
the base plate.
Action Note
1
DANGER
Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Unfasten the robot from the foundation, if Detailed in section Lifting robot with
fastened, and lift it away with lifting slings. lifting accessory (recommended lifting
Make sure the robot is positioned in the most method) on page 69.
stable position; the transport position!
3 Install the base plate to the foundation, if not Detailed in section Securing the base
used previously. plate on page 76.
4 Fit the four base spacers and guiding sleeves Shown in the figure Illustration, install-
to the base plate. ation of base spacers on page 89.
5 Lift the robot with lifting slings and move it to
the prepared base plate.
6 Guide the robot with the guiding sleeves as
lowering it towards the base plate and spacers.
7 Fasten the robot base to the spacers with en- M24 x 240, tightening torque: 775 Nm.
closed attachment screws and washers.
8
DANGER
Make sure all safety requirements are met when

performing the first test run. See Test run after
installation, maintenance, or repair on page 116.

2.5.10 Installation of cooling fan for motors (option)
General
A cooling fan can be installed on the motors of axes 1 or 2.
Cooling fans for axes 1 and 2 can not be combined!
The cabling for the fans is available in different designs:
• complete cabling, including connections for cooling fans at axes 1 and 2.
• separate cabling for axis 1 or 2, including only connections for the cooling
fans on axes 1 or 2. Installation of this cabling is detailed in section
Installation, separate fan cabling axis 1 or 2 on page 95.
If both cooling fans and position switches are installed on the robot, the complete
cabling must be used! It can not be combined with the separate cabling.
Location of cooling fans

The fans are installed on the motors, axes 1 or 2, as shown in the figure below.
xx1800000169 xx1800000170
A Cooling fan, axis 1

B Cooling fan, axis 2

Continued
Cooling fan
The details of the cooling fan are shown in the figure below.
xx0500002158
A Fanbox
B Attachment screws, fanbox plates (9 pcs)
C Groove in the connector
D Tightening screws, fanbox (3 pcs)
Required equipment

Cooling fan 3HAC15374-1
Cabling cooling fan, axes 1 3HAC023599-001 Choose this cabling if equipping the robot
or 2. with cooling fans on axis 1 or 2.
Plate for customer connec- 3HAC025778-001 An additional connection plate must be
tions fitted to the robot base, if not already in-
stalled. The plate is shown in the figure
Plate for customer connections, at base
on page 93.
Additional cabling to and in- - Specified in section Robot cabling and
side the controller connection points on page 111.
Material set fan axes 1 and 3HAC023999-001 The set includes:
2 • fan axes 1 & 2 cable harness
• plate, customer
• attachment screws and nuts.
Cable harness inside control- 3HAC025488-001
ler

Continued

Locking liquid - Loctite 243. Used for the three tightening
screws.
tools on page 421.
Circuit diagram - See chapter Circuit diagram on page 429.
Other tools and procedures These procedures include references to
may be required. See refer- the tools required.
ences to these procedures
in the step-by-step instruc-
tions below.
Plate for customer connections, at base
xx0500002301
A Plate for customer connections

B Attachment screws, 3 pcs, M6x16 quality 8.8-A2F

Continued
Installation, fan
The procedure below details how to install the cooling fan on any of the motors,
axes 1-3 .
Action Note
1
DANGER
Turn off all:

2 Prepare the fanbox for installation: Shown in the figure Cool-

• disassemble the two parts of the box by removing the ing fan on page 92.
nine attachment screws
• loosen the three tightening screws, to avoid damaging
the surfaces of the motor when fitting the fanbox
• turn the connector to the correct position; axis 1:
groove pointing inwards, as shown in the figure
Cooling fan on page 92. Positions for axis 2 and 3
are shown in the figure Location of cooling fans on
page 91.
3 Temporarily lift the motor cabling out of the way of the current
motor to make room for the fanbox.
4 Fit the parts of the fanbox to the motor and reassemble with
the nine attachment screws.
5 Lift the box (axis 1) so that it does not rest directly on the
robot and secure the box with the three tightening screws,
using locking liquid. Tighten them properly so that the box
is firmly attached to the motor.
6 Install the cabling and make adjustments in RobotWare, as
described in the following procedures.
Separate cabling for axis 1 or 2

The figure below shows the cabling used only for the fan on axis 1 or 2.
xx0500002173

Continued
A Cable bracket
B Connector R1.SW2/3, connected to the robot base
C Connector R3.FAN2, connected to the fan of axis 1 or 2
Installation, separate fan cabling axis 1 or 2

The procedure below details how to install the separate cabling for the cooling fan
of axis 1 or 2.
Action Note
1 Move the robot to its calibration position. This is detailed in section Syn-
chronization marks and synchron-
ization position for axes on
page 378.
2
DANGER
Turn off all:

3 Remove the rear cover plate from the robot base.
xx1800000161
4 Remove the cable bracket (A) Shown in the figure Separate

cabling for axis 1 or 2 on page 94
5 Fit the plate for customer connections, if not Art. no. is specified in Required
already fitted, to the connection plate of the robot equipment on page 92.
base.
xx1800000162
6 Run the cabling up through the base and frame,

beneath the balancing device.

Continued
Action Note
7 Secure the cable bracket to the bracket of the ro-
bot cabling inside the frame.
Run the cable underneath the robot cabling and
out through the side of the frame, at motor, axis
1 . The correct cable run is shown in the figure to
the right!
Note
There is a risk of the balancing device damaging

the cable if it is not protected by the robot cabling!
xx0500002174
A Cable bracket. Also shown

in the figure Separate
cabling for axis 1 or 2 on
page 94.
8 Connect the connector R3.FAN2 to the fan of axis
1 or 2. Note
Fans on both axis 1 and 2 can not

be used at the same time!
9 Connect the connector R1.SW2/3 to the base of

the robot. Make sure that the cabling, run through
the frame and base, is not twisted and runs freely
from the robot cabling.
10 Refit the rear cover plate to the robot base.
11 Install additional cabling to and inside the control- Cabling is specified in section
ler. Robot cabling and connection
Also make adjustments in RobotWare, as de- points on page 111.
scribed in the following procedure.

Continued
Adjustments in RobotWare
Action Note
1 Modify the settings in RobotWare to RobotWare 4.0: modify the settings in RobIn-
include the cooling fans. stall. RobotWare 4.063 and older must be up-
dated with a newer release.
RobotWare 5: modify the option information
in System Builder (RobotStudio). Read more
about modifying the system in Operating
manual - RobotStudio.
RobotWare 6: modify the option information
in Installation Manager (RobotStudio). Read
more about modifying the system in Operating
manual - RobotStudio.

2.5.11 Installation of Foundry Plus Cable guard (option)
2.5.11 Installation of Foundry Plus Cable guard (option)
Introduction
How to install the Foundry Plus Cable guard is described in the instruction delivered
with the cable guard.
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are
available in English, German, French, Spanish, and Italian and can be found for
registered users on myABB Business Portal (www.abb.com/myabb) and delivered
with the Cable guard, article number 3HAC035933-001.

2.5.12 Loads fitted to the robot, stopping time and braking distances
2.5.12 Loads fitted to the robot, stopping time and braking distances
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
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• User’s guide - S4Cplus (BaseWare OS 4.0)
• Operating manual - IRC5 with FlexPendant
Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached
to the robot. For more information, see product specification listed in References
on page 10.

2.5.13 Safety lamp (option for IRC5)
2.5.13 Safety lamp (option for IRC5)
Description
A signal lamp with a yellow fixed light can be mounted on the robot, as a safety
device.
Installation
See the assembly instruction delivered with the signal lamp.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.

2.5.14 Extended working range, axis 1 (option)
Overview
The working range of axis 1 can be extended on a floor-mounted robot, from the
default range limited by mechanical stops. The working range can be extended to
±220°.
CAUTION
The option Extended work range enables an extension of the working range for
axis 1, through a software configuration. With this option installed, the working
range can exceed the range limited by the mechanical stop on axis 1. The working
range shall be limited through the option SafeMove.
A risk analysis must be done to ensure that no risks remain when using option
Extended work range, to limit the working range, and before removing the
mechanical stops.
For information about the option SafeMove, see Application manual - Functional
safety and SafeMove2.
If the mechanical stop is removed, then the manipulator should have a marking
for this, for example, a label. If the robot is delivered with the option Extended
work range, then such a label is included on delivery.
Extending the working range
1 Configure the safety setup and verify it by
test.
2 Hold the mechanical stop pin in a firm grip,
and remove it by unscrewing the attach-
ment screw.
xx0400001034
3 In RobotWare, redefine the working range With the option Extended working range,
limitations in the system parameters, topic the maximum value for the system paramet-
Motion. The Arm parameters Upper Joint ers Upper Joint Bound and Lower Joint
Bound and Lower Joint Bound can be Bound is 3.84 respectively -3.84. The val-
changed to the values corresponding to ues are in radians, that is 3.84 radians =
the actual installation. 220 degrees.
Related information
The system parameters are described in detail in the reference manual, see
References on page 10.

Continued
For more information about SafeMove, see Application manual - Functional safety
and SafeMove2.
How to define the range of movement in M2000/M2000A is detailed in User’s
guide - S4Cplus (BaseWare OS 4.0), chapter System Parameters - topic Manipulator.

2.6.1 Axes with restricted working range
2.6 Restricting the working range
2.6.1 Axes with restricted working range
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop)
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. Note that this option also requires installation of option 810-1 Electronic
position switch.
This section describes how to install hardware that restricts the working range.
Note
Adjustments must also be made in the robot configuration software (system

parameters). References to relevant manuals are included in the installation
procedures.

2.6.2 Mechanically restricting the working range of axis 1
General
The working range of axis 1 is limited by fixed mechanical stops and adjustment
of the system parameter configuration. The working range 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 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
Equipment, etc. Article number Note

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 -

Continued

User’s guide - S4Cplus (BaseWare OS - Article number is specified in
4.0) (BaseWare 4.0) section References on page 10.
Technical reference manual - System
parameters
Installation, mechanical stops axis 1

Use this procedure to fit the additional mechanical stops to axis 1 of the robot. An
assembly drawing is also enclosed with the product.
Action Note
1
DANGER
Turn off all:

2 Fit the additional mechanical stop to the Tightening torque: 120 Nm.
frame according to the figure Mechanical
stops, axis 1 on page 104.
3 Adjust the software working range limitations How to define the range of movement in
(system parameter configuration) to corres- RobotWare 4.0 is detailed in User’s
pond to the mechanical limitations. guide - S4Cplus (BaseWare OS 4.0),
chapter System Parameters - topic Ma-
nipulator.
The system parameters that must be
changed (Upper joint bound and Lower
joint bound) are described in Technical
reference manual - System parameters.
4
WARNING
If the mechanical stop pin is deformed after

a hard collision, it must be replaced!
Deformed movable stops and/or additional
stops as well as deformed attachment
screws must also be replaced after a hard
collision.

General
The working range of axis 2 is limited by fixed mechanical stops and can be reduced
by adding up to six additional mechanical stops with 15 graduation in respective
direction.

The illustration shows the mounting position of the mechanical stops on axis 2.
xx0300000047
A Additional mechanical stops

B Fixed mechanical stop
Required equipment

Mechanical stop set, axis 2 3HAC11077-1 Includes six stops, 3HAC11407-1, each
one restricting the working range by
15°.
Includes attachment screws.
tools on page 421.

Continued

User’s guide - S4Cplus - Art. no. is specified in section Refer-
(BaseWare OS 4.0) (Robot- ences on page 10.
Ware 4.0)
Technical reference manu-
al - System parameters

Use the procedure to fit the mechanical stops for axis 2 to the robot. An assembly
drawing is also enclosed with the product.
Action Note
1
DANGER
Turn off all:

2 Fit and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop. Shown in the figure Mechanical stops,
axis 2 on page 106.
3 The software working range limitations must How to define the range of movement in
be redefined to correspond to the changes RobotWare 4.0 is detailed in User’s
in the mechanical limitations of the working guide - S4Cplus (BaseWare OS 4.0),
range. chapter System Parameters - topic Manip-
ulator.
The system parameters that must be
changed (Upper joint bound and Lower
4
WARNING

collision.

General
The working range of axis 3 is limited by fixed mechanical stops and can be reduced
by adding additional mechanical stops with 20 graduation in respective direction.

The illustration shows the mounting position of the mechanical stops on axis 3.
The figure shows IRB 7600 but the principle is the same.
xx0300000048
A Additional mechanical stops

B Fixed mechanical stop
C Attachment screw M16x60 quality 12.9

Continued
xx0600002973
A Mechanical stop pin, axis 3

B Attachment screw and washer
Required equipment

Mechanical stop set, axis 3 3HAC13128-2 Includes six stops, one with 80° re-
striction, 3HAC12708-4 (use when
limitation angle >=80), and five with
20°, 3HAC 12708-2.
Includes attachment screws.
tools on page 421.
User’s guide - S4Cplus (Base- - Art. no. is specified in section Refer-
Ware OS 4.0) (RobotWare 4.0) ences on page 10.
Technical reference manu-
al - System parameters

Continued

Use the procedure to fit the mechanical stops for axis 3 to the robot. An assembly
drawing is also enclosed with the product.
Action Note
1
DANGER
Turn off all:

2 Fit and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop. Shown in the figure Mechanical stops,
axis 3 on page 108
3 How to define the range of movement in
Note RobotWare 4.0 is detailed in User’s
guide - S4Cplus (BaseWare OS 4.0),
The software working range limitations chapter System Parameters - topic Manip-
(system parameters) must be redefined to ulator.
correspond to the changes in the mechanic- The system parameters that must be
al limitations of the working range. changed (Upper joint bound and Lower
4
WARNING

collision.

2.7.1 Robot cabling and connection points
2.7 Electrical connections
Introduction
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.
CAUTION
Connect the male and female connectors perfectly aligned horizontally to avoid
any kind of tilt or skew.
CAUTION
Verify that the robot serial number is according to the number(s) in the Declaration
of Incorporation (DoI).
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 112.
Fan cables (option) Handles supply to and feedback from any cooling fan on
the robot.
Specified in the table Fan cables (option) on page 113.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
The customer cables also handle databus communication.
See the product manual for the controller, see document
number in References on page 10.
External axes cables (option) Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See Application manual - Additional axes and standalone
controller, document number in References on page 10.
DressPack cables (option) Handles signals, process media and power feeding for
customer use, regarding material handling or spot welding.
See the Product manual - DressPack/SpotPack IRB
6650S/7600, see document number in References on
page 10.

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

Robot cable, power: 7 m 3HAC026787-001
Robot cable, signals
Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC7998-1
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10

Continued
Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.
xx1500001601
Note
How to ground DressPack/SpotPack cables is detailed in the Product

manual - DressPack/SpotPack IRB 6650S/7600, see the document number in
References on page 10.
Fan cables (option)

These cables are not included in the standard delivery, but are included in the
delivery if the fan option is ordered. The cables are completely pre-manufactured
and ready to plug in.
Cabling to be installed on the robot is specified in section Installation of cooling
fan for motors (option) on page 91.
Cabling between robot base and control cabinet, cooling fans, M2004
The cables specified below are specific for the IRC5 controller and used when the
robot is equipped with cooling fans. The cabling for the cooling fans runs all the
way from the robot base to the inside of the cabinet. Fans can also be ordered
without cables.
If equipping the robot with cooling fans, use the cabling specified below. The cables
for cooling fans listed below are used together with a distributing cable, also
specified below.
Cable Art. no. Connection point
Harness - cooling, 7 m 3HAC022723-001 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11

Continued
Cable Art. no. Connection point


2.8 Start of robot in cold environments
2.8 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.
Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.
Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
If the program consists of large wrist movements, it is possible that the reorientation
velocity, which is always high in predefined velocities, needs to be included in the
ramping up.

2.9 Test run after installation, maintenance, or repair
2.9 Test run after installation, maintenance, or repair
Safe handling
Use the following procedure after installation, maintenance, or repair, before
initiating motion.
DANGER
Initiating motion without fulfilling the following aspects, may increase the risk for
injury or cause damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Verify that all safety equipment is installed, as designed for the application.
6 Verify that no personnel are inside the safeguarded space.
7 If maintenance or repair has been done, verify the function of the part that was main-
tained.
8 Verify the application in the operating mode manual reduced speed.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before initiating motion.

3 Maintenance
3.1 Introduction
3 Maintenance
3.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
7600.
It is based on the maintenance schedule found at 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 the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 23 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the IRB 7600 is connected to power, always make sure that the IRB 7600 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
• Robot cabling and connection points on page 111.

3 Maintenance
3.2.1 Specification of maintenance intervals
3.2 Maintenance schedule and expected life
3.2.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 7600:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run.
The SIS used in M2004 is further described in the Operating manual - Service
Information System.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB Connected Services and its Assessment tools can help you to identify the
real stress level of your robot, and define the optimal ABB support to maintain your
robot working.
Contact your local ABB Customer Service to get more information.

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 following table.
Non-predictable situations also give rise to inspections of the robot. Any damage
must be attended to immediately.
The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 123
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 124
• Changing/replacement activities on page 163
• Cleaning activities on page 192
Activities and intervals, standard equipment

The following tables specifies the required maintenance activities and intervals.
Inspecting activities
Maintenance Equipment Interval Detailed in section

activity
Cleaning Robot - Cleaning the IRB 7600 on
page 194
Inspection Motor seal i Every: Inspecting the motor seal
• 12 months on page 124
Inspection Balancing device Every: Inspecting the balancing
• 6 months device on page 144
Inspection Robot harness Every: Inspecting the cable har-
12 months ii ness on page 150
Inspection Information labels Every: Inspecting the information

• 12 months labels on page 159
Inspection Dampers Every: Inspecting the damper on
• 12 months axes 2 to 5 on page 157
Inspection Mechanical stops Every: • Inspecting the axis-
• 12 months 1 mechanical stop
pin on page 153
• Inspecting the
mechanical stops on
axes 1, 2, and 3 on
page 155
i Only valid for robots that are equipped with Type B motors.
Type B motors include evacuation on the motor flange to indicate failure of primary sealing between
the gearbox and the motor. Robots with protection type Foundry Plus have a sight glass installed
in the evacuation holes.
See Type A vs type B motors on page 411.
ii Replace when damage or cracks is detected or life limit is approaching that specified in section
Expected component life on page 123.

3 Maintenance
Continued
Changing activities
Note
It is very important not to mix different types of oil. The oil change intervals are
determined based on the generation of the robot. For more information, see
Technical reference manual - Lubrication in gearboxes.

activity
Changing Oil in axis-1 gear- Every: • Changing oil, axis-1
box, robot genera- • 12,000 hours gearbox on page 165
tion 1:
Changing Oil in axis-1 gear- First change when DTC i Do not mix with other oils!
box, robot genera- reads: • Changing oil, axis-1
tion 2 and 3: 6,000 hours gearbox on page 165
Second change when DTC
i reads:
24,000 hours
Following changes:
Every 24,000 hours
tion 1:
i reads:
24,000 hours
Following changes:
Every 24,000 hours
tion 1:
i reads:
24,000 hours
Following changes:
Every 24,000 hours
Changing Oil in axis-4 primary First change when DTC i Do not mix with other oils!
gearbox, all genera- reads: • Changing oil, axis-4
tions: 6,000 hours gearbox on page 175
i reads:
24,000 hours
Following changes:
Every 24,000 hours

3 Maintenance
Continued

activity
Changing Oil in axis-4 second- Every: • Changing oil, axis-4
ary gearbox, robot • 12,000 hours gearbox on page 175
generation 1:
Changing Oil in axis-4 second- First change when DTC i Do not mix with other oils!
ary gearbox, robot reads: • Changing oil, axis-4
generation 2 and 3: 6,000 hours gearbox on page 175
i reads:
24,000 hours
Following changes:
Every 24,000 hours
Changing Oil in axis-5 primary First change when DTC i Do not mix with other oils!
gearbox, all genera- reads: • Changing oil, axis-5
i reads:
24,000 hours
Following changes:
Every 24,000 hours
Changing Oil in axis-5 second- Every: • Changing oil, axis-5
ary gearbox, robot • 12,000 hours gearbox on page 178
generation 1:
Changing Oil in axis-5 second- First change when DTC i Do not mix with other oils!
ary gearbox, robot reads: • Changing oil, axis-5
generation 2 and 3: 6,000 hours gearbox on page 178
i reads:
24,000 hours
Following changes:
Every 24,000 hours
box, all genera- reads: • Changing oil, axis-6
i reads:
24,000 hours
Following changes:
Every 24,000 hours
i DTC = Duty Time Counter. Shows the operational time of the robot.

3 Maintenance
Continued
Miscellaneous activities

activity
Cleaning Robot - Cleaning the IRB 7600 on
page 194
Overhaul Robot Every: Expected component life
40,000 hours on page 123
Replacement Battery pack, 36 months or battery low Replacing the SMB battery
measurement sys- alert i on page 185
tem of type
RMU101 or
RMU102 (3-pole
battery contact)
Replacement Battery pack, Battery low alert ii Replacing the SMB battery
measurement sys- on page 185
tem with 2-pole bat-
tery contact, e.g.
DSQC633A
Lubrication Balancing device Every:
bearings 12,000 hours iii
i The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
ii The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
iii Always lubricate the front eye bearing after refitting the shaft of the balancing device.
Activities and intervals, optional equipment

The following table specifies the required maintenance activities and intervals for
common optional equipment. The maintenance of other external equipment for the
robot is detailed in separate documents.
Maintenance Equipment Interval Note Detailed in section
activity
Inspection Signal lamp Every: Inspecting the UL
12 months lamp on page 161
Inspection Mechanical stop Every: Mechanical stops in Inspecting the mech-

axes 1-2-3 12 months addition to the fixed anical stops on axes
stops 1, 2, and 3 on
page 155
Inspection Motor fans, axes Every 12 Inspect the fans for -
1-2-3 months contamination that
could hinder the air
supply. Clean if ne-
cessary.

3 Maintenance
3.2.3 Expected component life
3.2.3 Expected component life
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Expected component life - protection type Standard
Component Expected life Note

Cable harness 40,000 hours ii Not including:
Normal usage i • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Cable harness 20,000 hours ii Not including:
Extreme usage iii • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Balancing device 40,000 hours iv
Gearboxes v 40,000 hours
i Examples of "normal usage" in regard to movement: most material handling applications and limited
use of bending backwards mode of axis 3.
ii Severe chemical or thermal environments, or similar environments, can result in shortened life
expectancy.
iii Examples of "extreme usage" in regard to movement: press tending, very severe palletizing
applications, major use of axis 1 movement and major use of bending backwards of axis 3.
iv The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from
the initial position and goes to maximum extension, and back. Deviations from this cycle will result
in differences in expected life!
v Depending on application, the lifetime can vary. The Service Information System (SIS) that is
integrated in the robot software can be used as guidance when planning gearbox service for the
individual robot. This applies to gearboxes on axes 1, 2, 3 and 6. The lifetime of gearbox axes 4
and 5 is not calculated by SIS (See the Operating manual - Service Information System). In some
applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature
or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB
Robotics Service team for more information.
The SIS for an IRC5 system is described in the Operating manual - Service Information System.
For an M2000 system, the SIS is described in section Service Information System, M2000 on
page 197.

3 Maintenance
3.3.1 Inspecting the motor seal
3.3 Inspection activities
Purpose of evacuation holes

This section is only valid for robots that are equipped with Type B motors.
The motors include evacuation on the motor flange to indicate failure of primary
sealing between the gearbox and the motor.
More information is found in Type A vs type B motors on page 411.
Location of evacuation hole on motor

The evacuation hole is located on each motor flange. The figure shows axis-1
motor as an example.
xx1500001057
Plug in the evacuation hole

New motors have a transparent plug/sight glass installed in the evacuation hole.
Remove the plug or drill a drainage hole with diameter 3 mm, if an open evacuation
hole is required instead.
xx2200002188

3 Maintenance
Continued
Inspecting the evacuation hole
Action Note
1
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.
2
WARNING
Handling gearbox oil involves several safety risks,

see Gearbox lubricants (oil or grease) on page 38.
3 Do a leakage check of the sight glass/evacuation

hole of each motor.
If any oil is available on the sight glass or if any
oil has been spilled out from the evacuation hole,
replacement of the motor is recommended.
Note
If oil is present in the evacuation it is an indication

that the primary seal of the motor is leaking. A
secondary seal after the evacuation is keeping
the oil out from the motor, but it is still recommen-
ded to replace the motor at a suitable timing if oil xx1500001057
is present in the evacuation.
Replacing of motors is described
in the repair chapter Motors on
page 291.

3 Maintenance
3.3.2 Inspecting the oil level in axis-1 gearbox
Location of gearbox
The axis-1 gearbox is located between the frame and base as shown in the following
figure.
xx0200000111
A Gearbox axis 1
B Oil plug, filling
C Motor, axis 1
D Oil plug, inspection (not available in all designs)
E Label, specifies type of oil in the axis 1 gearbox
Required equipment

Lubricating oil See Type and
amount of oil in
gearboxes on
page 163.

3 Maintenance
Continued

Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
Inspection through the oil plug, filling

Use this procedure to inspect the oil level in the axis-1 gearbox, when the oil plug
for inspection (shown in figure Location of gearbox on page 126) is not available.
Action Note
1
WARNING
Handling gearbox oil involves several safety

risks, see Gearbox lubricants (oil or grease)
on page 38.
2
DANGER
Turn off all:

area.
3 Make sure that the oil temperature is +25°C This is a precaution to reduce the
±10°C. temperature dependency of the
measurement.
4 Remove the motor, axis 1. Detailed in section Removal, motor
axis 1 on page 293.
5 Measure the oil level through the motor hole.
Required oil level: 35-45 mm to the motor hole.
6 Adjust the oil level, if required. Where to find type of oil and total
amount is detailed in Type and amount
of oil in gearboxes on page 163.
Filling and draining detailed in Chan-
ging oil, axis-1 gearbox on page 165.
7 Refit the motor, axis 1. Detailed in section Refitting, motor
axis 1 on page 294.
8
WARNING
Do not mix oil types! If wrong oil is refilled, the

gearbox must be rinsed as detailed in Technic-
al reference manual - Lubrication in gearboxes.

3 Maintenance
Continued
Inspection through the oil plug, inspection

Use this procedure to inspect the oil level in the axis-1 gearbox, when the oil plug
for inspection (shown in figure Location of gearbox on page 126) is available.
Action Note
1
WARNING

2
DANGER
Turn off all:

area.
measurement.
4 Open the oil plug, inspection. Shown in the figure Location of
gearbox on page 126.
5 Measure the oil level. A
Required oil level: 0-10 mm
C
xx1400002785
A Oil plug hole

B Required oil level
C Gearbox oil
amount is detailed in Type and
amount of oil in gearboxes on
page 163.
Detailed in section Changing oil,
axis-1 gearbox on page 165.
7 Refit the oil plug, inspection. Tightening torque: 24 Nm.
8
WARNING

gearbox must be rinsed as detailed in Technical
reference manual - Lubrication in gearboxes.

3 Maintenance
Different designs
The cover of the axis-2 gearbox is available in different designs, with different
locations of the oil plug hole for filling. The oil plug hole of the later design is located
33 mm lower than on the earlier design. The measured distance to the oil level
varies, depending on the design of the cover.
Oil plug, early design

The axis-2 gearbox is located in the lower arm rotational center. The following
figure shows the early design of the gearbox cover.
xx0300000068
A Gearbox, axis 2 (behind the motor attachment, not shown in figure)

B Oil plug, filling (early design)
C Oil plug, draining
D Label, specifies the type of oil in the axis-2 gearbox

3 Maintenance
Continued
Oil plug, later design

The axis-2 gearbox is located in the lower arm rotational center. The following
figure shows the later design of the gearbox cover.
E
A A
D D
B B
C C
xx0200000112
A Gearbox, axis 2 (behind the motor attachment, not shown in figure)

B Oil plug, filling/inspection (later design)
D Label, specifies the type of oil in axis-2 gearbox
E Oil plug, ventilation (later design)
Required equipment
Equipment etc. Art. no. Note

Lubricating oil See Type and amount
of oil in gearboxes on
page 163.
Inspecting the oil level in axis-2 gearbox

Use this procedure to inspect the oil level in the axis-2 gearbox.
Action Note
1
WARNING

risks, see Gearbox lubricants (oil or grease) on
page 38.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

area.
measurement.
4 Open the oil plug, filling/inspection (two different Read more about the differences in
designs). Changing oil, axis-2 gearbox on
page 169!
Required oil level, early design: 30-45 mm
Required oil level, later design: 0-15 mm
C
xx1400002785
A Oil plug hole

C Gearbox oil
Shown in the figures Oil plug, early
design on page 129 or Oil plug, later
design on page 130!
page 163.
Detailed in section Filling, oil on
page 170.
7 Refit the oil plug, filling. Tightening torque: 24 Nm.
8
WARNING


3 Maintenance
Location of gearbox
The axis-3 gearbox is located in the upper arm rotational center as shown in the
following figure.
xx0200000113
A Gearbox, axis 3
B Oil plug, filling/inspection
D Label, specifies the oil type of axis-3 gearbox
Required equipment

amount of oil in gear-
boxes on page 163.

3 Maintenance
Continued


Action Note
1
WARNING

page 38.
2 Move the robot to the calibration position. Detailed in section Synchronization

marks and synchronization position
for axes on page 378.
3
DANGER
Turn off all:

area.
measurement.
5 Open the oil plug, filling/inspection. Shown in the figure Location of
gearbox on page 132!
C
xx1400002785
A Oil plug hole

C Gearbox oil
page 163.

3 Maintenance
Continued
Action Note
8 Refit the oil plug. Tightening torque: 24 Nm.
9
WARNING


3 Maintenance
Location of gearbox
The axis-4 gearbox is located at the rear of the upper arm as shown in the following
figure.
xx0200000107
A Upper arm housing

B Cover, axis-4 gearbox
C Oil plug, filling/inspection, secondary gearbox
D Oil plug, draining, secondary gearbox
E Oil plug, filling/inspection, primary gearbox
The oil plug for draining of the primary gearbox is not shown in the figure
F Label, specifies the type of oil in the axis-4 secondary gearbox
G Label, specifies the type of oil in the axis-4 primary gearbox
Required equipment

Lubricating oil See Type and amount
of oil in gearboxes on
page 163.

3 Maintenance
Continued


Action Note
1
WARNING

page 38.
2 Move the robot to the calibration position. This is detailed in section Synchron-
ization marks and synchronization
position for axes on page 378.
3
DANGER
Turn off all:

area.
measurement.
5 Open the oil plug, filling/inspection, in the primary Shown in the figure Location of
gearbox. gearbox on page 135!
B
C
xx1400002859
A Oil plug hole

C Gearbox oil
7 Add oil if required. Where to find type of oil and total
page 163.

3 Maintenance
Continued
Action Note
8 Open the oil plug, filling/inspection, in the second- Shown in the figure Location of
ary gearbox. gearbox on page 135!
C
xx1400002785
A Oil plug hole

C Gearbox oil
10 Add oil if required. Where to find type of oil and total
page 163.
11 Refit the oil plugs. Tightening torque: 24 Nm.
12
WARNING


3 Maintenance
Location of gearbox
The axis-5 gearbox is located in the wrist unit as shown in the following figure.
A
B
C
E F G
D
xx0200000108
A Wrist housing
B Oil plug, filling/inspection, primary gearbox
The oil plug for draining of the primary gearbox is on the opposite side of the
wrist housing, not shown in the figure.
C Label, specifies the type of oil in the axis-5 primary gearbox
D Oil plug, draining/inspection, secondary gearbox
E Label, specifies the type of oil in the axis-5 secondary gearbox
F Oil plug, filling, secondary gearbox
G Cover, axis-5 gearbox

3 Maintenance
Continued
Required equipment

amount of oil in gear-
boxes on page 163.
Inspecting oil level in axis-5 gearbox

Action Note
1
WARNING

page 38.
2 Run the robot to the calibration position. This is detailed in section Synchron-
ization marks and synchronization
3
DANGER
Turn off all:

area.
measurement.
5 Open the oil plug, filling/inspection, in the Shown in the figure Location of
primary gearbox. gearbox on page 138.
6 Measure the oil level.
Required oil level to the upper edge of the filling
and inspection oil plug hole (a): 80-96 mm
xx0500002222

3 Maintenance
Continued
Action Note
page 163.
Detailed in section Changing oil, ax-
is-5 gearbox on page 178.
8 Open the oil plug, draining/inspection, in the Shown in the figure Location of
secondary gearbox. gearbox on page 138.
C
xx1400002785
A Oil plug hole

C Gearbox oil
page 163.
Detailed in section Changing oil, ax-
is-5 gearbox on page 178.
11 Refit the oil plugs. Tightening torque: 24 Nm.
12
WARNING


3 Maintenance
Location of gearbox
The axis-6 gearbox is located in the center of the wrist unit as shown in the following
figure.
xx0200000114
A Gearbox, axis 6
B Oil plug, filling/inspection (notice the different locations of the plug, shown as
B1 and B2)
C Oil plug, draining (can be located on the turning disk instead)
D Label, specifies the type of oil in gearbox axis 6
Required equipment

amount of oil in
gearboxes on
page 163.

3 Maintenance
Continued


Action Note
1
WARNING

2 Move axes 3 and 5 to a horizontal position, and Shown in the figure Location of
make sure that the oil plug, filling and inspection gearbox on page 141.
(B1 or B2) is facing upwards.
3
DANGER
Turn off all:

4 Make sure that the oil temperature is +25°C ±10°C. This is a precaution to reduce the
temperature dependency of the
measurement.
5 Open the oil plug, filling and inspection.
6 Open the oil plug, draining. This is a precaution to avoid vacu-
um effects by allowing air to enter
at the top of the gearbox.
Note
If equipment that covers the oil

plug, draining is fitted on the robot
so that the oil plug cannot be
opened, then this step can be
skipped.
7 Slowly turn axis 4, while adjusting axis 6 so that the

oil plug, filling and inspection always faces upwards.
Turn axis 4 until the axis-4 angle reads:
• -36° to -39° for oil plug position B1
• -80° to -83° for oil plug position B2

3 Maintenance
Continued
Action Note
8 Inspect the oil level in the hole for the oil plug, filling A
and inspection. B
The oil should reach all the way up to the external
edge of the thread for the oil plug, filling and inspec- C
tion.
xx1400002786
Note
A Oil plug hole
If the oil plug, draining is not opened, then use a B Required oil level
clean, narrow object, for example an oil stick or a C Gearbox oil
cable tie, to gently poke the oil surface. This will
avoid surface tension from stopping air to enter into
the gearbox.
page 163.
10 Refit the oil plugs. Tightening torque: 20 Nm
11
WARNING


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

If any faults are detected during the inspection, a maintenance may be performed
according to specific maintenance kits.
If the balancing device is an older model, it must in some cases be upgraded
instead! The instruction for the current inspection details if a fault requires a
maintenance / upgrade and the table below specifies the different models and
which of the two actions they require.
The article number of the balancing device is located on a label at the rear cover,
shown in the figure Inspection points, balancing device on page 145.
Balancing device, art. no. Action at detected faults

3HAC10538-1 Upgrade
3HAC14675-1 Maintenance

3 Maintenance
Continued
Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure.
The figure also shows the inspection points, further described in the instructions.
xx0300000580
A Balancing device
B Piston rod (inside)
C Shaft, including securing screw
D Ear, bearing and o-rings
E Label with article number
F Inspect the surroundings
G Bearing, balancing device attachments
Required equipment
The table below specifies the equipment used if damage is detected on the
balancing device. See section Action at detected faults on page 144 to determine
whether to perform maintenance or upgrade!
Equipment, etc. Spare part no. Art. no. Note
Maintenance kit, 3HAC14962-1 Includes:
bearings and seals • kit with bearings, o-
rings and seals only
• instructions for main-
tenance.

3 Maintenance
Continued

Includes
• kit with piston rod,
support shaft etc.
Securing screw Securing screw in the shaft.
M16 x 180
Locking liquid must be used
when fitting the screw (Loctite
243)!
Toolkit for mainten- 3HAC15943-1
ance
Puller for separator 4552-2 (Bahco) Used for removing the spher-
ical roller bearings.
Separator 4551-C (Bahco) Used for removing the spher-
ical roller bearings.
Standard toolkit 3HAC15571-1 Content is defined in section
Other tools and These procedures include
procedures may be references to the tools re-
required. See refer- quired.
ences to these
procedures in the
step-by-step in-
structions below.
Check for dissonance

The check points are shown in the figure Inspection points, balancing device on
page 145.
Check for dissonance If dissonance is detected...

from...
1 • bearing at the link ear ... perform maintenance or upgrade according to given
• bearings at the balan- instructions in Maintenance kit, bearings and seals /
cing devices attach- Upgrade kit. The replacement of the bearing at the ear
ments. is also detailed in section Replacement of spherical roller
bearing, balancing device on page 274.
Art. no. for the kit and the documentation are specified
in section Required equipment on page 145.
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 144.
2 • balancing device (a ...replace the balancing device or consult ABB Robotics.
tapping sound,
caused by the springs How to replace the device is detailed in section Repla-
inside the cylinder). cing the balancing device on page 279. This section also
specifies the spare part number!
3 • piston rod (squeaking If dissonance is detected, wipe clean the piston rod.
may indicate worn
plain bearings, intern- If dissonance continues after the piston rod is cleaned,
al contamination or perform maintenance according to given instructions in
insufficient lubrica- Maintenance kit, complete.
tion). Art. no. for the kit and the documentation are specified
in section Required equipment on page 145.
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 144.

3 Maintenance
Continued
Check for damage

Check for damage, such as scratches, general wear, uneven surfaces or incorrect
positions.
The check points are shown in the figure Inspection points, balancing device on
page 145.
Check for damage on... If damage is detected...

1 • the piston rod (part of the piston ... perform maintenance or upgrade accord-
rod that is visible at the front of the ing to given instructions in Maintenance
balancing device). kit, complete / Upgrade kit.
Art. no. for the kit and the documentation
are specified in section Required equip-
ment on page 145.
To decide whether to perform maintenance
or upgrade, see section Action at detected
faults on page 144.
2 • the securing screw in the front ear ...replace.
shaft.
Dimension is specified in section Required
Also check the tightening torque (50 Nm). equipment on page 145.
Check for leakage

The front ear of the balancing device is lubricated with grease. After filling, excessive
grease may normally be forced out between the shaft and the sealing ring in the
sealing spacer. This is normal behaviour and must not be confused with incorrect
leaks from the ear.
Leaks at the o-rings and/or sealings, are not acceptable and must be attended to
immediately in order to avoid any damage to the bearing!

3 Maintenance
Continued
Check the o-rings in the front ear of the balancing device for leaks, as shown and
detailed below.
xx0300000284
A Shaft
B O-ring
C Sealing spacer
D Sealing ring in sealing spacer
E Correct way out for excessive grease from inside the front ear
F Incorrect leakage from the front ear
Action Note
1 Clean the area at the front ear from old grease.
2 Run the robot for some minutes, in order to
move the balancing device piston.
3 Check the o-rings at the front ear for leakage. The o-rings are included in the Main-
Replace the o-rings, if any leaks are detected. tenance kit, bearings and seals,
Excessive grease from between the shaft and already assembled with sealing
the sealing ring is normal and is not considered spacers and sealing rings.
as a leak! Art. no. for the kit is specified in Re-
quired equipment on page 145.
The replacement of the complete
bearing is also detailed in section
Replacement of spherical roller bear-
ing, balancing device on page 274.
Incorrect leakage is shown in the
previous figure.

3 Maintenance
Continued
Check for contamination / lack of free space
Action
1
DANGER
Turn off all:

to the robot, before entering the safeguarded space.
2 Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 145.
Keep the areas around the balancing device clean and free from objects, such as
service tools.

3 Maintenance
3.3.9 Inspecting the cable harness
Location of cable harness, axes 1-4

The robot cable harness, axes 1-4, is located as shown in the figure below.
xx0200000097
A Lower arm
B Cables attached with velcro straps and mounting plate
C Connectors at cable harness division point, R2.M5/6
D Connectors at base
Required equipment

tools on page 421.
Other tools and procedures These procedures include references
may be required. See refer- to the tools required.
below.
Circuit diagram See chapter Circuit diagram on
page 429.

3 Maintenance
Continued
Inspection, cable harness 1-4

The procedure below details how to inspect the cable harness of axes 1-4.
Action Note
1
DANGER
Turn off all:

2 Make an overall visual inspection of the cable

harness, in order to detect wear and damage.
3 Check the connectors at the division point and Shown in the figure Location of cable
at the base. harness, axes 1-4 on page 150.
4 Check that velcro straps and the mounting Location is shown in the figure Location
plate are properly attached to the frame. Also of cable harness, axes 1-4 on page 150.
check the cabling, leading into the lower arm. A certain wear of the hose at the en-
Make sure it is attached by the straps and not trance to the lower arm is natural.
damaged.
5 Replace the cable harness if wear, cracks or Described in Replacement of cable
damage is detected. harness, axes 1-4 on page 214.
Location of cabling axes 5-6

The robot cable harness, axes 5-6, is located as shown in the figure below.
xx0200000155
A Cable attachment, upper arm tube

B Cable attachment, rear of upper arm
C Connectors at cable harness division point, R2.M5/6

3 Maintenance
Continued
Inspection, cable harness, axes 5-6

The procedure below details how to inspect the cable harness of axes 5-6.
Action Note
1
DANGER
Turn off all:

2 Make an overall visual inspection of the cable

harness, in order to detect wear and damage.
3 Check the attachments at the rear of the up- Shown in the figure Location of cabling
per arm and in the upper arm tube. axes 5-6 on page 151.
Check the connectors at the cable harness
division. Make sure the attachment plate is
not bent or in any other way damaged.
4 Replace the cable harness if wear, cracks or Described in section Replacement of
damage is detected. cable harness, axes 5-6 on page 224

3 Maintenance
3.3.10 Inspecting the axis-1 mechanical stop pin
WARNING
Mechanical stop pin can not be fitted onto robot if the option 561-1 Extended
working range is used for axis 1.
Location of mechanical stop pin

The axis-1 mechanical stop is located as shown in the figure.
xx0200000151
A Mechanical stop pin
Required equipment
Visual inspection, no tools are required.
Inspecting, mechanical stop pin

Use this procedure to inspect the axis-1 mechanical stop pin.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the safeguarded
space.

3 Maintenance
Continued
Action Note
2 Inspect the axis-1 mechanical stop pin.
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
The expected life of gearboxes can be reduced

after collision with the mechanical stop.
3 Make sure the mechanical stop pin can move in

both directions.

3 Maintenance
3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3
Location of the mechanical stops

The figure below shows the location of the additional mechanical stops on axes
1, 2 and 3.
xx0200000150
A Additional stop
B Fixed stop
Required equipment

Mechanical stop ax 1 3HAC11076-1 Limits the robot working range to
7.5°.
Mechanical stop ax 1 3HAC11076-2 Limits the robot working range to
15°.
Mechanical stop ax 2 3HAC11077-1
Mechanical stop ax 3 3HAC13128-2

3 Maintenance
Continued
Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on
axes 1, 2 and 3.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot working area.
2 Check the additional stops on axes 1, 2 and 3 for Shown in the figure Location of
damage. the mechanical stops on
page 155.
3 Make sure the stops are properly attached.
Correct tightening torque: 115 Nm.
4 If any damage is detected, the mechanical stops Art. no. is specified in Required
must be replaced! equipment on page 155!
Correct attachment screws:
• Axis 1: M16 x 35
• Axis 2: M16 x 50
• Axis 3: M16 x 80

3 Maintenance
3.3.12 Inspecting the damper on axes 2 to 5
Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0200000099
A Damper, axis 2 (2 pcs)

B Damper, axis 3 (2 pcs)
C Damper, axis 4 (2 pcs)
D Damper, axis 5 (2 pcs)
Required equipment

Damper axis 2 3HAC12990-1 Replace if damaged!

3 Maintenance
Continued

tools on page 421.
Inspection, damper axis 2-5

The procedure below details how to inspect the dampers, axis 2-5.
Action Note
1
DANGER
Turn off all:

2 Check all dampers for damage, such as cracks or ex- Shown in the figure Location
isting impressions larger than 1 mm. of dampers on page 157.
In order to inspect dampers, axis 4, the two covers on
top of the upper arm must be removed!
3 Check attachment screws for deformation.
4 If any damage is detected, the damper must be re- Art. no. is specified in Re-
placed with a new one! quired equipment on page 157.

3 Maintenance
3.3.13 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on manipulator labels on page 27.
xx0200000100
A Warning label concerning high temperature

B Warning sign, symbol of a lightning flash (located on motor cover)
C Instruction label
D Warning label concerning brake release
E Warning label, tools are not allowed around the balancing device during operation
F Warning label concerning shutting off power
G Label, type of oil in gearbox
H Label, type of oil in gearbox
I Label, type of grease in ear
- Information labels at gearboxes and at robot base, specifying which oil is used
in gearboxes

3 Maintenance
Continued
xx0200000101
J Instruction label concerning lifting the robot

K Warning label concerning risk of tipping
L Foundry logotype
M Warning label concerning stored energy
N Information label, specifying with type of oil is used in gearboxes of each axis
O Label, type of oil in gearbox
Required tools and equipment

Visual inspection, no tools are required.
Inspecting, labels
Action Note
1
DANGER
Turn off all:

2 Inspect the labels, located as shown in the figures.

3 Replace any missing or damaged labels. Article numbers for the labels and
plate set is specified in Spare part
lists on page 427.

3 Maintenance
3.3.14 Inspecting the UL lamp
Location of UL-lamp
The UL-lamp is located as shown in figure below. Notice that the location can vary
depending on how the customer harness for axes 4-6 is mounted.
xx0200000117
A UL signal lamp
B Warning sign
C Warning label
D Position for cable gland
Required equipment
Equipment, etc. Spare part no. Note

Signal lamp 3HAC10830-1 To be replaced in case of detected
damage.
Includes UL signal lamp, 3HAC 13097-
1, Warning label, 3HAC 4431-1,
Warning sign, 3HAC 1589-1
tools on page 421.

3 Maintenance
Continued
Inspection, UL-lamp
The procedure below details how to inspect the function of the UL-lamp.
Action Note
1 Check that the UL-lamp is lit, when the motors are in
operation ("motors ON").
2 If the lamp is not lit, trace the fault! Part no. is specified in Re-
• Check whether the UL-lamp is broken. If so, required equipment on
place it. page 161!
• Check the cable connections.
• Measure the voltage in connectors motor axis 3
(=24V).
• Check the cabling. Replace cabling if a fault is
detected.

3 Maintenance
3.4.1 Type of lubrication in gearboxes
3.4 Changing/replacement activities
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB.
Location of gearboxes
The figure shows the location of the gearboxes.
xx0400000798
A Axis 1 gearbox
B Axis 2 gearbox
C Axis 3 gearbox
D Axis 4 primary gearbox
E Axis 4 secondary gearbox
F Axis 5 primary gearbox
G Axis 5 secondary gearbox
H Axis 6 gearbox

3 Maintenance
Continued
Equipment
Equipment Note
Oil dispenser Includes pump with outlet pipe.
Use the suggested dispenser or a similar one:
• Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring

3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure
below.
The oil is drained with a hose that may be reached behind the rear cover of the
robot base.
xx0200000111
A Gearbox, axis 1
B Oil plug, filling
C Motor, axis 1
D Oil plug, inspection (not in all designs)
E Label, specifies the type of oil in the gearbox

3 Maintenance
Continued
Oil plug in the base

In some early versions of the robot, the oil plug for draining may be located in the
base, as shown in the figure below.
xx0300000065
A Oil plug in the base
Required equipment
Equipment, etc. Art. no. Amount Note

Lubricating oil See Type and See Type
amount of oil in and
gearboxes on amount of
page 163. oil in gear-
boxes on
page 163.
Oil collecting vessel Capacity: 8,000 ml.
Oil exchange equipment 3HAC17313-1 Content is defined in section
Special tools on page 422.
Other tools and proced- These procedures include refer-
ures may be required. See ences to the tools required.
references to these pro-
cedures in the step-by-
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.

3 Maintenance
Continued
Draining, oil, gearbox axis 1

The procedure below details how to drain the oil from the 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 166.
Action Note
1
WARNING

2
DANGER
Turn off all:

area.
3 Remove the rear cover on the base by unscrewing

its attachment screws.
4 Pull the oil hose out of the rear of the base.
Some early versions of the robot has the oil
draining plug in the base as shown in the figure
Oil plug in the base on page 166 instead of the
hose.
5 Place an oil vessel close to the hose end. Vessel capacity specified in Re-
6 Remove the oil plug, filling, in order to drain the
oil quicker!
7 Open the hose end and drain the oil into the ves-
sel. Note
CAUTION The draining is time-consuming.

Elapsed time depends on the tem-
Drain as much oil as possible. perature of the oil.
8 Close the oil drain hose, and put it back inside

the base.
9 Close the rear cover by securing it with its attach-
ment screws.

3 Maintenance
Continued
Filling, oil, gearbox axis 1

The procedure below details how to fill oil in gearbox, axis 1.
Action Note
1
WARNING

2
DANGER
Turn off all:

area.
3 Open the oil plug, filling. Shown in the figure Location of

4 Refill the gearbox with lubricating oil. Where to find type of oil and total
The amount of oil to be refilled depends on the amount is detailed in Type and
amount previously being drained. The correct oil amount of oil in gearboxes on
level is detailed in section Inspecting the oil level page 163.
in axis-1 gearbox on page 126.
5
WARNING

6 Refit the oil plug, filling. Tightening torque: 24 Nm.

3 Maintenance
Location of oil plugs

The axis-2 gearbox is located in the lower arm rotational center, underneath the
motor attachment.
E
A A
D D
B B
C C
xx0200000112
A Gearbox, axis 2
B Oil plug, filling/inspection (later design)
D Label, specifies the type of oil in the gearbox
E Oil plug, ventilation (later design)
The early design of the gearbox cover is shown in Oil plug, early design on page 129.
Required equipment

Lubricating oil See Type and See Type and Note! Do not mix with other oil
amount of oil in amount of oil in types!
gearboxes on gearboxes on
page 163. page 163.
Oil collecting vessel - Capacity: 5,000 ml.
Oil exchange equip- 3HAC021745-001 Content is defined in section
ment Special tools on page 422.

3 Maintenance
Continued
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
Action Note
1
DANGER
Turn off all:

2
WARNING

on page 38.
3 Remove the oil plug, draining, and drain the Shown in the figure Location of oil plugs
gearbox oil using a hose with nipple and an on page 169.
oil collecting vessel. Vessel capacity is specified in Required
CAUTION
Note
Drain as much oil as possible.
Draining is time-consuming. Elapsed
time varies depending on the temperat-
ure of the oil.
Filling, oil
Use this procedure to fill oil into the axis-2 gearbox.
Action Note
1
DANGER
Turn off all:

2
WARNING


3 Maintenance
Continued
Action Note
3 Remove the oil plug for filling and the plug from Shown in the figure Location of oil
the vent hole. plugs on page 169.
4 Refill the gearbox with clean lubricating oil. Where to find type of oil and total
The correct oil level is detailed in section Inspect- amount is detailed in Type and
ing the oil level in axis-2 gearbox on page 129. amount of oil in gearboxes on
page 163.
5
WARNING


3 Maintenance
Location of gearbox
The axis-3 gearbox is located in the upper arm rotational center as shown in the
following figure.
xx0200000113
A Gearbox, axis 3
B Oil plug, filling
D Label, specifies the type of oil in gearbox
Required equipment

Lubricating oil See Type and See Type Note! Do not mix with other oil
amount of oil in and types!
boxes on
page 163.

3 Maintenance
Continued

Oil exchange equipment 3HAC021745-001 Content is defined in section
Special tools on page 422.
Oil collecting vessel - Capacity: 5,000 ml.
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
Action Note
1
DANGER
Turn off all:

2
WARNING

on page 38.
3 Remove the oil plug, filling.

4 Remove the oil plug, draining, and drain the Shown in the figure Location of gearbox
gearbox oil using a hose with nipple and an on page 172.
oil collecting vessel. Vessel capacity is specified in Required
CAUTION
Note
Draining is time-consuming. Elapsed time
varies depending on the temperature of
the oil.

3 Maintenance
Continued
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 3.
Action Note
1
DANGER
Turn off all:

2
WARNING

3 Remove the oil plug, filling. Shown in the figure Location of

4 Refill the gearbox with clean lubricating oil. Where to find type of oil and
The correct oil level is detailed in section Inspecting total amount is detailed in Type
the oil level in axis-3 gearbox on page 132. and amount of oil in gearboxes
on page 163.
5
WARNING
Do not mix oil types! If wrong oil is refilled, the gear-

box must be rinsed as detailed in Technical reference
manual - Lubrication in gearboxes.
6
Note
Do not mix Kyodo Yushi TMO 150 with other oil types!

3 Maintenance
Different types of oil

The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 192.
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure
below.
xx0200000107
A Upper arm housing

B Cover, axis 4 gearbox
C Oil plug, filling, secondary gear
D Oil plug, draining, secondary gear
E Oil plug, filling, primary gearbox (draining not shown in figure, located further
down on the motor flange)
F Label, specifies the type of oil in the secondary gear
G Label, specifies the type of oil in the primary gear

3 Maintenance
Continued
Required equipment

Lubricating oil See Type and See Type
amount of oil in and
boxes on
page 163.
Oil collecting vessel, Capacity: 1,000 ml.
primary gearbox
Oil collecting vessel, Capacity: 4,000 ml.
secondary gearbox
Oil exchange equip- 3HAC17313-1 Content is defined in section Special
ment tools on page 422.
Standard toolkit - Content is defined in section Stand-
ard tools on page 421.
Draining, oil, gearbox axis 4

The procedure below details how to drain the oil from the gearbox, axis 4.
Action Note
1
WARNING

2 Open the oil plug, draining, secondary gear. Shown in the figure Location of
3 Drain the oil from the secondary gearbox by running Vessel capacity specified in Re-
the upper arm -45° from calibration position. quired equipment on page 176.
4 Run the robot back to its calibration position. Detailed in section Synchroniza-
tion marks and synchronization
5
DANGER
Turn off all:

6 Drain the primary gear by opening the oil plug, Vessel capacity specified in Re-
draining, primary gearbox. quired equipment on page 176.
CAUTION

3 Maintenance
Continued
Action Note
7 Refit the both oil plugs, draining. Tightening torque: 24 Nm.
Filling, oil, gearbox axis 4

Action Note
1
WARNING

2
DANGER
Turn off all:

3 Refill the secondary gear with lubricating oil through Where to find type of oil and total
the oil plug, filling, secondary gear. amount is detailed in Type and
page 163.
Shown in the figure Location of
4 Refill the primary gearbox with oil through the oil Kyodo Yushi TMO 150
plug, filling, primary gear. Make sure the air is Shown in the figure Location of
ventilated through the oil plug during filling, to avoid gearbox on page 175.
overpressure in the gearbox.
The amount of oil to be refilled depends on the Where to find type of oil and total
amount previously being drained. The correct oil amount is detailed in Type and
level is detailed in section Inspecting the oil level amount of oil in gearboxes on
in axis-4 gearbox on page 135. page 163.
5
WARNING

6 Refit the both oil plugs, filling. Shown in the figure Location of
Tightening torque: 24 Nm.

3 Maintenance

The primary and secondary gear may require different types of oil, that must never
be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a
contaminated gearbox on page 192.
Location of gearbox
The axis-5 gearbox is located in the wrist unit as shown in the following figure.
A
B
C
E F G
D
xx0200000108
A Wrist housing
B Oil plug, filling/inspection, primary gearbox
The oil plug for draining of the primary gearbox is on the opposite side of the
wrist housing, not shown in the figure.
C Label, specifies the type of oil in the axis-5 primary gearbox

3 Maintenance
Continued
D Oil plug, draining/inspection, secondary gearbox

E Label, specifies the type of oil in the axis-5 secondary gearbox
F Oil plug, filling, secondary gearbox
G Cover, axis-5 gearbox
Required equipment

Lubricating oil See Type and amount of
oil in gearboxes on
page 163.
Oil collecting vessel Capacity: 1 liter
Oil collecting vessel Capacity: 4 liters
Oil exchange equipment 3HAC17313-1 Content is defined in section Special
tools on page 422.
tools on page 421.
Note
Draining oil, axis-5 gearbox

The procedure below details how to drain the oil from the gearbox, axis 5.
Action Note
1
WARNING

2
DANGER
Turn off all:

3 Open the oil plug, draining, primary gearbox.

4 Drain the oil from the primary gearbox. Vessel capacity: 1 liter
5 Run axis 4 to a position +90° from the calibration
position.

3 Maintenance
Continued
Action Note
6 Open the oil plug, draining/inspection, secondary Shown in the figure Location of
gearbox. gearbox on page 178.
7 Drain the oil from the secondary gear. Vessel capacity: 4 liters
CAUTION
8 Refit the oil plugs. Shown in the figure Location of

Filling oil, axis-5 gearbox

Action Note
1
WARNING

2
DANGER
Turn off all:

3 Refill the primary gearbox with lubricating oil through Where to find type of oil and total
the oil plug, filling. Make sure the air is ventilated amount is detailed in Type and
through the oil plug during filling, to avoid overpres- amount of oil in gearboxes on
sure in the gearbox. page 163.
The amount of oil to be refilled depends on the Shown in the figure Location of
amount previously being drained. The correct oil gearbox on page 178.
level is detailed in section Inspecting the oil level in
4 Refill the secondary gearbox with lubricating oil Where to find type of oil and total
through the oil plug, filling. amount is detailed in Type and
The amount of oil to be refilled depends on the amount of oil in gearboxes on
amount previously being drained. The correct oil page 163.
level is detailed in section Inspecting the oil level in Shown in the figure Location of
axis-5 gearbox on page 138. gearbox on page 178.
5
WARNING


3 Maintenance
Continued
Action Note
6 Refit the oil plugs. Shown in the figure Location of

3 Maintenance
Location of gearbox
The axis-6 gearbox is located in the center of the wrist unit as shown in the following
figure.
xx0200000114
A Gearbox, axis 6
B Oil plug, filling/inspection (notice the different locations of the plug, shown as
B1 and B2)
C Oil plug, draining (can be located on the turning disk instead)
D Label, specifies the type of oil in gearbox axis 6
Required equipment

Lubricating oil See Type and See Type and
amount of oil in amount of oil in
gearboxes on gearboxes on
page 163. page 163.
Oil collecting vessel Vessel capacity: 1,000 ml.
Oil exchange equip- 3HAC17313-1 Content is defined in section
ment Special tools on page 422.

3 Maintenance
Continued

Note
Draining oil, gearbox axis 6

The procedure below details how to drain the oil in the gearbox, axis 6.
Action Note
1
WARNING

2 Move the wrist so that the oil plug, draining of axis Shown in the figure Location of
6 gearbox faces downwards. gearbox on page 182!
If the oil plug, draining is located on the turning
disc, rotate the disc so that the plug faces down-
wards.
3
DANGER
Turn off all:

area.
4 Drain the oil from gearbox 6 by removing the oil Vessel capacity: 1000 ml.
plug. Collect the oil with a suitable vessel.
CAUTION
Measure the amount of oil drained. The amount of oil to be refilled de-
pends on the amount previously
being drained. The correct oil level
is detailed in section Inspecting
the oil level in axis-6 gearbox on
page 141.

3 Maintenance
Continued
Filling oil, gearbox axis 6

The procedure below details how to fill oil in the gearbox axis 6.
Action Note
1
WARNING

2 Run the robot to a position where the oil plug,

filling (B1 or B2) of axis 6 gearbox, is facing up-
wards.
If the oil plug for draining is located on the turning
disk, rotate the disk so that the oil plug faces up-
wards.
3
DANGER
Turn off all:

area.
4 Remove the oil plug, filling. Shown in the figure Location of

5 Refill the wrist with lubricating oil. Where to find type of oil and total
Make sure the air is ventilated through the oil plug amount is detailed in Type and
during filling, to avoid overpressure in the gearbox. amount of oil in gearboxes on
If the plug hole for draining is located on the turn- page 163.
ing disk, the air is ventilated through the open plug
hole.
6
WARNING

7 Refit both oil plugs. Tightening torque: 20 Nm.

3 Maintenance
3.4.8 Replacing the SMB battery
Note
The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new
battery is 36 months if the robot is powered off 2 days/week or 18 months if the
robot is powered off 16 h/day. The lifetime can be extended for longer production
breaks with a battery shutdown service routine. See the operating manual for
the robot controller for instructions.
WARNING
See Hazards related to batteries on page 40.

3 Maintenance
Continued
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.
Battery pack with a 2-pole battery contact (DSQC)
xx0200000238
A SMB battery cover

B SMB battery pack with 2-pole battery contact.
C Battery cable

3 Maintenance
Continued
Battery pack with a 3-pole battery contact (RMU)
B
xx1300000308
A Battery pack RMU

B Battery holder
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole
battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not exchange battery contacts!

Battery unit For spare part no. Battery includes protection circuits. Only re-
see: place with a specified spare part or an ABB-
• Spare part approved equivalent.
lists on
page 427
Standard toolkit - Content is defined in section Standard tools
on page 421.
Circuit diagram - See chapter Circuit diagram on page 429.
Removing, battery
Use this procedure to remove the SMB battery.
Action Note
1 Move the robot to its calibration position. This is done in order to facilitate
updating of the revolution counter.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

space.
3
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 62
4 Remove the SMB battery cover by unscrewing the Shown in figure Location of SMB
attachment screws. battery on page 186.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Pull out the battery and disconnect the battery Shown in figure Location of SMB
cable. battery on page 186.
6 Remove the SMB battery. Shown in figure Location of SMB
Battery includes protection circuits. Only replace battery on page 186.
with a specified spare part or with an ABB- ap-
proved equivalent.
Refitting, battery
Use this procedure to refit the SMB battery.
Action Note
1
DANGER
Turn off all:

space.
2

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 62

3 Maintenance
Continued
Action Note
3 Reconnect the battery cable and install the battery Art. no. is specified in Required
pack into the SMB/battery recess. equipment on page 187.
Shown in figure Location of SMB
Note battery on page 186.
A
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
B
xx1300000308
A Battery pack RMU

B Battery holder
4 Secure the SMB battery cover with its attachment Shown in figure Location of SMB
screws. battery on page 186.
5 Update the revolution counters. Detailed in chapter Calibration -
section Updating revolution coun-
ters on IRC5 robots on page 380.
6
DANGER


3 Maintenance
3.5.1 Lubrication of spherical roller bearing, balancing device
3.5 Lubrication activities
Location of bearing
The spherical roller bearing is located at the front ear of the balancing device, as
shown in the figure below.
Note! The balancing device must be mounted on the robot when lubricating the
bearing!
xx0200000109
A Ear (spherical roller bearing located inside)

B Securing screw
C Sealing spacer
D Hole through which the shaft is pressed
Required equipment

Grease 3HAC042534-001 Tribol GR 100-0-PD, 150 ml

3 Maintenance
Continued

Lubrication nipple M6.
Grease pump -
Lubrication, balancing device bearing

The procedure below details how to lubricate the spherical roller bearing.
Action Note
1
DANGER
Turn off all:

space.
2 Replace the securing screw at the link ear M6

with a lubrication nipple.
3 Lubricate the spherical roller bearing through Art. no. and amount is specified in Re-
the lubrication nipple in the ear with grease, quired equipment on page 190!
approximately 5 grams. Shown in the figure Location of bearing
on page 190!
The balancing device must be mounted
on the robot when lubricating the
bearing!
4 Remove the lubrication nipple and refit the M6x10, washer: D=6.4/12 T=1.6
securing screw and washer. Tightening torque: 6 Nm.
5 Clean the area from any excessive grease Read more about the inspection in
and check the area once again after operation section Inspection, balancing device -
of the robot, in order to make sure there is Check for leakage on page 147.
no incorrect leakage from the o-rings.

3 Maintenance
3.6.1 Flushing a contaminated gearbox
3.6 Cleaning activities

As the Shell Tivela S 150 is not compatible with mineral oil, contamination with
other types of oils used in the gearboxes is not accepted. Equipment used in
handling of Tivela S 150 must be carefully cleaned.
This section details how to flush the primary gears of axis 4 and 5, and the gearbox
of axis 6 in case of contamination with other type of oil.
Required equipment

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
Amount: 700 ml for each gearbox and flush.
Three flushes required.
Oil collecting vessel -
Syringe + plastic hose - Dinside=4 mm, L= 400 mm.
Standard toolkit 3HAC15571-1 Content is defined in section Standard tools
on page 421.
Service program
Create a program with motions on axis 3, 4, 5 and 6. There is no need to remove
the tool and equipment installed on the robot if the Service program can be created
and is possible to run.
Recommended motion
• axis 3: ± 15 degrees
• axis 4-6: maximum working range with regard to the installation (limitation:
axis 4 and 5: ± 90 degrees, axis 6: ± 180 degrees).
Draining the gearbox properly

The contaminated gearbox must be drained properly before and during the flushing
procedure:
• Axis 4 gearbox: open both oil plugs (filling and draining) and run axis 3 in
different directions. Draw out the last volume (approx. 40 –60 ml) by using
a syringe with a prepared hose end.
• Axis 5 gearbox: open both oil plugs (filling and draining) and run axis 4 back
and forward until the oil draining has stopped.
• Axis 6 gearbox: open both oil plugs (filling and draining) and run axis 5 and
6 in different directions until the oil draining has stopped.

3 Maintenance
Continued
Flushing
The procedure below details how to flush a contaminated gearbox. The procedure
is the same for all gearboxes.
Action Note
1 Run the Service program until the castings of the Recommended service program
gearboxes axis 4, 5 and 6 have reached a temperat- described in section Service
ure of about 30-35º C. Use the finger tips to measure program on page 192.
the temperature.
2 Drain the gearbox properly. Described in section above:
Draining the gearbox properly
on page 192.
3 Fill the gearbox with 700 ml of lubricating oil. Kyodo Yushi TMO 150
Art. no . is specified in Required
5 Run the Service program at low speed (25%) during
10 minutes.
6 Drain the gearbox properly.
7 Repeat the steps above until the gearbox is flushed
three times.

3 Maintenance
3.6.2 Cleaning the IRB 7600
DANGER
Turn off all:

General
To secure high uptime it is important that the IRB 7600 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 7600.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 124.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.
Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.

3 Maintenance
Continued
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Foundry Plus Yes Yes. With light Yes. It is highly re- Yes i .
cleaning deter- commended that It is highly recommended
gent or spirit. the water contains that the water and steam
a rust-prevention contains rust preventive,
solution. without cleaning deter-
gents.
i Perform according to section Cleaning with water and steam on page 195.
Cleaning with water and steam

Instructions for rinsing with water
ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
1 See Cleaning methods on page 195 for exceptions.
2 See Cleaning methods on page 195 for exceptions.

3 Maintenance
Continued
• Clean the cables if they have a crusty surface, for example from dry release
agents.
Cooling fans
Inspect the air supply inlet of the the motor cooling fans. Clean to remove any
contamination that could hinder the air supply.

3 Maintenance
3.7.1 Using the SIS system
3.7 Service Information System, M2000
3.7.1 Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS for
M2000 robot systems. Details may be found in:
• Service Information System, SIS
• Defining the SIS input parameters
• Setting the SIS parameters
• Importing/exporting SIS data
• Reading the SIS output logs
The section is only valid for M2000 systems. For information regarding M2004
robot systems, see additional documentation, Operating manual - Service
Information System. Article number is specified in section References on page 10.
Basic procedure
Action Reference
1 Determine which of the system functions These are described in Description of
you require. Service Information System (SIS) on
page 198.
2 Define what values are adequate and suit- Recommendations on how to define these
able for your application in your production are given in SIS system parameters on
environment. page 201.
3 Enter these parameters in the system. How to do this is detailed in Setting the
SIS parameters on page 202.
4 Run the robot in normal operation.
5 Reset the counter if a repair is made, or if a The TPU displays for resetting any SIS
counter for any other reason is restarted. value are shown in Description of Service
Information System (SIS) on page 198.
6 When a time limit, set in the parameters, is How to access this is detailed in Reading
exceeded, a message may be read on the the SIS output logs on page 203.
Tech Pendant Unit (TPU).
7 If the log containing the message is to be These are described in Exporting the SIS
available from an external PC, or if the SIS data on page 204.
parameters are to be entered from an extern-
al PC, a set of software tools are available
to build such an application.

3 Maintenance
3.7.2 Description of Service Information System (SIS)
General
Service Information System (SIS) is a software function within the robot controller,
which simplifies maintenance of the robot system. It supervises the operating time
and mode of the robot, and alerts the operator when a maintenance activity is
scheduled.
Maintenance is scheduled by setting the system parameters of the type SIS
Parameters, see section Setting the SIS parameters on page 202. All system
parameters are described in User´s Guide - System Parameters.
Supervised functions
The following counters are available:
• Calendar time counter, a general alarm based on calendar time
• Operation time counter, a general alarm based on operational time
• Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox
service interval
service interval
service interval
service interval
Counters are reset when maintenance has been performed.
The counter status is displayed after running the service routine for maintenance.
Status “OK” indicates that no service interval limit has been exceeded by that
counter.
Calendar time
This is a clock within the control system that keeps track of the service interval,
based on calendar time.
When the calendar time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 203.
The following information is available about the calendar time in the service routine.
Prev service Date when the counter was reset last time, i.e. after the last service.
Elapsed time Elapsed time since the counter was reset the last time.
Next service Date when next scheduled service is planned. This date is calcu-
lated using system parameters, as detailed in section Setting the
SIS parameters on page 202.
Remaining time Remaining time to next scheduled service date.

3 Maintenance
Continued
Operation time
This is a function within the control system that keeps track of the amount of time
the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the
operating mode.
When the operation time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 203.
The following information is available about the operation time in the service routine.
Service interval The specified service interval until another service will be required.
This parameter was entered manually as detailed in section Setting
the SIS parameters on page 202.
Elapsed time Operation time since the service interval was set the last time.
Remaining time Remaining operation time until the time set in service interval has
expired.
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an
expected service interval for each gearbox. When service is due, a message will
be shown on the TPU. How to access this is detailed in section Reading the SIS
output logs on page 203.
The following information is available about the joint service status in the service
routine.
Joint x OK Service status for axis x, i.e. the automatically calculated time
parameter has not been exceeded.
Joint x NOK The service interval for the axis in question has been reached.
Joint x N/A No service time parameter calculation available.
Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
The following information is available for the axis service status in the service
routine.
Consumed time The consumed time as a percentage of the total amount of time.
Elapsed time Operation time for axis x since calculation began.
Remaining time Remaining operation time for axis x until the service time parameter
value has been reached.
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in
section Exporting the SIS data on page 204!
Service interval exceeded

When the service time has been exceeded for the selection made, an error message
(Service interval exceeded!) is displayed.

3 Maintenance
Continued
No data available
When no data is available for the selection made, a message (No data available!)
is displayed when trying to display the data.

3 Maintenance
3.7.3 SIS system parameters
3.7.3 SIS system parameters
General
This section details the system parameters that may be set with estimated values.
The values can be defined by the operating organization as knowledge of the
robot's working conditions are accumulated.
Since the counters are to be used for purposes defined by the user, ABB cannot
give any recommendations regarding their definitions.
Operation time limit (service level)

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

A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an
operation time "Reset" was made the last time.
Calendar time limit (service level)

The number of calendar years selected as service interval.
E.g. by setting the value "2", the SIS will save this as the nominal time for activating
the alarm, not counting the percentage described below.
Calendar time warning

A percentage of the "Calendar time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator after 90% of two years,
i.e. 657 days after a calendar time "Reset" was made the last time.
Gearbox warning
A percentage of the gearbox service interval as calculated by the system. E.g. by
setting the value "90", the SIS will alert the operator after 90% of the expected
service interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate
the expected service interval (estimated remaining lifetime) of each gearbox. This
is done by extrapolating data from earlier operation into a function of time, using
a formula including:
• input and output torque
• gearbox spindle speed
• other variables

3 Maintenance
3.7.4 Setting the SIS parameters
3.7.4 Setting the SIS parameters
General
If the SIS system is to function properly, a number of parameters must be set. This
is detailed below.
Procedure M2000
This is an instruction of how to enter SIS parameters to the M2000 robot system.
Action Note
1 Open "System parameters" Detailed in the User's Guide.
using the TPU.
2 Go to "System paramet-
ers/Manipulator/types 2".
3 Select "0 SIS parameters"
and press "Enter".
4 Select the required system
The parameter list is dis-
played.
5 Select the required paramet- Available parameters are described in section SIS system
ers by stepping up and parameters on page 201.
down through the parameter
list.

3 Maintenance
3.7.5 Reading the SIS output logs
3.7.5 Reading the SIS output logs
General
Whenever a set condition has expired (e.g. max allowed operation time before
service), a message to this effect will be shown in the Operational log.
Access to logs
How to open a log and show its contents is detailed in the User's Guide, chapter
Service.
Available messages
The following messages may be shown:
Available in: SIS message in the Meaning:
log:
Calendar time Service Message The manually set calendar time limit has expired.
Service is due! How to set the limit is detailed in section Setting
X calendar days
since last service. Proceed with the required service as detailed in
chapter Repair on page 205 or chapter Maintenance
on page 117 depending on which type of service.
Calendar time Service Message X number of calendar days remain until the
X calendar days to manually set calendar time limit expires.
next service. How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
Operation time Service Message The manually set operation time limit has expired.
Service is due! How to set the limit is detailed in section Setting
X production hours
since last service. Proceed with the required service as detailed in
Operation time Service Message X number of operation hours remain until the
X production hours manually set operation time limit expires.
to next service. How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
Gearbox time Service Message The automatically calculated gearbox time limit
Gearbox x requires has expired.
service! Proceed with the required service as detailed in
Gearbox time Service Message X percent of gearbox hours remain until the auto-
X% of the service in- matically calculated gearbox time limit expires.
terval has expired for How to set the value determining when the mes-
gearbox x! sage is to be shown, is detailed in section Setting

3 Maintenance
3.7.6 Exporting the SIS data
3.7.6 Exporting the SIS data
General
This section describes the available variables for entering SIS parameters as well
as showing any values of exceeded time limits as detected by the SIS counters.
In a M2000 robot system, the values can be read on a PC using "Webware SDK".
How to access these variables and how to perform the actual programming
sequences are detailed in the robot system User's Guide.
Definitions
The table below defines the names and functions of all software variables available
for communication between the SIS and an external computer.
Signal Unit Counter type Function
sisRestartDate seconds Calendar time The date on which the supervision was star-
ted/reset last time.
sisCalendarT seconds Calendar time The number of hours since start/last reset.
sisTotRunT seconds Operation time Total number of operation hours since the
system was started. Corresponds to the oper-
ating time counter on the control cabinet.
sisRunT seconds Operation time The number of operation hours since start/last
reset of the operation time counter. Corres-
ponds to the operating time counter on the
control cabinet.
sisL10h_1 hours Gearbox time Estimated life of gearbox axis 1
sisL10h_Time_1 seconds Gearbox time Operation time of gearbox axis 1
sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6

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

This chapter describes repair activities for the IRB 7600. Each procedure contains
the information required to perform the activity, for example spare parts numbers,
required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Report replaced units
Note
When replacing a part on the IRB 7600, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 23 before commencing any
service work.
Note
If the IRB 7600 is connected to power, always make sure that the IRB 7600 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.

4 Repair
4.2.1 Performing a leak-down test
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test

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.
The gearbox must be drained of oil before performing the leak-down test.
Required equipment

Leak-down tester -
Leak detection spray -
Performing a leak-down test
Action Note
1 Finish the refitting procedure of the motor or gear in
question, but do not refill the gearbox with oil before
performing the leak-down test.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher

than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
4 Disconnect the compressed air supply.

5 Wait for approximately 8-10 minutes and make sure If the compressed air is signific-
that no pressure loss occurs. antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
6 If any pressure drop occurred, then localize the leak
as described in step 7.
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
7 Spray any suspected leak areas with the leak detec-
tion 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 describes how to mount and grease different types of bearings on the
robot.
Equipment

Grease 3HAC042536-001 Shell Gadus S2
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Attend to the following instructions while 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 the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
3 Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure 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 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 durab-
ility of the bearing.
Greasing of bearings
Note
This instruction is not valid for solid oil bearings.

4 Repair
Continued
The bearings must be greased after assembly according to the following

instructions:
• 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 following description:
• 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 sealings
General
This section describes how to mount different types of sealings.
Equipment
Consumable Article number Note

Rotating sealings
The following procedures describe how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:

• Protect the sealing during transport and mounting, especially the main lip
on radial sealings.
• Keep the sealing in its original wrappings or protect it well before actual
mounting.
• The fitting of sealings and gears must be carried out on clean workbenches.
• Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
Radial sealings
A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only
one side of the sealing is static with a metal insert.
xx2300000433
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.

4 Repair
Continued
Action Note
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 209.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap

4 Repair
Continued
Flange sealings and static sealings

The following procedure describes how to fit flange sealings and static sealings.
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 com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes 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, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
3 Check the o-ring grooves and mating surfaces.
They should be free of pores, contamination
and obvious scratches/damage.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.

4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Standard/Foundry 3HAC067974-001 Graphite White
Plus
Touch up paint Standard/Foundry 3HAC037052-001 ABB Orange
Plus
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx2300000950
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

4 Repair
4.2.5 The brake release buttons may be jammed after service work
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the 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.
DANGER
If 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 Verify that the push-buttons of the brake release unit are working 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.

4 Repair
4.3.1 Replacement of cable harness, axes 1-4
4.3 Complete robot
Location of cable harness

The cable harness for axes 1-4 is run throughout the base, frame and lower arm
as shown in the figure below.
The brake release unit can be located at two alternative places, either at the rear
of the base or at the side of the frame. Depending on the location, the two types
of harnesses are distinguished some from each other! Any differences are pointed
out in the procedures!
xx0100000140
1 Alternative with brake release at frame

2 Alternative with brake release at base
A Connector at robot base, R1.MP and R1.SMB
B Connectors at motor 1; R2.FB1 and R2.MP1
C Connectors at motor 2; R2.FB2 and R2.MP2
D Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release
located at the frame: also connectors X8, X9 and X10!

4 Repair
Continued
E Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and
R2.H2
F Connectors at motor 4; R2.FB4 and R2.MP4
G Connectors at cable harness separation; R2.M5/6
H Connectors at motor 5; R3.FB5 and R3.MP5
J Connectors at motor 6; R3.FB6 and R3.MP6
K Rear cover plate
L Connector R1.MP
M Connector R1.SMB
N Connection of earth cable
Required equipment

Cable harness, axes 1-4 3HAC12782-1 Brake release located at
base.
Cable harness, axes 1-4 3HAC14940-1 Brake release located in
frame.
Locking liquid Loctite 243
Used to secure the attach-
ment screws for the attach-
ment plate inside the frame.
Other tools and proced- These procedures include
ures may be required. See references to the tools re-
references to these proced- quired.
ures in the step-by-step
instructions below.
Circuit diagram See chapter Circuit diagram
on page 429.
Removal, cable harness, axes 1-4

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

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

3 Remove the rear cover plate from the robot by remov- Shown in the figure Location of
ing its attachment screws. cable harness on page 214.
4 Disconnect the earth cable. Attachment point is shown in the
figure Location of cable harness
on page 214!
5 Disconnect connectors R1.MP and R1.SMB. Attachment points are shown in
the figure Location of cable har-
ness on page 214.
6 Pull the cable and connectors up through the cable
guide in the center of the frame.
7 Disconnect all connectors at motors 1 and 2. Specified and shown in the figure
Location of cable harness on
page 214!
8 Open the SMB cover carefully.
The cable between the battery and the SMB-unit may
stay connected, in order to avoid an update of the
revolution counter. Be careful not to let the weight
of the cover strain the cable!
In order to remove the cover completely, the connect-
or R1.G must be disconnected! This causes a neces-
sary updating of the revolution counter!
9 Disconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 from the SMB unit.
Disconnect X8, X9 and X10 if the brake release board
is located in frame.
xx0200000118

4 Repair
Continued
Action Note
10 Remove
• the cable gland (A), by removing the four at-
tachment screws from inside the SMB recess
(B)
• the attachment plate (C), by removing the at-
tachment screws and the velcro strap (D).
Note
Different robot versions are fitted with different ver-

sions of the attachment plate. When replacing the
cable harness, make sure the correct one is used to
avoid cable failure.
xx0300000560
• A: Cable gland
• B: Attachment screws,
cable gland
• C: Attachment plate
• D: Velcro strap
11 Remove the cable gland securing the cables inside
the lower arm.

4 Repair
Continued
Action Note
12 Remove the cable gland securing the cables to the
arm house.
xx0100000143
13 Remove the velcro strap from the harness at the Shown in the figure Location of
cable fixing bracket at the arm house. cable harness on page 214.
14 Disconnect connector R2.M5/6 at the cable division Shown in the figure Location of
point. cable harness on page 214!
15 Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
page 214!
16 Gently pull the cable harness out.
Refitting, cable harness, axes 1-4

The procedure below details how to refit the cable harness, axes 1-4.
Action Note
1
DANGER
Turn off all:

2 In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly
move the robot to the specified position: to improve access.
• Axis 1: 0 degrees
• Axis 5: +90 degrees

4 Repair
Continued
Action Note
3 Pull the cable and connectors down through the Make sure the cables are not twis-
cable guide in the center of the frame. ted with each other or with eventual
customer harnesses!
Make a note of the correct positions
of the connectors!
4 Reconnect connectors R1.MP and R1.SMB at the Tightening torque for R1.SMB: 10
rear cover plate. Nm.
Make a note of the correct positions
of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 214.
5 Reconnect the earth cable. Attachment point is shown in the
figure Location of cable harness on
page 214!
6 Refit the rear cover plate to the robot with its at- Shown in the figure Location of
tachment screws. cable harness on page 214.
7 Reconnect all connectors at motors 1 and 2. Specified and shown in the figure
page 214!

4 Repair
Continued
Action Note
8 Secure the cable gland (A) with four attachment Locking liquid is specified in Re-
screws (B) from inside the SMB recess. quired equipment on page 215.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws, using
locking liquid.
Refit the velcro strap (D).
Note
Different robot versions are fitted with different

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

4 Repair
Continued
Action Note
9 Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 if the brake release
board is located in frame.
Reconnect R1.G if it has been disconnected.
xx0200000118
10 Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
11
WARNING
Before continuing any service work, please ob-

serve the safety information in section The brake
release buttons may be jammed after service work
on page 213!
12 Pull the cable harness through the lower arm.

13 Refit the cable gland securing the cables inside
the lower arm.
xx0100000142
14 Refit the cable gland securing the cables to the

arm house.
Make sure not to twist the harness!
xx0100000143

4 Repair
Continued
Action Note
15 Reconnect all connectors at motor 3 and motor Specified and shown in the figure
4. Location of cable harness on
page 214!
16 Reconnect the connector R2.M5/6 gently at the Shown in the figure Location of
cable division point. cable harness on page 214!
Be careful not to bend the attachment plate when M6, 2 pcs.
fastening the screws!
17 Secure the cable harness to the upper arm house Shown in the figure Location of
by refitting the velcro strap to the cable bracket cable harness on page 214!
at the upper arm house.
18 Fit a cable protection to the lower arm, if not
already mounted, with two securing screws (A),
M6x16.
A
xx0500002320
19 Secure the cable harness with five velcro straps

(B), according to the figure. Fix the strap by
wrapping it two turns around the largest cable
before wrapping around the complete harness.
B
xx1900001419
20 Refit the cable harness to the guide plate axis 2. Shown in the figure Location of
cable harness on page 214.
21 Refit the velcro strap at the guide plate axis 2. Shown in the figure Location of
cable harness on page 214.
22 Make an overall inspection of the installed cable See Inspecting the cable harness
harness. on page 150.

4 Repair
Continued
Action Note
23 If the connection between the SMB battery and Detailed in the Calibration chapter
the SMB unit has been broken, the revolution - section Updating revolution coun-
counters must now be updated! ters on IRC5 robots on page 380.
24
DANGER


4 Repair
Location of cable harness ax 5-6

The location of the cable harness, axes 5-6, is shown in the figure below.
xx0100000145
A Cable attachment, upper arm

B Cable attachment, rear
C Connector at cable harness division; R2.M5/6
D Connectors at motor 5; R3.FB5 and R3.MP5
E Connectors at motor 6; R3.FB6 and R3.MP6
Required equipment

Cable harness ax.5-6 3HAC11440-1
Gasket 3HAC033489-001 Recommended to be changed for
Foundry Plus robots.
tools on page 421.

4 Repair
Continued

page 429.
Removal, cable harness, axes 5-6

The procedure below details how to remove the upper arm cable harness.
Action Note
1 Position the upper arm as follows:
2
DANGER
Turn off all:

3 Remove the left hand side wrist cover by unscrewing its

attachment screws.
4
Note
Axis 5 must be oriented in the correct position (+90º) to

allow the motor 6 cover to open!
5 Disconnect all connectors at motor 5 and motor 6. Specified in the figure Loca-
tion of cable harness ax 5-6
on page 224.
6 Remove the plastic cover on the rear of the upper arm,
by removing the attachment screws.
7 Remove the spiral plate by unscrewing the screw at the
bottom of the spiral cup.
8 Remove eventual cable straps from the harness.
9 Disconnect connector R2.M5/6 at the cable harness di- Shown in the figure Location
vision. of cable harness ax 5-6 on
page 224.
10 Remove the cable attachment inside the upper arm.
11 Gently pull the cable harness out.
Refitting, cable harness, axes 5-6

The procedure below details how to refit the upper cable harness.
Action Note
1 Position the upper arm as follows:

4 Repair
Continued
Action Note
2 Gently insert the cable harness from the rear into
the upper arm.
3 Pull the small spiral plate past motor 5.
4 Route the cables outside the heat protection plate.
5 Secure the small plate to the large plate. Secure the
spiral cup with its attachment screw in the bottom
of the cup.
6 Secure any excess cable length tightly to the large Excess cable length may be
plate in the wrist housing, using cable straps. present if upper arm length is not
Use the attachment holes in the large plate intended the maximum.
for the cable straps!
7 Reconnect all connectors at motor 5 and motor 6. Specified in the figure Location
of cable harness ax 5-6 on
page 224.
8 Secure the cable with the cable attachment inside
the upper arm.
9 Refit the left hand side wrist cover with its attach- Tightening torque: 14 Nm.
ment screws. Add Loctite to screw before
fastening. Screw 3HAB3409-25,
Washer 3HAC062379-001
10 Reconnect connector R2.M5/6 gently at the cable Shown in the figure Location of
harness division with two screws, M6. cable harness ax 5-6 on page 224.
Be careful not to bend the attachment plate when M6, 2 pcs.
11 Refit the plastic cover on the rear of the upper arm.
12 Make an overall inspection of the installed cable See Inspecting the cable harness
harness. on page 150.
13 Update the revolution counters. Detailed in section Updating re-
volution counters on IRC5 robots
on page 380.

4 Repair
4.3.3 Replacement of complete arm system
Location of complete arm system

The complete arm system is defined as the complete robot except for the base
and gearbox axis 1, that is the upper and lower arms, balancing device and frame.
This is shown in the figure below.
xx0100000150
A Gearbox, axis 1
B Motor, axis 1
C Base attachment screws
D Upper arm
E Lower arm
F Frame

4 Repair
Continued
G Balancing device
H Block for calibration
Required equipment

Lifting device, robot 3HAC15607-1 Instruction 3HAC15971-2 enclosed!
Guide pins, M12 x 130 - Used to guide the complete arm sys-
tem when refitting.
Other tools and procedures These procedures include references
may be required. See refer- to the tools required.
below.
Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 386.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, complete arm system

The procedure below details how to lift and remove the complete arm system.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning the
repair procedure.

4 Repair
Continued
Action Note
2 Position the robot in its most stable position, If the brakes need to be released, see
as shown in the figure to the right. section Manually releasing the brakes
on page 73.
xx0100000103
3
DANGER
Turn off all:

area.
4 Drain the oil from the gearbox, axis 1. Detailed in section Changing oil, axis-
1 gearbox on page 165.
5 Disconnect the cabling in the rear of the robot
base and remove the cable support plate inside
of the base.
6 Pull the disconnected cabling up through the
center of the axis-1 gearbox.
axis 1 on page 293.
8 Run the overhead crane to a position above
the robot.
9
CAUTION
The complete arm system weighs 2000 kg! All

lifting equipment used must be sized accord-
ingly!
10 Fit the lifting device and adjust it as detailed Art. no. is specified in Required
in enclosed instruction. equipment on page 228!
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!
11 Remove the block for calibration from the bot- Shown in the figure Location of com-
tom of the frame. plete arm system on page 227!

4 Repair
Continued
Action Note
12 Remove the arm system from the base by un- Shown in the figure Location of com-
screwing the 24 base attachment screws. plete arm system on page 227!
13 Lift the arm system and secure it in a safe area. Make sure all hooks and attachments
maintain in correct position while lifting
the robot!
Refitting, complete arm system

The procedure below details how to refit the complete arm system to the robot.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot
working area.
2
CAUTION
The complete arm system weighs 2000 kg!

All lifting equipment used must be sized
accordingly!
3 Fit and adjust the lifting device as detailed Art. no. is specified in Required equip-
in enclosed instruction. ment on page 228.
4 Lift the complete arm system and move it Make sure all the hooks and attachments
at very low speed, making sure it does not maintain in correct position while lifting
tip! the robot!
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
5 Fit two guide pins, M12 x 130, in the frame
attachment holes as shown in the figure to
the right.
Fit one guide pin next to the guiding hole
(for the spring pin in the gearbox) and the
other guide pin straight across the frame.
xx0300000070
The figure above shows a view from be-

low of the frame.
A Attachment holes for the guide
pins, M12.
B Guiding hole for the spring pin loc-
ated in the gearbox, axis 1.

4 Repair
Continued
Action Note
6 Look through the empty mounting hole of This is a complex task to be performed
motor axis 1, to assist in aligning the as- with outmost care in order to avoid injury
sembly during refitting of the arm system. or damage!
The guiding pin in the gearbox must be fitted
to the guiding hole of the frame (B).
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
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 complete
system to the base with the 24 base attach- arm system on page 227.
ment screws and washers. 24 pcs, M12 x 110; 12.9 quality UN-
BRAKO, tightening torque: 110 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 417 before fitting.
9 Refit the block for calibration at the bottom Shown in the figure Location of complete
of the frame. arm system on page 227.
10 Refit the motor, axis 1. Detailed in section Refitting, motor axis
1 on page 294.
11 Perform a leak-down test. Detailed in section Performing a leak-
down test on page 206.
12 Refill the gearbox axis 1 with lubricating oil. Detailed in section Filling, oil, gearbox
axis 1 on page 168.
13 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 385.
General calibration information is included
in section Calibration on page 373.
14
DANGER
Make sure all safety requirements are met

when performing the first test run. See Test
run after installation, maintenance, or repair
on page 116.

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

The turning disk is located in the center of the wrist unit as shown in the figure
below.
xx0100000129
A Turning disk
B Oil plug, filling (oil plug for draining is located on the opposite side of the tilt-
house)
C Turning disk attachment screws, 33 pcs
Required equipment

Turning disk, dia. 250 3HAC13193-1 Does not include o-ring!
Turning disk, insulated 3HAC023124-002
O-ring 3HAB3772-83 Must be replaced when repla-
cing the turning disk!
Grease 3HAC042536- Used to lubricate the o-ring.
001

4 Repair
Continued

ures may be required. references to the tools re-
See references to quired.
these procedures in
the step-by-step in-
structions below.
Removing turning disk

Use the procedure to remove the turning disk.
Action Information
1
DANGER
Turn off all:

• hydraulic pressure supply to the ro-
bot
2 Drain the oil from gearbox 6. Detailed in section Changing oil, axis-6
3 Remove the attachment screws (33 pcs) Shown in the figure Location of turning
securing the turning disk. disk on page 232.
4 Remove the turning disk.
xx1000001135

4 Repair
Continued
Refitting turning disk

Use this procedure to refit the turning disk.
Action Information
1
DANGER
Turn off all:

bot
2 Lubricate the o-ring with grease and fit it to Art. no. is specified in Required equipment
the rear of the turning disk. on page 232.
xx0100000130
O-ring, turning disk

3 Secure the turning disk with its attachment Attachment screws:
screws. • M10 x 25, 12.9 quality UNBRAKO
• Tightening torque: 50 Nm.
4 Refill the gearbox, axis 6, with oil.

4 Repair
Continued
Action Information
5
DANGER

on page 116.

4 Repair
4.4.2 Replacement of complete wrist unit
Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm as shown in the
figure below.
A more detailed view of the component and its position may be found in Exploded
views in Product manual, spare parts - IRB 7600.
xx0100000147
A Wrist unit
B Wrist unit attachment screws and washers
C Attachment, cable harness axis 5-6
D Connectors at cable harness division; R2.M5/6
E Turning disk
F Cover, axis 5
G Rear cover
H View with cable harness mounted on robot
Required equipment

Wrist For spare part num-
ber, see Spare part
lists on page 427.

4 Repair
Continued

Friction washer 3HAC11755-1 A new friction washer must always
be used when refitting the wrist
unit.
Lifting tool, wrist unit 3HAC12734-1
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes op-
erating manual.
Required if Calibration Pendulum
is the valid calibration method for
the robot.
Calibration tool box, Axis Calibra- 3HAC055412-001 Delivered as a set of calibration
tion tools.
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
Circuit diagram - See chapter Circuit diagram on
page 429.

Action Note
calibration:

4 Repair
Continued
Removal, wrist unit

The procedure below details how to remove the complete wrist unit.
Action Note
1 Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
2
DANGER
Turn off all:

3 Remove all equipment fitted to the turning disk.

4 Turn axis 4 to a position where the cover, axis 5 Shown in the figure Location of
faces upwards. wrist unit on page 236.
5 Remove the cover, axis 5, by unscrewing its attach-
ment screws.
6
CAUTION
The complete wrist unit weighs 200 kg! All lifting

7 Fit the lifting tool, wrist unit to the two holes on the Art. no. is specified in Required
sealing surface against the cover, axis 5. equipment on page 236.
If required, cut any cable ties
securing the cables in order to
fit the tool.
8 Remove the rear cover by unscrewing its attach- Shown in the figure Location of
ments. wrist unit on page 236.
9 Disconnect connector R2.M5/6 at the rear cable divi- Shown in the figure Location of
sion point. wrist unit on page 236.
10 Remove all cable attachment inside the upper arm Do not remove the attachments
and at the rear of the robot. from the cabling!
11 Slightly raise the wrist unit to unload the screw joint,
facilitating removal of the attachment screws.
12 Remove the wrist unit attachment screws and wash-
ers.
13 Pull the cabling forwards through the upper arm tube. Make sure the attachments do
not get stuck inside the tube!
14 Remove the friction washer between the wrist unit A new washer must always be
and the upper arm tube. used on reassembly.
15 Lift the wrist unit down and place it on a secure sur-
face.

4 Repair
Continued
Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
Action Note
1
DANGER
Turn off all:

2
CAUTION
The complete wrist unit weighs 200 kg! All lifting

3 Remove the cover, axis 5 from the wrist unit to be Art. no. is specified in Required
fitted. Fit the lifting tool, wrist unit to the wrist unit. equipment on page 236.
4 Lift the wrist unit and move it to its mounting posi-
tion.
5 Fit a new friction washer between the upper arm Art. no. is specified in Required
tube and the wrist unit. equipment on page 236.
6 Gently pull the wrist unit cable harness through the
upper arm and out the rear.
7 Secure the wrist unit with its attachment screws and Screws: M12 x 50, UNBRAKO
washers. quality 12.9, tightening torque:
115 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints
on page 417 before fitting.
8 Secure the cable harness with the cable attachment Make sure the cabling is not twis-
inside the upper arm as well as at the rear of the ted!
upper arm.
9 Remove the lifting tool and refit the cover, axis 5 Shown in the figure Location of
with its attachment screws. wrist unit on page 236.
10 Refit any cable ties that were previously cut during
disassembly.
11 Reconnect connector R2.M5/6 at the rear cable di- Shown in the figure Location of
vision point. wrist unit on page 236.
12 Refit the rear cover with its attachment screws. Shown in the figure Location of
wrist unit on page 236.
13 Check the oil levels at gearboxes axis 5 and 6. Detailed in sections:
• Inspecting the oil level in
axis-5 gearbox on page 138
• Inspecting the oil level in
axis-6 gearbox on page 141

4 Repair
Continued
Action Note
14 Re-calibrate the robot. Pendulum Calibration is described
in Operating manual - Calibration
Pendulum, enclosed with the cal-
ibration tools.
Axis Calibration is described in
Calibrating with Axis Calibration
method on page 385.
General calibration information is
included in section Calibration on
page 373.
15 Refit any equipment previously removed from the
turning disk.
16
DANGER

performing the first test run. See Test run after in-
stallation, maintenance, or repair on page 116.

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

The upper arm is located on top of the robot as shown in the figure below.
A more detailed view of the component and its position may be found in chapter
Exploded views in Product manual, spare parts - IRB 7600.
xx0100000148
A Upper arm
B Attachment screws, upper arm
C Connectors at cable harness division; R2.M5/6
D Rear cable attachment
E Oil plug, draining
F Oil plug, filling
G Attachment hole, M12
H Sealing between lower arm and gearbox 3
J Attachment holes for lifting device, upper arm
K Attachment holes for lifting eye

4 Repair
Continued
Required equipment

Sealing, axis 2/3 3HAC17213-1 Always use a new sealing
when reassembling!
Washer 3HAC11828-1 Replace if damaged!
Lifting eye, M12 3HAC14457-3
Lifting device, upper arm 3HAC15536-1
Lifting tool (chain) 3HAC15556-1
Hoisting block - Standard hoisting block, capa-
city 200 kg.
Guide pins, sealing axis 2/3 3HAC14627-2 80 mm.
For guiding "Sealing, axis 2/3".
Guide pins, sealing axis 2/3 3HAC14627-3 100 mm
For guiding "Sealing, axis 2/3".
Other tools and procedures may be These procedures include ref-
required. See references to these erences to the tools required.
procedures in the step-by-step in-
structions below.

Action Note
calibration:

4 Repair
Continued
Removal, upper arm

The procedure below details how to remove the complete upper arm.
Action Note
1 Decide which calibration routine to use, and take ac-
tions accordingly prior to beginning the repair proced-
ure.
2 Run the upper arm to a horizontal position.
3
DANGER
Turn off all:

4
CAUTION
The complete upper arm weighs 450 kg without any

additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
5 Fit the lifting eye to the attachment hole in the wrist Shown in the figure Location of
unit. upper arm on page 241.
Art. no. is specified in Required
6 Fit one of the pieces included in the lifting device, Shown in the figure Location of
upper arm to the attachment holes for lifting device, upper arm on page 241.
upper arm using the included attachment screws. Art. no. is specified in Required
7 Run the lifting chain from the rear lifting point through Art. no. is specified in Required
the overhead crane hook, through the hoisting block equipment on page 242.
to the lifting eye in the front.
8 Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
9 Drain the oil from gearbox 3. Detailed in section Changing
oil, axis-3 gearbox on page 172.
10 Disconnect connector R2.M5/6 at the rear cable divi-
sion point as well as all remaining connections to the
upper arm.
11 Disconnect all connectors inside motors 3 and 4.
12 Remove all brackets securing cabling to the upper
arm by unscrewing their attachment screws respect-
ively.
13 Raise the lifting equipment to take the weight of the
upper arm.
14 Carefully remove the upper arm attachment screws . Shown in the figure Location of
Make sure that the upper arm is lifted in a completely upper arm on page 241.
level position in all planes in order not to damage the 30 pcs.
upper arm!
15 Lift the upper arm and place it on a secure surface.

4 Repair
Continued
Action Note
16 Remove the sealing from the lower arm.
Refitting, upper arm

The procedure below details how to refit the upper arm to the robot.
1
DANGER
Turn off all:

2 Fit the new sealing, axis 2/3 onto the axis-3 gearbox Always use a new sealing when
and keep it in place by also fitting the two guide reassembling!
pins, sealing axis 2/3 in two of the attachment screw Art. no. is specified in Required
holes on the gearbox, see figure to the right. equipment on page 242.
xx0200000125
Holes for guide pins in the

gearbox.
3
CAUTION
The complete upper arm weighs 450 kg without any

additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
4 Fit the lifting eye to the attachment hole in the wrist Shown in the figure Location of
unit. upper arm on page 241.
5 Fit one of the pieces included in the lifting device, Shown in the figure Location of
upper arm to the attachment holes for lifting device, upper arm on page 241.
upper arm using the included attachment screws. Art. no. is specified in Required
6 Run the lifting chain from the rear lifting point Art. no. is specified in Required
through the overhead crane hook, through the equipment on page 242.
hoisting block to the lifting eye in the front.

4 Repair
Continued
7 Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
8 Lift the upper arm and move it to its mounting posi-
tion.
9 Fit the three washers to be placed beneath the at- Make sure the washers are not
tachment screws. scarred or pitted in the surface
facing the screw heads. If both
washer sides are damaged, re-
place the washer. Art. no. is spe-
cified in Required equipment on
page 242.
10 Insert the attachment screws. In some cases, removing the
Do not remove the guide pins until the attachment plastic mechanical stops may be
screws are tightened as detailed below! required before fitting the upper
arm.
If guide pins are removed before
the screws are tightened, the
sealing can be involuntarily
moved into wrong position.
11 Secure the lower arm to gearbox axis 3 with the 30 pcs: M16 x 50. Tightening
upper arm attachment screws . torque: 300 Nm.
upper arm on page 241.
12 Remove the guide pins and fit the two remaining
attachment screws. Tighten them as detailed above!
13 Refit any cabling removed during the removal pro-
cess.
14 Reconnect all connectors inside motors 3 and 4.
15 Reconnect connector R2.M5/6 gently at the rear
cable division point.
Be careful not to bend the attachment plate when
16 Refill the gearbox with oil. Detailed in section Filling, oil on
page 174.
ibration tools.
method on page 385.
page 373.
18
DANGER


4 Repair
4.4.4 Replacement of complete lower arm
Location of lower arm

The lower arm is located as shown in the figure below.
xx0100000149
A Lower arm
B Pivot point, axis 2
C Front shaft, balancing device, including securing screw
D Attachment for lifting eye, M12, balancing device
Attachment points, lower arm

The lower arm attachment points are located as shown in the figure below:
• The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation
to the gearbox is identical for axis 3.
• The figure (2) shows a cut view through the lower arm pivot point in axis 2
(item B in the figure above!), valid for robots with protection Standard.

4 Repair
Continued
xx0200000031
A Gearbox
B Lower arm
C Balancing device piston rod ear
D Frame
E Shaft hole
201 Sealing, axis 2/3
202 Attachment screw
204 Washer
401 Bearing
402 Thrust washer
403 Bushing
404 Retaining ring
405 Shaft
406 Protection plug
409 Protection washer

4 Repair
Continued
Components, lower arm shaft for robots with protection Foundry Plus and Foundry Prime
The figure shows components fitted to the lower arm shaft when the robot has
protection Foundry Plus and Foundry Prime.
xx1100000954
A Bearing
B Thrust washer
C Bushing
D Shaft for the lower arm
E Set screw with cup point, M4x6 (2 pcs)
F Hexagon bolt M8x190
G Conical spring washer 8.4x16x1.6
H Shaft tap
J Shaft for the sealing cover
K O-ring
L Sealing cover
M Radial sealing with dust lip
Required equipment

Bearing 3HAC4310-1 Always use a new bearing.
Sealing, axis 2/3 3HAC17213-1 Always use a new sealing.
VK cover 3HAA2166-23 Replace if damaged.
Only used on lower arms with a hole
in the upper end (axis 3).

4 Repair
Continued

Lifting tool, lower arm 3HAC14691-1 Tool that may be rented from ABB.
Includes
• Guidances, 3HAC14445-1
The guidings are used for guiding the
sealing, axis 2/3.
Rotation tool 3HAC17105-1
Lifting eye M12 3HAC14457-3 Used to lift the balancing device.
Press equipment, balan- 3HAC076202-001 For replacing the balancing device
cing device shaft shaft.
User instructions are enclosed with
the tool.
Hydraulic pump, 80 MPa 3HAC13086-1 To be used with the press and puller
tools.
See technical specifications in the user
instructions for the press equipment.
Hydraulic pump, 150 MPa 3HAC021563-012 To be used with the press and puller
(Glycerin) tools.
See technical specifications in the user
instructions for the press equipment.
Press device, axis 2 shaft 3HAC076203-001 Hydraulic pressing accessory.
the tool.
Press tool, axis 2 bearing 3HAC13453-1
Power supply - 24 VDC, 1.5 A.
For releasing the brakes.
Retaining ring pliers -
tools on page 421.
Calibration Pendulum 3HAC15716-1 Complete kit that also includes operat-
toolkit ing manual.
Required if Calibration Pendulum is
the valid calibration method for the
robot.
Calibration tool box, Axis 3HAC055412-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot.
Other tools and proced- These procedures include references
ures may be required. See to the tools required.
references to these proced-
ures in the step-by-step
instructions below.

4 Repair
Continued

Action Note
calibration:
Removal, lower arm

The procedure below details how to remove the complete lower arm.
Action Note
repair procedure.
2
DANGER
Turn off all:

3 Remove the upper arm. Detailed in section Replacement of

complete upper arm on page 241.
4 Disconnect and remove the cables from inside Detailed in section Replacement of
the lower arm. cable harness, axes 1-4 on page 214.
Release any cable attachments.
5 Apply the lifting eye to the balancing device Art. no. is specified in Required equip-
and raise to unload the device. ment on page 248.
Attachment is shown in the figure Loc-
ation of lower arm on page 246.

4 Repair
Continued
Action Note
6 Unload the balancing device in order to make Detailed in section Unloading the bal-
the piston rod and front ear adjustable when ancing device on page 283.
pulling the front shaft out.
DANGER

injury.
for the tool.
7 Remove the securing screw from the balancing Shown in the figure Location of lower
device front shaft. arm on page 246.
8 Pull the shaft out using the press equipment, Art. no. is specified in Required equip-
balancing device shaft, according to user in- ment on page 248.
structions enclosed with the equipment. User instructions are enclosed with the
tool.
xx0900000813

press tool.
DANGER

injury.
for the tool.
9 Lower the balancing device until it rests safely

against the bottom of the frame, out of reach
from the lower arm.
10 Move the lower arm backwards to the lowest
position possible.
xx0300000015
11
CAUTION
The lower arm weighs 225 kg! All lifting

12 Apply the lifting tool to the lower arm. Article number is specified in Required
equipment on page 248!

4 Repair
Continued
Action Note
13 Drain the oil from gearbox 2. Detailed in section Changing oil, axis-
14 Raise the tool to unload the lower arm.
15 Remove the lower arm shaft and all additional
components, as detailed in section Replace-
ment of lower arm shaft on page 256.
DANGER

injury.
for the tool.
16 Remove the lower arm attachment screws and Shown in the figure Attachment points,
washers that attaches the lower arm to the lower arm on page 246.
gearbox 2.
17 Lift the lower arm down and place it on a se-
cure surface.
18 Remove the bearing and thrust washer from Shown in the figure Attachment points,
the shaft hole in the lower arm. lower arm on page 246.
On reassembly a new bearing must be
used!
19 Remove the sealing from the lower arm. Shown in the figure Attachment points,
lower arm on page 246.
On reassembly a new sealing must be
used!
Refitting, lower arm

The procedure below details how to refit the lower arm to the robot.
Action Note
1
DANGER
Turn off all:


4 Repair
Continued
Action Note
2 If the lower arm is designed with a hole, fit a Spare part number is specified in Re-
new VK-cover on a new lower arm or replace quired equipment on page 248.
existing if damaged.
xx1700000917
3 Fit the two guidings in the attachment holes of Included in the lifting tool, lower arm,
the lower arm. article number is specified in Re-
xx0200000262
A Attachment holes for the two

guidings.
4 Fit the new sealing, axis 2/3 on the guidings. Always use a new sealing when reas-
sembling!
Article number is specified in Re-
5
CAUTION
The lower arm weighs 225 kg! All lifting equip-

ment used must be sized accordingly!
6 Apply the lifting tool to the lower arm. Article number is specified in Re-
7 Lift the lower arm and move it to its mounting
position.

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

the motor cover, directly on the motor
shaft as shown in the figure above!
9 Secure the lower arm with 28 of the 30 attach- 30 pcs: M16 x 50; tightening torque:
ment screws and washers in gearbox 2. 300 Nm.
Shown in the figure Attachment
points, lower arm on page 246.
10 Remove the guidings and secure the two remain-
ing attachment screws as detailed above!
11 Refit the lower arm shaft and all additional
components, as detailed in section Replacement
of lower arm shaft on page 256.
DANGER

injury.
Read and follow enclosed user instructions for
the tool.
12 Refit and restore the balancing device. Detailed in section Refitting, balan-
13 Refit the upper arm. Detailed in section Refitting, upper
arm on page 244.
15 Refill the axis 2 gearbox with oil. Detailed in section Filling, oil on
page 170.
16 Refit and reconnect all cables inside the lower Detailed in section Refitting, cable
arm. harness, axes 1-4 on page 218.
Refit removed cable attachments.

4 Repair
Continued
Action Note
17 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 385.
General calibration information is in-
cluded in section Calibration on
page 373.
18
DANGER


4 Repair
4.4.5 Replacement of lower arm shaft
Prerequisites
This section details how to remove and refit the lower arm shaft as a step in the
procedure of removing/refitting the complete lower arm. To perform the procedure
described in this section, it is required that the preceding instructions in section
Replacement of complete lower arm on page 246 are followed! These include:
• removing the upper arm
• removing the cabling in the lower arm
• unloading the balancing device and removing the front eye shaft
• draining the oil in gearbox axis 2
• unloading the lower arm with specific lifting equipment.
Components, lower arm shaft for robots with protection Standard

protection Standard.
xx0300000487
A Protection plug
B Lower arm shaft (axis 2 shaft)
C Thrust washer
D Bearing
E Protection washer
F Retaining ring

4 Repair
Continued
Components, lower arm shaft for robots with protection Foundry Plus
protection Foundry Plus.
xx1100000954
A Bearing
B Thrust washer
C Bushing
D Shaft for the lower arm
E Set screw with cup point, M4x6 (2 pcs)
F Hexagon bolt M8x190
G Conical spring washer 8.4x16x1.6
H Shaft tap
J Shaft for the sealing cover
K O-ring
L Sealing cover
M Radial sealing with dust lip
Required equipment

Bearing For spare part number Always use a new bearing
see: when reassembling!
• Spare part lists
on page 427.
Puller device, axis 2 shaft 3HAC075427-001 Hydraulic pressing accessory.
User instructions are enclosed
with the tool.

4 Repair
Continued

Press device, axis 2 shaft and 3HAC076203-001 Hydraulic pressing accessory.
bearing User instructions are enclosed
with the tool.
Hydraulic pump, 80 MPa 3HAC13086-1 To be used with the press and
puller tools.
See technical specifications in
the user instructions for the
press equipment.
Hydraulic pump, 150 MPa (Glycer- 3HAC021563-012
in)
Retaining ring plier -
Isopropanol 11771012-208 For cleaning the shaft.
Grease 3HAB3537-1 For lubrication of the bearing.
For lubrication of the shaft.
Rust preventive 3HAC026621-001 Equivalent:
• Mercasol 3106
Locking liquid (only for robots with 3HAB7116-1 Loctite 243
protection Foundry Plus and
Foundry Prime)
Removal, lower arm shaft from robot with protection Standard

Use this procedure to remove the lower arm shaft if the robot has protection
Standard.
If encountering any problems when removing the shaft, contact ABB Robotics!
1
WARNING
This procedure is a step in the complete

procedure of removing the lower arm! Make
sure all the preceding steps specified in Re-
placement of lower arm shaft on page 256 are
made before removing the lower arm shaft!
2 Remove the protection plug. Shown in the figure Components, lower

arm shaft for robots with protection
Standard on page 256!
3 Remove the protection washer and the retain- Shown in the figure Components, lower
ing ring. arm shaft for robots with protection
Standard on page 256!
Use a plier for the retaining ring.

4 Repair
Continued
4 Pull out the axis-2 shaft with the puller device Art. no. is specified in Required equip-
according to user instructions enclosed with ment on page 257!
the equipment. User instructions are enclosed with the
tool.
xx0900000813

press tool.
DANGER
Handling the tool incorrectly will cause seri-

ous injury.
for the tool.
5 Remove the bearing and thrust washer from

the shaft hole in the lower arm, recommend-
able after removing the complete lower arm
as detailed in section Replacement of com-
plete lower arm on page 246.
Removal, lower arm shaft on robot with protection Foundry Plus

Use this procedure to remove the lower arm shaft if the robot has protection Foundry
Plus.
If encountering any problems when removing the shaft, contact ABB Robotics!
Action Note
1
WARNING
This procedure is a step in the complete procedure

of removing the lower arm! Make sure all the preced-
ing steps specified in Replacement of lower arm
shaft on page 256 are made before removing the
lower arm shaft!
2 Remove the two set screws. Shown in the figure Components,

lower arm shaft for robots with
3 Remove the shaft sealing cover. protection Foundry Plus on
4 Remove the sealing cover. page 257.
5 Remove the radial sealing, if the lower arm is to be

replaced with a new one.
If the same lower arm is refitted, the radial sealing
can be left in the lower arm.
6 Remove the hexagon bolt with the washer and shaft
tap.

4 Repair
Continued
Action Note
7 Pull out the axis-2 shaft with the puller device accord- Art. no. is specified in Required
ing to user instructions enclosed with the equipment. equipment on page 257!
User instructions are enclosed
with the tool.
xx0900000813
Go to the user instructions enclosed with the press

tool.
DANGER
Handling the tool incorrectly will cause serious in-

jury.
Read and follow enclosed user instructions for the
tool.
8 Remove the bearing and thrust washer from the

shaft hole in the lower arm, recommendable after
removing the complete lower arm as detailed in
section Replacement of complete lower arm on
page 246.
Refitting, lower arm shaft on robot with protection Standard

Use this procedure to refit the lower arm shaft if the robot has protection Standard.
1 Clean the shaft with isopropanol and lubricate it Art. no. is specified in Required
with grease. equipment on page 257!
2 If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the Support shaft axis 2.
• Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
A
A
Apply mercas
• A: Mercasol on marked
areas.
3 Push the shaft in by hand.

4 Repair
Continued
4 Refit the thrust washer to the shaft. Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Standard on
page 256!
5 Fit the axis-2 shaft with the press device, axis 2 Art. no. is specified in Required
shaft according to user instructions enclosed with equipment on page 257!
the equipment. User instructions are enclosed with
the tool.
xx0900000813

tool.
DANGER

jury.
tool.
6 Remove the press device, axis 2 shaft.

7 Apply grease to the location of the shaft where the Art. no. is specified in Required
bearing is to be mounted. equipment on page 257
8 Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed Note
with the equipment..
Always use a new bearing when
reassembling!
xx0900000813 the tool.
tool.
DANGER

jury.
tool.
9 Refit the protection washer and the retaining ring. Shown in the figure Components,
lower arm shaft for robots with
10 Refit the protection plug. protection Standard on page 256.
11 Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete

4 Repair
Continued
Refitting, lower arm shaft on robot with protection Foundry Plus

Use this procedure to refit the lower arm shaft if the robot has protection Foundry
Plus.
1 Clean the shaft with isopropanol and lubricate it Art. no. is specified in Required
with grease. equipment on page 257!
2 If the robot is going to work in a water jet applica-
tion cell:
Apply Mercasol 3106 on the support shaft axis 2.
• Apply Mercasol 3106 on both sides of the
thrust washer, all around the bearing and on
surface on the shaft.
A
A
Apply mercas
A Mercasol on marked areas.

3 Push the shaft in by hand.
4 Refit the thrust washer to the shaft. Also shown in the figure Compon-
ents, lower arm shaft for robots
with protection Foundry Plus on
page 257!
5 Fit the axis-2 shaft with the press device, axis 2 Art. no. is specified in Required
shaft according to user instructions enclosed with equipment on page 257!
the equipment. User instructions are enclosed with
the tool.
xx0900000813

tool.
DANGER

jury.
tool.
6 Remove the press device, axis 2 shaft.

7 Apply grease to the location of the shaft where the Art. no. is specified in Required
bearing is to be mounted. equipment on page 257

4 Repair
Continued
8 Press in the new bearing with the press tool, axis
2 bearing according to user instructions enclosed Note
with the equipment.
Always use a new bearing when
reassembling!
xx0900000813 the tool.
tool.
DANGER

jury.
tool.
9 Fit a radial sealing to the lower arm, if there is none Shown in the figure Components,
left during removal of the arm. lower arm shaft for robots with
protection Foundry Plus on
10 Refit the hexagon bolt with a spring washer and a page 257.
shaft tap through the hole in the lower arm shaft.
11 Fit the shaft for the sealing cover onto the hexagon
bolt and tighten the bolt with torque: 24 Nm.
12 Check the o-ring in the sealing cover. Replace if
damaged.
13 Refit the sealing cover onto the shaft. Press it
tightly against the radial sealing while tightening
the set screws. Use locking liquid.
14 Proceed with the refitting procedure of the lower
arm, detailed in section Replacement of complete

4 Repair
4.5.1 Replacing the SMB unit
4.5 Frame and base
Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side
of the frame as shown in the figure.
A B C D
E F G H J
xx0200000203
A Brake release unit

B Brake unit cover
C Hexagon nut
D Pins
E Battery unit
F SMB cover
G Attachment screw, (2 pcs)
H Attachment screw, brake unit cover (2 pcs)
J Pins
Required equipment
Note
There are different variants of SMB units and batteries. The variant with the
3-pole battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

4 Repair
Continued

SMB unit For spare part number,
see: Spare part lists on
page 427.
tools on page 421.
Circuit diagram - See chapter Circuit diagram on
page 429.
Removing, SMB unit

Use this procedure to remove the SMB unit.
Action Note
1 Move the robot to the calibration position.
2
DANGER
Turn off all:

3
The unit is sensitive to ESD. Before handling the unit

read the safety information in section The unit is
sensitive to ESD on page 62.
4 Remove the SMB cover by unscrewing its attachment Shown in the figure Location of
screws. SMB unit on page 264.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Use caution and 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 guide pins Shown in the figure Location of
that secure the board. SMB unit on page 264.
7 Use caution and disconnect the connectors from the Connectors R1.SMB1-3,
SMB unit when pulling the board out. R1.SMB4-6 and R2.SMB

4 Repair
Continued
Action Note
8 Disconnect the battery cable by pressing down the
upper lip of the R2.G connector to release the lock
while pulling the connector upwards.
xx1700000993
Refitting, SMB unit

Use this procedure to refit the SMB unit.
Action Note
1
DANGER
Turn off all:

area.
2

unit read the safety information in section The
unit is sensitive to ESD on page 62.
3 Connect the battery cable to the SMB unit. Shown in the figure Location of SMB
Make sure the lock on the battery cable connect- unit on page 264.
or R2.G snaps into place during refitting.
4 Connect all connectors to the SMB board: Art. no. is specified in Required
R1.SMB1-3, R1.SMB4-6 and R2.SMB equipment on page 264.
Shown in the figure Location of SMB
unit on page 264.
5 Fit the SMB unit onto the guide pins.
6 Secure the SMB unit to the pins with the nuts
and washers.
7 If disconnected, reconnect the connectors X8,
X9 and X10 to the brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
X9
are snapped down properly.
xx1700000978

4 Repair
Continued
Action Note
8 Secure the SMB cover with its attachment Shown in the figure Location of SMB
screws. unit on page 264.
If cabling is used for 7th axis (option), refit the
7th axis connector to the SMB cover and tighten
with 6 Nm.
9 Update the revolution counters. See Updating revolution counters on
IRC5 robots on page 380.
10
DANGER


4 Repair
4.5.2 Replacement of brake release board
Different designs
Depending on the robot version, the brake release board may be located either at
the base or at the frame. The following two figures show the different locations.
The early design includes a brake release board with or without push buttons,
located at the base. The later design instead includes a brake release board with
push buttons, placed together with the SMB unit on the left hand side of the frame.
The different designs are not compatible.
Location of brake release board, base

The early design includes a brake release board with or without push buttons,
located at the base as shown in the figure below.
xx0200000127
A Brake release circuit (brake release unit inside)

B Attachment screws, brake release circuit, 4 pcs

4 Repair
Continued
Location of brake release board, frame

The later design includes a brake release board with push buttons, placed together
with the SMB unit on the left hand side of the frame as shown in the figure below.
A B C D
E F G H J
xx0200000203
A Break release unit

B Break unit cover
C Hexagon nut
D Pins
E Battery unit
F SMB cover
G Attachment screw, (2 pcs)
H Attachment screw, brake unit cover (2 pcs)
J Pins
Required equipment
Equipment, etc. Spare part number Note

Brake release circuit 3HAC14219-1 Brake release at the base, according to fig-
without buttons, at base ure Location of brake release board, base
on page 268.
Includes brake release unit 3HAC14228-1.
Brake release circuit with 3HAC12989-1 Brake release at the base, according to fig-
buttons, at base ure Location of brake release board, base
on page 268.
Includes brake release board 3HAC16036-
1.
Brake release unit with 3HAC065021-001 Brake release unit at the frame, according
harness, at frame to figure Location of brake release board,
frame on page 269.
DSQC1052

4 Repair
Continued
Equipment, etc. Spare part number Note

Push button guard 3HAC2744-1
Standard toolkit - Content is defined in section Standard tools
on page 421.
Other tools and proced- These procedures include references to the
ures may be required. See tools required.
references to these pro-
cedures in the step-by-
Removal of brake release circuit, located at base

The procedure below details how to remove the brake release board, located at
the rear of the base. See the figure Location of brake release board, base on
page 268.
Action Note
1
DANGER
Turn off all:

2
The unit is sensitive to ESD. Before handling the unit

read the safety information in section The unit is
sensitive to ESD on page 62.
3 Remove the cover at the rear of the base.

4 Unscrew the four attachment screws, brake release Shown in the figure Location of
circuit on the outside of the base. brake release board, base on
page 268.
5 Disconnect the cable from the brake release circuit
and remove the circuit from the base.

4 Repair
Continued
Removal of brake release board, located on frame

The procedure below details how to remove the brake release board, located on
the side of the frame. See the figure Location of brake release board, frame on
page 269.
Action Note
1
DANGER
Turn off all:

working area.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling

the unit read the safety information in sec-
tion The unit is sensitive to ESD on page 62.
3 Remove the push button guard from the Shown in the figure Location of brake re-
SMB cover. lease board, frame on page 269.
The guard must be removed to ensure a
correct refitting of the brake release unit.
4 Remove the SMB cover by unscrewing the Shown in the figure Location of brake re-
attachment screws. lease board, frame on page 269.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
5 Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
6 Disconnect the connectors X8, X9 and X10
from the brake release board.
X8
X10
X9
xx1700000978
7 Unscrew the two attachment screws, brake Shown in the figure Location of brake re-
release unit. lease board, frame on page 269!
8 Unscrew the two attachment screws and Shown in the figure Location of brake re-
nuts, brake unit cover, and remove the brake lease board, frame on page 269!
unit cover.
9 Remove the brake release board from the Shown in the figure Location of brake re-
plate. lease board, frame on page 269!

4 Repair
Continued
Refitting of brake release circuit, located at base

The procedure below details how to refit the brake release circuit, located at the
rear of the base. See the figure Location of brake release board, base on page 268.
Action Note
1

unit read the safety information in section The unit
is sensitive to ESD on page 62.
2 Place the brake release unit in the base of the ro- Spare part no. is specified in Re-
bot. quired equipment on page 269.
brake release board, base on
page 268.
3 Reconnect the cable to the brake release unit.
4 Secure the SMB cover with its attachment screws. Shown in the figure Location of
brake release board, base on
page 268.
5 Refit the cover of the rear of the base.
Refitting of brake release board, located on frame

The procedure below details how to refit the brake release board, located on the
side of the frame. See the figure Location of brake release board, frame on page 269.
Action Note
1
The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 62.
2 Fit the brake release board on the plate with Maximum tightening torque: 5 Nm.
the attachment screws. Shown in the figure Location of brake
Make sure the board is positioned as straight release board, frame on page 269.
as possible on the plate! The push buttons can Spare part no. is specified in Required
otherwise get jammed when the SMB-cover is equipment on page 269.
refitted.
3 Place the brake unit cover on the brake release
unit .
4 Secure the brake unit cover with the two attach-
ment screws and nuts, brake unit cover.
5 Connect the connectors X8, X9 and X10 to the
brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
are snapped down properly. X9
xx1700000978

4 Repair
Continued
Action Note
6 Verify that the robot cabling is positioned cor- Make sure that the white cables run
rectly, according to previously taken pic- like shown in the figure.
ture/notes.
WARNING
Screened cables must not get in contact with

the brake release board after installation.
Eliminate all risks of contact between screened
cables and the brake release board.
xx1700001155
7 Refit the SMB cover with its attachment screws. Shown in the figure Location of brake
release board, frame on page 269.
8
WARNING
Before continuing any service work, follow the

safety procedure in section The brake release
buttons may be jammed after service work on
page 213!
9 Refit the push button guard on the SMB cover. Shown in the figure Location of brake
release board, frame on page 269.
10 Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving freely
and do not stay in any locked position.
11 If the battery has been disconnected the revolu- Detailed in section Updating revolution
tion counters must be updated. counters on IRC5 robots on page 380.
12
DANGER

when performing the first test run. See Test run
after installation, maintenance, or repair on
page 116.

4 Repair
4.5.3 Replacement of spherical roller bearing, balancing device
Location of bearing
The bearing is located at the front ear of the balancing device, as shown in the
figure below.
xx0500002249
A Spherical roller bearing

B Sealing ring
C O-ring
D Sealing spacer
E Front ear of balancing device
Required equipment
Equipment Spare part no. Art. no. Note

Spherical roller bear- 3HAA2167-17
ing
Sealing spacer 3HAC12988-1 2 pcs required.
O-ring 3HAB3772-76 2 pcs required.
Sealing ring 3HAC11581-6 2 pcs required.
Grease 3HAC042536-001 For lubrication of the com-
ponents.

4 Repair
Continued

Toolkit 3HAC15943-1 The tools in the set are
shown in the section Tool
set.
these procedures in
structions below.
Tool set
The parts of the tool set for replacing the spherical roller bearing are shown in the
figure.
xx0500002259
A Threaded bar
B Dolly
C Press tool for removal of bearing
D Press tool for refitting of bearing
E Hexagon nut M12 (2pcs)
F Plain washer 13x24x2,5 (2pcs)
Removal, spherical roller bearing

Use this procedure to remove the spherical roller bearing from the balancing device
front ear.
Action Note
1
DANGER
Turn off all:


4 Repair
Continued
Action Note
2 Remove the balancing device from the ro- Detailed in section Replacing the balan-
bot. cing device on page 279.
3 Remove the both sealing spacers with a Shown in the figure Location of bearing
screwdriver or any equal tool. on page 274.
4 Insert the threaded bar through the bearing.
5 Fit the press tool and dolly to the threaded
bar.
Secure with the nut and washer at each end.
xx0500002255
A Threaded bar 3HAC15945-1

B Dolly 3HAC15948-1
C Press tool 3HAC15941-1
6 Press out the bearing from the front ear.
Refitting, spherical roller bearing

Use this procedure to refit the spherical roller bearing to the balancing device front
ear.
Action Note
1
DANGER
Turn off all:

bot
2 Grease the inside walls of the front ear.

4 Repair
Continued
Action Note
3 Insert the threaded bar through the new Spare part no. is specified in Required
bearing and place it at the front ear. Fit also equipment on page 274.
the press tool and the dolly to the bar as
shown in the figure to the right.
Secure with the nut and washer at each end.
xx0500002257

B Dolly 3HAC15948-1
4 Press in the bearing properly inside the ear.
5 Apply grease to the new sealing rings and Spare part no:s are specified in Required
o-rings and fit one of each to the new seal- equipment on page 274.
ing spacers. Also, grease the sealing
spacers.
6 Press in the sealing spacers with the press
tools, as shown in the figure to the right.
Secure the press tool and dolly with nuts
and washers.
Note
Fit the sealing spacers one at a time!
xx0500002258

B Dolly 3HAC15948-1
7 Refit the balancing device to the robot. Detailed in section Refitting, balancing
device on page 286.
8 Lubricate the spherical roller bearing in the Detailed in section Lubrication of spherical
ear. roller bearing, balancing device on
page 190
Note
The balancing device must be mounted on

the robot when lubrication is performed!
9 Make sure no incorrect leakage occurs. It This is detailed in section Check for leak-
could indicate damaged o-rings. age on page 147.

4 Repair
Continued
Action Note
10
DANGER

on page 116.

4 Repair
4.5.4 Replacing the balancing device
Location of balancing device

The balancing device is located on rear top of the frame as shown in the figure
below.
xx0100000139
A Balancing device
B Rear cover
C Support shaft inside (included in balancing device 3HAC14675-1)
D Attachment screws, rear cover
E Balancing device shaft, including screw and washer
F Bearing attachment
G Parallel pin (inside bearing attachment)
H Attachment screws, bearing attachment

4 Repair
Continued
Attachment points, balancing device

The attachment points for the lifting tools etc. are located as shown in the figure
below.
xx0600002653
A Attachment hole for lifting eye, M12

B Attachment hole for securing screw that secures the bearing attachment to the
balancing device (protection plug fitted normally)
C Hole in frame to access the balancing device front eye shaft with the puller/press
tool
D Attachment hole for locking screw that secures the lower arm to the frame

4 Repair
Continued
Required equipment

Balancing device See Spare part Includes:
lists on page 427. • balancing device
3HAC14675-1 or
3HAC023018-001
• o-ring 3HAB3772-44
(2 pcs)
O-ring 3HAB3772-44 2 pcs , to be replaced if
damaged! (included with
the new balancing device)
Locking screw 3HAB3409-90 M16 x 90
For securing the lower arm.
Securing screw 9ADA183-66 M12 x 35, 2 pcs required
For securing the bearing
attachments to the balan-
cing device when lifting.
Bearing grease 3HAC042536-001 For lubricating the o-rings
and the shaft.
Grease 3HAA1001-294 150 ml, Tribol GR 100-0-PD
For lubrication of spherical
roller bearing in ear, in case
of new balancing device.
Locking liquid - Loctite 243
To apply to the securing
screw in the shaft.
Locking liquid - Loctite 577
Used to secure the attach-
ment screws of the rear
cover at the end of the bal-
ancing device.
Grease pump - To lubricate spherical roller
bearing.
Guide pins M16 x 300 3HAC13120-5 Always use guide pins in
pairs!
Lifting eye M12 3HAC14457-3
Lifting tool (chain) 3HAC15556-1
Press equipment, bal- 3HAC074411-001 For unloading the balancing
ancing device device.
User instructions are en-
closed with the tool.
Adapter for Press 3HAC078221-001 To be used with
equipment, balancing 3HAC074411-001 for balan-
device cing devices from 2002 and
older.
Press equipment, bal- 3HAC076202-001 For replacing the balancing
ancing device shaft device shaft.
User instructions are en-
closed with the tool.

4 Repair
Continued

Hydraulic cylinder 3HAC11731-1 To be used with the press
and puller tools.
See technical specifications
in the user instructions for
the press equipment.
Hydraulic pump 80 3HAC13086-1 To be used with the hydraul-
MPa ic cylinder.
See technical specifications
in the user instructions for
the press equipment.
Standard toolkit - Content is defined in sec-
tion Standard tools on
page 421.
Other tools and pro- These procedures include
cedures may be re- references to the tools re-
quired. See refer- quired.
ences to these proced-
ures in the step-by-
step instructions be-
low.
Removal, balancing device

The procedures below detail how to remove the balancing device.
Preparations before removing the balancing device
Action Note
1 Move the lower arm to a position close to the
calibration position.
2
DANGER
Turn off all:

3 Secure the lower arm to the frame by inserting Attachment hole for the locking screw
the locking screw into the attachment hole in is shown in the figure Attachment
the frame. points, balancing device on page 280.
4
CAUTION
The balancing device weighs 300 kg! All lifting

5 Fit the lifting eye, M12 to the balancing device Art. no. is specified in Required
and raise to unload the weight. equipment on page 281!
Attachments are shown in the figure
Attachment points, balancing device
on page 280.

4 Repair
Continued
Unloading the balancing device
Action Note
1 Remove the rear cover of the balancing device,
by unscrewing the attachment screws.
DANGER
DO NOT! remove any other screws then the

rear cover attachment screws.
xx0200000175
• E: Rear cover attachment

screws, 4 pcs
2 Remove the o-ring from the balancing device
end.
3 Remove the support shaft.
4 Unload the balancing device with the press Art. no. is specified in Required
equipment in order to make the piston rod and equipment on page 281!
front ear adjustable when pulling the shaft out. User instructions are enclosed with
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.
Removing the balancing device shaft
Action Note
1 Remove the securing screw and washer from Shown in the figure Location of balan-
the balancing device shaft. cing device on page 279!

4 Repair
Continued
Action Note
2 Pull the shaft out using the press equipment, Art. no. is specified in Required
balancing device shaft, according to user in- equipment on page 281!
structions enclosed with the equipment. User instructions are enclosed with
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.
Restoring the balancing device
Action Note
1 Restore the balancing device according to in- Art. no. is specified in Required
structions for the press equipment. equipment on page 281!
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.
2 Lubricate and refit the o-ring at the end of the Make sure the o-ring is seated prop-
balancing device. erly! Replace if damaged.
3 Refit the support shaft to the balancing device.
4 Lubricate and refit the o-ring on the support Make sure the o-ring is seated prop-
shaft. erly! Replace if damaged.

4 Repair
Continued
Action Note
5 Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
xx0200000175
• E: 4 pcs: M10x30, tightening

torque: 50 Nm.
Locking liquid is specified in Required
6
DANGER
The rear cover of the balancing device is a

safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!
Removing the balancing device
Action Note
1 Secure the two bearing attachments to the bal- Shown in the figure Attachment points,
ancing device by replacing the protection plug balancing device on page 280!
on the outside of each attachment, with secur- Dimensions for the securing screws
ing screws. are specified in Required equipment
The protection plugs must be refitted after refit- on page 281.
ting the balancing device, do not loose them!
2 Remove the two bearing attachments from the Shown in the figure Location of balan-
frame by unscrewing their four attachment cing device on page 279!
screws. Make sure the parallel pins inside are
not lost!
3 Fit two guide pins through the upper holes of Art. no. is specified in Required
the bearing attachments, to the frame. equipment on page 281!
4 Lift the balancing device gently backwards to
a secure area, allowing the bearing attachments Note
to slide on the guide pins.
Make sure not to burden the guide
pins with the weight of the balancing
device!

4 Repair
Continued
Refitting, balancing device

The procedures below detail how to refit the balancing device.
Refitting the balancing device
Action Note
1
DANGER
Turn off all:

2 Secure the lower arm to the frame by inserting Art. no. is specified in Required
the locking screw into the attachment hole in equipment on page 281!
the frame. Attachment hole is shown in the fig-
ure Attachment points, balancing
device on page 280.
3 Secure the bearing attachments to the balan- Shown in the figure Attachment
cing device with securing screws. points, balancing device on page 280!
Dimension of the securing screws is
specified in Required equipment on
page 281.
4 Refit the two parallel pins in the frame. Shown in the figure Location of bal-
ancing device on page 279!
5 Fit two guide pins to the upper holes in the
frame, where the bearing attachments are to
be attached.
6 Fit the lifting eye to the balancing device. Art. no. is specified in Required
Attachments are shown in the fig-
ureAttachment points, balancing
device on page 280.
7
CAUTION
The balancing device weighs 300 kg! All lifting

8 Lift the balancing device and bring it forward,

gliding the bearing attachments on to the guide Note
pins.
Make sure not to burden the guide
pins with the weight of the balancing
device!
9 Remove the guide pins.

4 Repair
Continued
Action Note
10 Secure the rear of the balancing device by Shown in the figure Location of bal-
fastening the two bearing attachments to the ancing device on page 279!
frame with their four attachment screws. 4 pcs, M16x90, 12.9 quality UN-
BRAKO, tightening torque: 300 Nm.
providing they are lubricated as de-
tailed in section Screw joints on
page 417 before fitting.
11 Remove the screws from outside of the bearing
attachments and refit the protection plugs.
12 Raise the balancing device to a position where
the balancing device shaft may be inserted
through the piston shaft front eye.
Unloading the balancing device
Action Note
1 Remove the rear cover of the balancing device,
by unscrewing the attachment screws.
DANGER
DO NOT! remove any other screws then the

rear cover attachment screws.
xx0200000175
• E: Rear cover attachment

screws, 4 pcs
2 Remove the o-ring from the balancing device
end.
3 Remove the support shaft.
4 Unload the balancing device with the press Art. no. is specified in Required
equipment in order to make the piston rod and equipment on page 281!
front ear adjustable when pulling the shaft out. User instructions are enclosed with
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.

4 Repair
Continued
Refitting the balancing device shaft
Action Note
1 Lubricate the shaft with grease. Art. no. is specified in Required
2 Fit the shaft to the piston shaft front eye Art. no. is specified in Required
through the hole in the frame, using the press equipment on page 281!
equipment, balancing device shaft, according User instructions are enclosed with
to user instructions enclosed with the equip- the tool.
ment.
Note
Make sure the shaft is pressed all

the way to the bottom.
xx0900000813

press tool.
DANGER

injury.
the tool.
3 Refit the securing screw and washer into the M16 x 180, tightening torque: 120
shaft using locking liquid. Nm.
Locking liquid is specified in Re-
quired equipment on page 281!
4 Lubricate the spherical roller bearing through Art. no. and amount are specified in
the lubrication nipple in the ear with grease, Required equipment on page 281!
approximately 5 grams. Lubrication is further detailed in
section Lubrication of spherical roller
bearing, balancing device on
page 190.
5 Clean the area from any excessive grease.

4 Repair
Continued
Restoring the balancing device
Action Note
1 Restore the balancing device according to in- Art. no. is specified in Required
structions for the press equipment. equipment on page 281!
the tool.
xx0900000813

press tool.
DANGER

injury.
the tool.
2 Lubricate and refit the o-ring at the end of the Make sure the o-ring is seated prop-
balancing device. erly! Replace if damaged.
3 Refit the support shaft to the balancing device.
4 Lubricate and refit the o-ring on the support Make sure the o-ring is seated prop-
shaft. erly! Replace if damaged.
5 Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.
xx0200000175
• E: 4 pcs: M10x30, tightening

torque: 50 Nm.
Locking liquid is specified in Required
6
DANGER
The rear cover of the balancing device is a

safety device for the piston rod during opera-
tion! Make sure the cover is properly secured
before commissioning of the robot!

4 Repair
Continued
Concluding procedure
Action Note
1 Remove the locking screw that secures the
lower arm to the frame.
xx0200000454
1 Attachment hole for the secur-

ing screw.
2
DANGER

when performing the first test run. See Test run
after installation, maintenance, or repair on
page 116.

4 Repair
4.6.1 Replacement of motor, axis 1
4.6 Motors
Note
This procedure requires calibration of the robot.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at
factory. Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
Location of motor
The motor axis 1 is located on the left hand side of the robot as shown in the figure
below.
xx0100000123
A Motor, axis 1
B Cable gland cover, motor axis
C Cover for connector access
D Motor attachment screws

4 Repair
Continued
Required equipment

Motor including pinion See Spare part lists Includes
on page 427. • motor
• pinion
• o-ring 21522012-
430.
O-ring 21522012-430 Must be replaced when
reassemling the motor.
Mobilux EP 2 - - Used to lubricate the mo-
tor clutch.
Grease 3HAC042536-001 Used to lubricate the o-
ring.
Removal tool, motor 3HAC14973-1 Always use the removal
M12x tools in pairs!
Lifting tool, motor ax 3HAC14459-1
1, 4, 5
Extension 300mm for 3HAC12342-1
bits 1/2"
Power supply - 24 VDC, max. 1,5 A
page 421.
Calibration Pendulum 3HAC15716-1 Complete kit that also in-
toolkit cludes operating manual.
Required if Calibration
Pendulum is the valid cal-
ibration method for the
robot.
Calibration tool box, 3HAC055412-001 Delivered as a set of calib-
Axis Calibration ration tools.
Required if Axis Calibra-
tion is the valid calibration
method for the robot.
these procedures in
structions below.
Circuit diagram See chapter Circuit dia-
gram on page 429.

4 Repair
Continued

Action Note
calibration:
Removal, motor axis 1

The procedure below details how to remove motor, axis 1.
Action Note
procedure.
2
DANGER
Turn off all:

3 Remove the cover for connector access on top of

the motor by unscrewing its four attachment screws.

4 Repair
Continued
Action Note
4 Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
Note
Make sure the gasket is not damaged!
xx0200000199
• A: Cable gland cover

5 Disconnect all connectors beneath the motor cover.
6 Apply lifting tool, motor axis 1, 4, 5 to the motor. Art. no. is specified in Required
7 In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1
power supply. • +: pin 2
• -: pin 5
8 Remove the motor by unscrewing its four attach- Shown in the figure Location of
ment screws and plain washers. motor on page 291.
If required, use the extension 300mm for bits 1/2". Art. no. is specified in Required
9
CAUTION
The motor weighs 32 kg! All lifting equipment used

must be sized accordingly!
10 Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
11 Remove the motor by gently lifting it straight up.
Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.
Action Note
1
DANGER
Turn off all:

2 Make sure the o-ring on the circumference of the Art no. is specified in Required
motor is seated properly. Lightly lubricate the o- equipment on page 292.
ring with grease.

4 Repair
Continued
Action Note
3
CAUTION

4 Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in Required
5 In order to release the brake, connect the 24 VDC Connect to connector R2.MP1
• -: pin 5
6 Fit the motor, making sure the motor pinion is Make sure the motor is turned the
properly mated to gearbox of axis 1. correct way, that is connection of
motorcable forwards. .
Make sure the motor pinion does
not get damaged!
7 Fit the clutch on the pinion on the motor.
8 Secure the motor with its four attachment screws M10 x 40, tightening torque: 50
and plain washers. Nm.
9 Disconnect the brake release voltage.
10 Reconnect all connectors beneath the motor cover.
11 Refit the cable gland cover at the cable exit with its Make sure the cover is tightly
two attachment screws. sealed!
12 Refit the motor cover with its four attachment Make sure the cover is tightly
screws. sealed!
13 Recalibrate the robot! Pendulum Calibration is described
Pendulum, enclosed with the calib-
ration tools.
method on page 385.
page 373.
14
DANGER


4 Repair
4.6.2 Replacement of motor axis 2
Location of motor
The motor, axis 2, is located on the left-hand side of the robot as shown in the
figure below.
xx0100000124
A Motor, axis 2
B Cable gland cover, motor axis 2
C Hole for lock screw
Required equipment

Motor axis 2 See Spare part Includes:
lists on page 427. • motor
• pinion
• o-ring 2152 2012-430
O-ring 21522012-430 Must be replaced when re-
assembling motor!
Grease 3HAC042536-001 For lubricating the o-ring.
Locking screw 3HAA1001-266 M16 x 60
For securing the lower arm.
Removal tool, motor 3HAC14973-1 Always use the removal
M12x tools in pairs!
Guide pins M10 x 100 3HAC15521-1 For guiding the motor.
Guides are to be used in
pairs!

4 Repair
Continued

Guides are to be used in
pairs!
Lifting tool, motor ax 3HAC15534-1
2, 3, 4
bits 1/2"
Extension bar, 300 3HAC12342-1
mm for bits 1/2"
Power supply - 24 VDC, 1.5 A
Rotation tool 3HAC17105-1 Used to rotate the motor
pinion when mating it to the
gear when brakes are re-
leased with 24VDC power
supply.
page 421.
Required if Calibration Pen-
dulum is the valid calibra-
tion method for the robot.
Calibration tool box, 3HAC055412-001 Delivered as a set of calibra-
Axis Calibration tion tools.
Required if Axis Calibration
is the valid calibration
Other tools and pro- These procedures include
cedures may be re- references to the tools re-
quired. See refer- quired.
ences to these pro-
cedures in the step-
by-step instructions
below.
on page 429.

Action Note

4 Repair
Continued
Action Note
calibration:
Removal, motor
The procedure below details how to remove the motor, axis 2.
Action Note
1 Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
2 Move the robot to a position close Shown in the figure Location of motor on page 296.
enough to its calibration position, to
allow the lock screw to be inserted
into the hole for lock screw .
3
DANGER
Turn off all:

• electric power supply to the
robot
• hydraulic pressure supply to
the robot
• air pressure supply to the ro-
bot
Before entering the robot working
area.
4 Lock the lower arm by inserting the Art. no. and dimension is specified in Required
lock screw into the hole. equipment on page 296.
5 Drain the oil from gearbox, axis 2. Detailed in the section Changing oil, axis-2 gear-
box on page 169.
6 Remove the cover on top of the mo-
tor by unscrewing its four attach-
ment screws.
7 Remove the cable gland cover at the Shown in the figure Location of motor on page 296.
cable exit by unscrewing its two at- Make sure the gasket is not damaged!
tachment screws.
8 Disconnect all connectors beneath
the motor cover.

4 Repair
Continued
Action Note
9 Use the lock screw to lock the lower arm, as de-
DANGER tailed above!
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!
10 In order to release the brake, con- Connect to connector R2.MP2

nect the 24 VDC power supply. • +: pin 2
• -: pin 5
11 Remove the motor by unscrewing
its four attachment screws and plain
washers.
12 Fit the two guide pins in two of the Art. no. is specified in Required equipment on
motor attachment holes. page 296.
Shown in the figure Location of motor on page 296.
13 If required, press the motor out of Art. no. is specified in Required equipment on
position by fitting the removal tool, page 296.
motor to the remaining motor attach- Shown in the figure Location of motor on page 296.
ment holes.
Always use the removal tools in pairs!
14 Remove the removal tools and fit the Art. no. is specified in Required equipment on
lifting tool, motor axis 2, 3, 4 to the page 296.
motor.
15
CAUTION
The motor weighs 32 kg! All lifting

equipment used must be sized ac-
cordingly!
16 Lift the motor to get the pinion away Make sure the motor pinion does not get dam-
from the gear. aged!
17 Remove the motor by gently lifting
it straight out and place it on a se-
cure surface. Disconnect the brake
release voltage.
Refitting, motor
The procedure below details how to refit the motor axis 2.
Action Note
1
DANGER
Turn off all:


4 Repair
Continued
Action Note
2 Make sure the o-ring on the circumference Art. no. is specified in Required equip-
of the motor is seated properly. Lightly lubric- ment on page 296.
ate the o-ring with grease.
3 Foundry Plus: Tightening torque, transparent plug: 20
If the motor is a new spare part, the evacu- Nm ±10%.
ation hole protection filter must be replaced Tightening torque, protection filter: 10
with a transparent plug/sight glass (enclosed Nm ±10%.
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
xx1800000101
xx1800000102
xx1600000576
Protection filter
(Standard). Transparent plug
(Foundry Plus).
4 In order to release the brake, remove the Connect to connector R2.MP2

cover on top of the motor and connect the 24 • +: pin 2
VDC power supply. • -: pin 5
5 Fit the lifting tool, motor axis 2, 3, 4 to the Art. no. is specified in Required equip-
motor. ment on page 296.
6 Fit the two guide pins in the two lower motor Art. no. is specified in Required equip-
attachment holes. ment on page 296.
Shown in the figure Location of motor
on page 296.
7
CAUTION
The motor weighs 32 kg! All lifting equipment

used must be sized accordingly!
8 Lift the motor and guide it onto the guide pins,

as close to the correct position as possible
without pushing the motor pinion into the
gear.
Make sure that the motor is turned the right
direction, that is the cables facing downwards.
9 Remove the lifting tool and allow the motor
to rest on the guide pins.

4 Repair
Continued
Action Note
10 Use the rotation tool in order to rotate the Art. no. is specified in Required equip-
motor pinion when mating it to the gear (see ment on page 296.
the figure to the right). Fit the motor, making
sure the motor pinion is properly mated to
the gear of gearbox axis 2 and that it does
not get damaged.
xx0200000165
The rotation tool is used beneath the

motor cover, directly on the motor shaft
as shown in the figure above.
• A: Rotation tool
12 Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
and plain washers. Reused screws may be used, providing
If required, use the extension 300mm for bits they are lubricated as detailed in section
1/2". Screw joints on page 417 before fitting.
14 Reconnect all connectors beneath the motor Connect in accordance with markings
cover. on connectors.
15 Refit the cable gland cover at the cable exit Shown in the figure Location of motor
with its two attachment screws. on page 296.
16 Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
17 Remove the lock screw from the hole for lock Shown in the figure Location of motor
screw. on page 296.
18 Perform a leak down test. Detailed in Performing a leak-down test
on page 206.
19 Refill the gearbox with oil. Detailed in the section Changing oil,
lum, enclosed with the calibration tools.
page 385.
page 373.
21
DANGER

on page 116.

4 Repair
Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure
below.
xx0200000186
A Motor axis 3
C Motor attachment holes (4 pcs)
Required equipment

Motor, axis 3 See Spare part lists Includes:
• pinion
• o-ring 21522012-430.
O-ring 21522012-430 Must be replaced when reas-
sembling motor!
Mechanical stop 3HAC12708-2 May be used to fix axis 3.
axis 3 Use attachment screws 3HAB
3409-86 (M16 x 60).
Removal tool, mo- 3HAC14973-1 Always use the removal tools
tor M12x in pairs!

4 Repair
Continued

Lifting tool, motor 3HAC15534-1
ax 2, 3, 4
Bolts M16x60 3HAB3409-86
(for mechanical
stop axis 3)
Washers (for 3HAA1001-186
mechanical stop
axis 3)
Guide pins M10 x 3HAC15521-1 For guiding the motor.
100
Guide pins M10 x 3HAC15521-2 For guiding the motor.
150
Extension 300mm 3HAC12342-1
for bits 1/2"
Rotation tool 3HAC17105-1 Used to rotate the motor pin-
ion when mating it to the gear
when brakes are released with
24 VDC power supply.
Power supply - 24 VDC, max. 1.5 A
Calibration Pendu- 3HAC15716-1 Complete kit that also includes
lum toolkit operating manual.
Required if Calibration Pendu-
lum is the valid calibration
Calibration tool 3HAC055412-001 Delivered as a set of calibra-
box, Axis Calibra- tion tools.
tion Required if Axis Calibration is
the valid calibration method
for the robot.
Other tools and These procedures include ref-
procedures may be erences to the tools required.
required. See refer-
ences to these pro-
cedures in the
step-by-step in-
structions below.
on page 429.

4 Repair
Continued

Action Note
calibration:
Removal, motor
The procedure below details how to remove motor, axis 3.
Action Note
1 Decide which calibration routine to
use, and take actions accordingly
prior to beginning the repair proced-
ure.
2 Unload the upper arm of the robot
by either:
• Move the robot to a position
where the turning disk rests
against the foundation (re-
commended).
• Use a fork lift to rest the up-
per arm onto.
• Use lifting slings and an
overhead crane to rest the
upper arm.
• Use a mechanical stop to rest
the upper arm. Fit the mech-
anical stop in the attachment
hole (A) with tightening xx0300000051
torque: 115 Nm.
Fit the mechanical stop to the third and final attach-
ment hole (A), below the fixed stop (B) in the upper
arm. See the figure above!

4 Repair
Continued
Action Note
3
DANGER
Turn off all:

robot
• hydraulic pressure supply to
the robot
• air pressure supply to the ro-
bot
area.
4 Drain the oil from gearbox axis 3. Detailed in section Changing oil, axis-3 gearbox
on page 172.
5 Remove any equipment hindering
access to motor axis 3.
6 Remove the cover on top of the
motor by unscrewing its four attach-
ment screws.
7 Remove the cable gland cover at Shown in the figure Location of motor on page 302.
the cable exit by unscrewing its two Make sure the gasket is not damaged!
securing screws.
8 Disconnect all connectors beneath
the motor cover.
9 Unscrew the motors four attachment Shown in the figure Location of motor on page 302.
screws and plain washers .
10 Fit the two guide pins in two of the Art. no. is specified in Required equipment on
motor attachment screw holes. page 302.
11 Press the motor out of position by Art. no. is specified in Required equipment on
fitting removal tool, motor to the re- page 302.
maining motor attachment screw Always use the removal tools in pairs!
holes.
12 Apply the lifting tool, motor axis 2 Art. no. is specified in Required equipment on
,3, 4 to the motor. page 302.
13
CAUTION
The motor weighs 32 kg! All lifting

equipment used must be sized ac-
cordingly!
14 Lift the motor to get the pinion away

from the gear.
15 Remove the motor by gently lifting Make sure the motor pinion is not damaged!
it straight out and disconnect the
brake release voltage.

4 Repair
Continued
Refitting, motor
Action Note
1
DANGER
Turn off all:

2 Make sure the o-ring on the circumference of the Art no. is specified in Required
motor is seated properly. Lightly lubricate it with equipment on page 302.
grease.
3 Foundry Plus: Tightening torque, transparent plug:
If the motor is a new spare part, the evacuation 20 Nm ±10%.
hole protection filter must be replaced with a Tightening torque, protection filter:
transparent plug/sight glass (enclosed with the 10 Nm ±10%.
spare part delivery). Remove the protection filter
and install the transparent plug/sight glass.
xx1800000101
xx1800000102 xx1600000576
Protection filter
(Standard). Transparent plug
(Foundry Plus).
4 Fit the lifting tool, motor axis 2, 3, 4 to the motor. Art no. is specified in Required
5 Fit the two guide pins in the two lower motor at- Art no. is specified in Required
tachment holes. equipment on page 302.
Shown in the figure Location of mo-
tor on page 302
6
CAUTION
The motor weighs 32 kg! All lifting equipment

7 Lift the motor and guide it onto the guide pins, as

close to the correct position as possible without
pushing the motor pinion into the gear.
8 Remove the lifting tool and allow the motor to stay
on the guide pins.
• -: pin 5

4 Repair
Continued
Action Note
10 Use the rotation tool in order to rotate the motor Art no. is specified in Required
pinion when mating it to the gear! equipment on page 302.
Fit the motor, making sure the motor pinion is Make sure the motor pinion does
properly mated to the gear of gearbox, axis 3. not get damaged!
Make sure the motor is turned the
right direction, that is the cables fa-
cing forwards.
xx0200000165
The rotation tool is used beneath

the motor cover, directly on the mo-
tor shaft as shown in figure above.
• A: Rotation tool.
12 Secure the motor with four attachment screws 4 pcs: M10 x 40, tightening torque:
and plain washers. 50 Nm.
If required, use the extension 300mm for bits 1/2". Art. no. is specified in Required
14 Reconnect all connectors beneath the motor Connect in accordance with mark-
cover. ings on connectors.
15 Refit the cable gland cover at the cable exit with Make sure the cover is tightly
its two attachment screws. sealed!
Shown in the figure Location of mo-
tor on page 302.
16 Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws. sealed!
17 Remove the equipment used to unload the upper
arm.
18 Perform a leak-down test. Detailed in the section Performing
a leak-down test on page 206.
19 Refill the gearbox with oil. Detailed in the section Changing oil,
20 Recalibrate the robot! Pendulum Calibration is described
ration tools.
Axis Calibration is described in Cal-
ibrating with Axis Calibration meth-
od on page 385.
page 373.

4 Repair
Continued
Action Note
21
DANGER


4 Repair
Location of motor
The motor axis 4 is located on the left-hand side of the upper arm as shown in the
figure below.
xx0200000202
A Motor, axis 4
C Motor attachment holes (4 pcs)
Required equipment

Motor including pinion See spare part number Includes:
in Spare part lists on • motor
page 427. • pinion
• o-ring 21522012-430
sembling motor!
Lifting tool, motor ax 1, 4, 5 3HAC14459-1
Lifting tool, motor ax 2, 3, 4 3HAC15534-1
Grease 3HAC042536-001 Used to lubricate the o-ring.
Loctite 574, Flange sealant 12340011-116 Option Foundry Plus
Lifting tool, motor ax 1, 4, 5 3HAC14459-1 To be used if the upper arm is
positioned vertically.
Lifting tool, motor ax 2, 3, 4 3HAC15534-1 To be used if the upper arm is
positioned horizontally.

4 Repair
Continued

Removal tool, motor M12x 3HAC14973-1 Always use the removal tools in
pairs!
Extension 300mm for bits 1/2" 3HAC12342-1
Rotation tool 3HAC17105-1 Used to rotate the motor pinion
when mating it to the gear when
brakes are released with 24 VDC
power supply.
Power supply - 24 VDC, max. 1,5 A
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes
operating manual.
the robot.
Calibration tool box, Axis Calibra- 3HAC055412-001 Delivered as a set of calibration
tion tools.
valid calibration method for the
robot.
page 429.

Action Note

4 Repair
Continued
Action Note
calibration:

Action Note
take actions accordingly prior to beginning
the repair procedure.
2 Move the upper arm to one of the basic pos-
itions:
• upper arm is pointed straight up. This
position enables the motor to be re-
placed without draining the gear oil,
which in turn saves time.
• upper arm is close to horizontal. This
position is recommended if the gear-
box is also to be replaced, i.e. when
the gearbox oil has to be drained
anyway.
3
DANGER
Turn off all:

4 In horizontal position: unload the upper arm

to avoid movement of the axis, with one of
the given methods:
• move the upper arm to a position
where the turning disk rests against
the foundation (recommended)
• use a fork lift or an overhead crane
and lifting slings to rest the weight of
the upper arm.
5 In horizontal position: drain the gearbox, Detailed in section Draining, oil, gearbox
axis 4. axis 4 on page 176.

4 Repair
Continued
Action Note
6 Remove the cable gland cover at the cable Shown in the figure Location of motor on
exit of the motor by unscrewing its two at- page 309.
tachment screws. Make sure the gasket is not damaged!
7 Remove the cover on top of the motor by
unscrewing its four attachment screws.
8 Disconnect all connectors beneath the motor
cover.
9 In order to release the brake, connect the Connect to connector R2.MP4
24 VDC power supply. • +: pin 2
• -: pin 5
10
CAUTION
The motor weighs 22 kg! All lifting equip-

11 Unscrew the motors four attachment screws Shown in the figure Location of motor on
and plain washers. page 309.
12 Fit the two guide pins in two of the motor
attachment screw holes.
13 If required, press the motor out of position Art. no. is specified in Required equipment
by fitting removal tool, motor to the motor on page 309.
attachment screw holes. Always use the removal tools in pairs!
14 Fit the lifting tool to the motor. Choose the correct lifting tool:
• lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned vertic-
ally.
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equipment
on page 309.
15 Lift the motor to get the pinion away from
the gear and disconnect the brake release
voltage.
16 Remove the motor by gently lifting it straight Make sure the motor pinion is not dam-
out. aged!

Action Note
1
DANGER
Turn off all:


4 Repair
Continued
Action Note
2 Make sure the o-ring on the circumference Art. no. is specified in Required equip-
of the motor is seated properly. Lightly lub- ment on page 309.
ricate the o-ring with grease.
3 Foundry Plus: Tightening torque, transparent plug: 20
If the motor is a new spare part, the evacu- Nm ±10%.
ation hole protection filter must be replaced Tightening torque, protection filter: 10 Nm
with a transparent plug/sight glass (enclosed ±10%.
with the spare part delivery). Remove the
protection filter and install the transparent
plug/sight glass.
xx1800000101
xx1800000102
Protection filter xx1600000576
Transparent plug
(Standard).
(Foundry Plus).
4
CAUTION
The motor weighs 22 kg! All lifting equip-

5 Fit the lifting tool to the motor. Choose the correct lifting tool:
the upper arm is positioned vertic-
ally
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required equip-
ment on page 309.
6 In order to release the brakes, connect the Connect to connector R2.MP4:
24 VDC power supply. • +: pin 2
• -: pin 5
7 Fit the two guide pins in two of the motor Art. no. is specified in Required equip-
attachment holes. ment on page 309.
Shown in the figure Location of motor on
page 309.
8 Fit the motor with guidance of the pins, Make sure the motor pinion does not get
making sure the motor pinion is properly damaged!
mated to the gear of gearbox 4.

4 Repair
Continued
Action Note
9 Use the rotation tool in order to rotate the Art. no. is specified in Required equip-
motor pinion when mating it to the gear! ment on page 309.
Fit the motor, making sure the motor pinion Make sure the motor pinion does not get
is properly mated to the gear, axis 4. damaged!
Make sure the motor is turned the right
direction, that is the cables facing for-
wards.
xx0200000165
The rotation tool is used beneath the mo-

tor cover, directly on the motor shaft as
shown in figure above.
• A: Rotation tool.
11 Secure the motor with four attachment 4 pcs: M10 x 80, tightening torque: 50 Nm.
screws and plain washers. Art. no. is specified in Required equip-
If required, use the extension 300mm for ment on page 309.
bits 1/2".
13 Reconnect all connectors beneath the motor
cover.
14 Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
15 Refit the cable gland cover at the cable exit Shown in the figure Location of motor on
with its two attachment screws. page 309.
16 Perform a leak-down test if the gearbox has Detailed in the section Performing a leak-
been drained. down test on page 206.
17 Refill the gearbox with oil if drained. Detailed in the section Filling, oil, gearbox
axis 4 on page 177.
18 Recalibrate the robot! Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
page 385.

4 Repair
Continued
Action Note
19
DANGER

on page 116.

4 Repair
Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!
xx0100000127
A Motor, axis 5
C Heat protection plate
Required equipment

Motor, axis 5 See Spare part lists Includes:
• pinion
• o-ring 21522012-430
O-ring 21522012-430 Must be replaced when replacing
motor!
Lifting tool, motor ax 1, 4, 5 3HAC14459-1 For lifting the motor in a vertical pos-
ition
Power supply 24 VDC, 1.5 A.
Extension 300mm for bits 1/2" 3HAC12342-1
Removal tool, motor M12x 3HAC14973-1 Always use the removal tools in
pairs!

4 Repair
Continued

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes oper-
ating manual.
Required if Calibration Pendulum is
the valid calibration method for the
robot.
Calibration tool box, Axis Calib- 3HAC055412-001 Delivered as a set of calibration tools.
ration Required if Axis Calibration is the
valid calibration method for the robot.
these procedures in the step-
by-step instructions below.
page 429.

Action Note
calibration:

Action Note
procedure.

4 Repair
Continued
Action Note
2 Move the robot to a position where the motor in axis
5 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
3
DANGER
Turn off all:

4 Remove the left hand side cover of the wrist unit by The motor is accessible behind
unscrewing its six attachment screws. the rear part of the cover.
5 Remove the heat protection plate by unscrewing its Shown in the figure Location of
two attachment screws. motor on page 316.
6 Remove the cover on top of the motor by unscrewing
its four attachment screws.
7 Remove the cable gland cover at the cable exit by Shown in the figure Location of
unscrewing its two attachment screws. motor on page 316.
8 Disconnect all connectors beneath the motor cover.
• -: pin 5
10
CAUTION

11 Remove the motor by unscrewing its four attachment Art. no. is specified in Required
screws and plain washers. equipment on page 316.
If required, use the extension 300 mm for bits 1/2.
12 Fit the lifting tool, motor axis 1, 4, 5 to the motor. Art. no. is specified in Required
13 Fit the two guide pins in two of the motor attachment Art. no. is specified in Required
screw holes. equipment on page 316.
14 If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 316.
holes. Always use the removal tools in
pairs and diagonally!
15 Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
16 Remove the motor by gently lifting it straight out. Make sure the motor pinion is
not damaged!

4 Repair
Continued

The procedure below details how to refit the motor, axis 5.
Action Note
1
DANGER
Turn off all:

2 Make sure the o-ring on the circumference of the Art. no. is specified in Required
motor is seated properly. Lightly lubricate the o-ring equipment on page 316.
with grease.
3
CAUTION

4 Fit the lifting tool, motor axis 1, 4, 5 to the motor.

5 In order to release the brakes, connect the 24 VDC Connect to connector R3.MP5
power supply to the motor. • +: pin 2
• -: pin 5
6 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required
ment holes. equipment on page 316.
7 Fit the motor, with guidance from the pins, making Make sure the motor pinion does
sure the motor pinion is properly mated to the gear not get damaged!
of gearbox, axis 5. Make sure the motor is turned the
right direction, that is the cables
facing forward.
8 If necessary, use the rotation tool in order to rotate Art. no. is specified in Required
the motor pinion when mating it to the gear! equipment on page 316.
xx0200000165
The rotation tool (A) is used be-

neath the motor cover, directly on
the motor shaft as shown in figure
above.
9 Secure the motor with four attachment screws and M10 x 40, 12.9 quality.
plain washers. Tightening torque: 50 Nm.
If required, use the extension 300 mm for bits 1/2". Art. no. is specified in Required
11 Reconnect all connectors beneath the motor cover.

4 Repair
Continued
Action Note
12 Refit the cable gland cover at the cable exit with its Shown in the figure Location of
two attachment screws. motor on page 316.
13 Refit the cover on top of the motor with its four at- Make sure the cover is tightly
tachment screws. sealed!
14 Refit the heat protection plate with its two attach- Shown in the figure Location of
ment screws. motor on page 316.
15 If cables are loose, place them correctly and tie
them up with cable ties.
16 Refit the left hand side cover of the wrist unit with
its six attachment screws.
17 Recalibrate the robot. Pendulum Calibration is described
ibration tools.
method on page 385.
page 373.
18
DANGER


4 Repair
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure
below.
xx0100000128
A Motor, axis 6
Required equipment

Motor, axis 6 See spare part Includes:
number in Spare • motor
part lists on • pinion
page 427.
• o-ring
sembling motor!
Gasket 3HAC048560-001 Must be replaced when repla-
i cing motor
3HAC063071-001
ii
Gasket, cover 3HAC033489-001 Must be replaced when

opening cover.
Removal tool, motor 3HAC14972-1 Always use the removal tools
M10x in pairs!
bits 1/2"

4 Repair
Continued

Power supply - 24 VDC, 1.5 A
Grease 3HAC042536- For lubricating the o-ring.
001
Loctite 574, Flange 12340011-116 Option Foundry Plus
sealant
Calibration tool box, 3HAC055412- Delivered as a set of calibra-
Axis Calibration 001 tion tools.
is the valid calibration meth-
od for the robot.
See references to these quired.
procedures in the step-
by-step instructions be-
low.
Circuit diagram - See chapter Circuit diagram
on page 429.
i Only fits type A motor.
ii Only fits type B motor.

Action Note

4 Repair
Continued
Action Note
calibration:
Removal, motor
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 325.
Action Note
procedure.
2 Move the robot to one of the recommended posi-
tions:
• to a position where the motor in axis 6 is
pointed straight up. This position enables the
motor to be replaced without draining the
gear oil, which in turn saves time.
• to a position where the motor in axis 6 is
close to horizontal. This position may be se-
lected when the gearbox is to be replaced,
i.e. when the gearbox oil has to be drained
anyway.
3
DANGER
Turn off all:

4 In horizontal position: drain the oil from the axis 6 Detailed in section Draining oil,
gearbox. gearbox axis 6 on page 183.
5 Remove the rear motor cover by unscrewing the
five attachment screws.
6 Disconnect all connectors beneath the cover.

4 Repair
Continued
Action Note
7 Connect the 24 VDC power supply to release the Connect to connector R3.MP6
brakes. • +: pin 2
• -: pin 5
8 Remove the motor by unscrewing its four attach- Art. no. is specified in Required
ment screws and plain washers. equipment on page 321.
If required, use the extension 300mm for bits 1/2".
9 If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 321.
holes. Always use the removal tools in
pairs!
10 Lift the motor carefully to get the pinion away from Make sure the motor pinion is not
the gear and disconnect the brake release voltage. damaged!
11 Remove the motor by gently lifting it straight out.
Refitting, motor
Note
Robots with protection type Foundry Plus or Foundry Prime require special repair
routines to maintain the tightness level, in addition to the procedure below,
described in Replacement of the motor axis 6 (Foundry Plus) on page 325.
Action Note
1 Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 321.
the o-ring with grease.
2 In order to release the brake, connect the 24 Connect to connector R3.MP6
VDC power supply. • +: pin 2
• -: pin 5
3 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required
ment holes. equipment on page 321.
4 Fit the motor, with guidance from the pins, Make sure the pinion on the motor
making sure the motor pinion is properly mated shaft is not damaged!
to the gear of gearbox, axis 6.
6 Secure the motor with its four attachment screws 4 pcs: M8 x 25, tightening torque: 24
and plain washers. Nm.
If required, use extension 300mm for bits 1/2". Art. no. is specified in Required
8 Reconnect all connectors beneath the motor
cover.
9 Refit the cover on top of the motor with its five Make sure the cover is tightly sealed!
attachment screws.
10 Perform a leak-down test (if the gearbox has Detailed in section Performing a leak-
been drained). down test on page 206.

4 Repair
Continued
Action Note
11 Refill the gearbox with oil, if it has been drained. Detailed in section Filling oil, gearbox
axis 6 on page 184.
12 Re-calibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pen-
dulum, enclosed with the calibration
tools.
rating with Axis Calibration method
on page 385.
page 373.
13
DANGER

Replacement of the motor axis 6 (Foundry Plus)

Robots with protection type Foundry Plus require special repair routines to maintain
the tightness level.
The repair must be done according to the previous repair procedure with the
following additions.
Action Note
1 Move the robot to one of the recommended
positions:
• to a position where the motor in axis 6
is pointed straight up. This position en-
ables the motor to be replaced without
draining the gear oil, which in turn saves
time.
• to a position where the motor in axis 6
is close to horizontal. This position may
be selected when the gearbox is to be
replaced, that is when the gearbox oil
has to be drained anyway.
2
DANGER
Turn off all:

3 In horizontal position: drain the oil from the Detailed in section: Draining oil, gear-
axis 6 gearbox. box axis 6 on page 183.

4 Repair
Continued
Action Note
4 Remove the rear motor cover by unscrewing
the five attachment screws.
xx1500002524
• A: Motor unit
• B: Connection box
• C: Attachment screw (5 pcs)
• D: Rear motor cover
• E: Gasket
5 Continue to remove the motor unit, according
to step 6 and forwards in Removal, motor on
page 323.
6
Note
Keep the old rear motor cover with the air

nipple.

4 Repair
Continued
Action Note
7 Remove the protection strip on the gasket and
mount it on the motor.
xx1500002425
• A: Attachment screw (4pcs)

Mercasol 3106
• B: Motor unit
• C: O-ring
• D: Sikaflex in screw recesses
• E: Tilt house
• F: Washer
• G: Rear motor cover
• H: Sealing
• J: Loctite 574
8 Apply Mercasol 3106 on the motor end cover.
9 Apply Loctite 574 flange sealant on the contact
surface.
xx1400000992
10 Apply grease on the o-ring on the motor.

11 Continue to refit the new motor according to
section, Refitting, motor on page 324.

4 Repair
4.7.1 Replacing the axis 1 gearbox
4.7 Gearboxes
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure.
xx0100000133
A Gearbox, axis 1
B Oil plug, filling
C Attachment screws, gearbox to frame
D Frame
E Base
- Attachment screws, base to gearbox (not shown in figure)
Required equipment

Gearbox For spare part no. see: Includes:
• Spare part lists on • gearbox
page 427. • all o-rings and sealing rings
O-ring 3HAB3772-54 Replace if damaged!
Sealing ring 3HAC11581-4 Replace if damaged!

4 Repair
Continued

For lubricating the o-ring.
Support, base and gear 1 3HAC15535-1
Lifting accessory, base 3HAC15560-1
Lifting accessory (chain) 3HAC15556-1
Guide pins 2 pcs, M16x150.
Used for guiding the gearbox into
place in the base.
Always use guide pins in pairs!
erating manual.
the robot.
Calibration tool box, Axis 3HAC055412-001 Delivered as a set of calibration
Calibration tools.
bot.
Other tools and procedures These procedures include refer-
may be required. See references to the tools required.
tions below.

Action Note

4 Repair
Continued
Action Note
calibration:
Removal, gearbox axis 1

Use this procedure to remove gearbox, axis 1.
Action Note
take actions accordingly prior to beginning
the repair procedure.
2 Move the robot to its most stable position,
shown in the figure to the right.
xx0300000022
3
DANGER
Turn off all:

working area.
4 Drain the axis 1 gearbox. See Changing oil, axis-1 gearbox on

page 165.
5 Remove the complete arm system. Detailed in section Replacement of com-
plete arm system on page 227.
6 Unfasten the robot base from the foundation
by removing the base attachment screws.

4 Repair
Continued
Action Note
7 Attach the lifting accessory, base and gear
1 and the lifting tool (chain) to the gearbox
and base.
xx1000001395
Specified in Required equipment on

page 328.
8
CAUTION
The base and axis 1 gearbox weighs 310

kg + 200 Kg.
All lifting accessories used must be sized
accordingly!
9 Lift the robot base including the axis 1 Art. no. is specified in Required equip-
gearbox to allow the base and gear 1 sup- ment on page 328.
port be fitted on each sides of the base.
10 Secure the support to the base and to the
foundation.
Make sure the base remains in a stable
position before performing any work under-
neath the base!
xx1000000364
A Support base (4 pcs)

4 Repair
Continued
Action Note
11 Remove the bottom plate from underneath
the base in order to get access to the attach-
ment screws.
It may be necessary to also remove the rear
connector plate.
xx1000001385
xx0300000612
A Bottom plate
B Rear connector plate
C Attachment screw
D Groove
12 Unscrew the attachment screws and re-
move the washers.
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
13 Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
xx1000001387
14
CAUTION
The gearbox weighs 200 Kg.

All lifting accessories used must be sized
accordingly!
15 Lift the gearbox away with the already

mounted lifting tools.
16 Turn the gearbox, and remove the protec-
tion pipe by unscrewing two attachment
screws.
Note
Move the protective pipe over to the new

gearbox.
xx1400000786

4 Repair
Continued
Refitting, gearbox axis 1

Use this procedure to refit gearbox, axis 1.
Action Note
1 Fit the support, base and gear 1 to the base. Mounting of the support, base and gear
1 is detailed in section Removal, gear-
box axis 1 on page 330.
xx1000000364
A Support base (4 pcs)

2 Make sure the two o-rings on the circumfer- Art no. is specified in Required equip-
ence of the gearbox are seated properly in ment on page 328.
their respective groove. Lubricate them with
grease.
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 Make sure the small o-ring around the oil hole
is fitted properly!
xx1000001392
4 Attach the lifting accessory, base and gear 1 Specified in Required equipment on
and the lifting tool (chain) to the gearbox. page 328.
xx1000001395
5 Fit two guide pins in two of the attachment Specified in Required equipment on
holes in the gearbox, parallel to each other. page 328.
6
CAUTION
The gearbox weighs 200 Kg.

cordingly!

4 Repair
Continued
Action Note
7 Lift the gearbox.
Make sure the guide pin in the bottom face of
the gearbox is properly aligned with the base.
xx1000001389
xx1000001391
8 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs!
lower it carefully to its mounting position.

4 Repair
Continued
Action Note
9 Secure the gearbox with its attachment 18 pcs, M16 x 90, 12.9 quality UN-
screws and washers. BRAKO.
Tightening torque: 300 Nm
they are lubricated as detailed in sec-
tion Screw joints on page 417 before fit-
ting.
xx0200000227
A view from below:

• A: Oil drain hose
• B: Attachment screws, gearbox
axis 1, 18 pcs
• C: Washers, 3 pcs
10 Refit the cable guide in the center of gearbox
1 with its attachment screws.
xx1000001393

4 Repair
Continued
Action Note
11 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 down-

wards!
xx0300000612
• A: Bottom plate
• B: Rear connector plate
• C: Attachment screw
• D: Groove
12
CAUTION
The base and axis 1 gearbox weighs 310 kg

+ 200 Kg.
cordingly!
13 Lift the robot base and gearbox 1 and remove

the base and gear support.
14 Secure the base to the mounting site. See Orienting and securing the robot
on page 81.
15 Refit the complete arm system. Detailed in section Replacing the axis
CAUTION
This is a complex task to be performed with

utmost care in order to avoid injury or dam-
age!
16 Perform a leak-down test. See section Performing a leak-down

test on page 206.
17 Refill the gearbox with oil. See Changing oil, axis-1 gearbox on
page 165.
lum, enclosed with the calibration tools.
page 385.
page 373.

4 Repair
Continued
Action Note
19
DANGER

on page 116.

4 Repair
4.7.2 Replacement of gearbox, axis 2
Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the
figure below.
Exploded views in Product manual, spare parts - IRB 7600 .
xx0100000135
A Gearbox, axis 2 (behind motor attachment not shown in figure )

B Motor, axis 2
C Oil plug, filling
D Oil plug, draining
E Front gearbox attachment screws
F Attachment holes, fixture lower arm
G Motor attachment
I Hole for locking screw, lower arm, M16 x 60
- Sealing (between gearbox and motor attachment, not shown in figure)
- Friction washer (between the gearbox and lower arm, not shown in figure)

4 Repair
Continued
Required equipment
Equipment, etc. Spare part num- Article number Note

ber
Gearbox, axis 2 3HAC12641-1 Includes gearbox and o-
ring
O-ring 3HAB3772-51
Sealing, axis 2/3 3HAC17213-1 A new sealing must be
used on each assembly!
Grease 3HAC042536- For lubricating the o-ring.
001
page 421.
Lifting accessory, axis-2 and 3HAC032723-
axis-3 gear 001
Fixture lower arm 3HAC13660-1
Locking screw, lower arm M16 x 60 8.8.
Included in the fixture,
lower arm.
Guide pins M16 x 150 3HAC13120-2 To be used in pairs!
Guide pins M16 x 200 3HAC13120-3 To be used in pairs!
Guide pins M16 x 300 3HAC13120-5 For guiding the gearbox.
Always use the guide pins
in pairs.
Guide pins, sealing ax 2/3, 3HAC14627-2 For guiding the sealing ax-
80mm is 2/3. Guides are to be
used in pairs!
Guide pins, sealing ax 2/3, 3HAC14627-3 For guiding the sealing ax-
100mm is 2/3. Guides are to be
used in pairs!
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also in-
cludes operating manual.
Required if Calibration
Pendulum is the valid calib-
ration method for the robot.
Calibration tool box, Axis 3HAC055412- Delivered as a set of calib-
Calibration 001 ration tools.
is the valid calibration
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures quired.
tions below.

4 Repair
Continued

Action Note
calibration:
Removal, gearbox
The procedure below details how to remove gearbox, axis 2.
Action Note
procedure.
2 Remove any equipment fitted to the turning disk.
3 Run the robot to the calibration position. The up-
per arm may be directed in three different ways,
shown in figure to the right.
The lowered position, as in figure A, is recommen-
ded as it gives the least load on the tool.
xx0200000260

4 Repair
Continued
Action Note
4
DANGER
Turn off all:

5 If the robot is fitted with moveable mechanical

stops on axis 2 (not stock equipment), these must
be removed at this point.
The attachment holes of the mechanical stops
are used to attach the fixture, lower arm.
6 Secure the lower arm to the frame by inserting Art. no. is specified in Required
the locking screw into the hole. equipment on page 341!
gearbox on page 340!
7 Fit the fixture, lower arm to prevent the lower arm Art. no. is specified in Required
from falling. equipment on page 341!
• Make sure that both adjusters (B) on the Attachment holes for the fixture are
fixture are screwed back. shown in the figure Location of
• Align the fixture with the frame and lower gearbox on page 340!
arm. Make sure the fixture is pressed
• Tighten the four M16 bolts (C) on the in- tightly against the lower arm before
side of the frame, in attachment holes, with securing with screws!
tightening torque: 220 Nm.
• Screw in the two adjusters (B) until they
rest against the flats on the lower arm.
Tighten by hand.
• Lock, using the two ring nuts (D).
• Tighten the two M12 bolts (E) in the attach-
ment holes, fixture lower arm with tighten-
ing torque: 91 Nm.
xx0200000261
• A: Locking screw, lower arm

8 Unload the balancing device shaft by using a Detailed in section Unloading the
specific press tool. balancing device on page 283.
DANGER

injury.
the tool.
9 Drain the gearbox, axis 2. Detailed in section Draining, oil on

page 170.
on page 298.

4 Repair
Continued
Action Note
11 Remove the 30 rear gearbox attachment screws
(A) from inside the lower section of the lower arm.
xx0300000064
12 Remove the motor attachment by unscrewing Shown in the figure Location of

the front gearbox attachment screws. gearbox on page 340!
13 Fit the lifting tool, gearbox axis 2, to the motor Art. no. is specified in Required
attachment and secure it with the hook on the equipment on page 341.
tool.
Remove the motor attachment.
14
CAUTION
The gearbox weighs 125 kg! All lifting equipment

15 Fit the lifting tool, gearbox axis 2, to the gearbox. Art. no. is specified in Required
16 Fit two guide pins in 180° relation to each other Art. no. is specified in Required
instead of the removed front attachment screws. equipment on page 341.
17 If required, apply an M16 screw to the hole shown Art. no. is specified in Required
in the figure to press it free. equipment on page 341.
xx0200000033
• A: M16 holes for pressing the

gearbox out
18 Remove the gearbox using an overhead crane or
similar.
19 Remove the friction washer and clean it.

4 Repair
Continued
Action Note
20 Remove the sealing from the lower arm. On reassembly a new sealing must
be used!
Art. no. is specified in the refitting
instructions Required equipment on
page 341!

The procedure below details how to refit the gearbox, axis 2.
Action Note
1
DANGER
Turn off all:

2 Fit the guide pins, sealing axis 2/3 on gearbox,

axis 2.
Only the holes showed in figure beside are al-
lowed to be used to the guide pins!
xx0200000125
Holes for guide pins, sealing

axis 2/3 on gearbox 2.
Always use a new sealing when re-
assembling!
3 Fit the new sealing, axis 2/3 on gearbox, axis 2,
with guidance from the guide pins.
4 Fit two guide pins, M16 180° in relation to each Article number is specified in Re-
other in the attachment holes in the frame. quired equipment on page 341.
5 Fit the cleaned friction washer onto the guide pins.
6 Fit the lifting tool, gearbox axis 2, to the gearbox. Article number is specified in Re-

4 Repair
Continued
Action Note
7 Make sure the o-ring is fitted to the rear of the Article number is specified in Re-
gearbox. Lightly grease the o-ring. quired equipment on page 341.
xx0100000136
A O-ring, gearbox, axis 2

8 Lift the gearbox to its mounting position.
9 Fit the gearbox onto the guide pins and slide it Make sure the gearbox is seated
into position. properly.
10 Remove the lifting tool.
11 In a similar way, fit the lifting tool to the motor
flange. Lock the tool with the hook.
Lift it and slide it onto the guide pins.
Remove the lifting tool.
12 Insert and secure 18 of the 20 attachment screws Tightening torque: 280±15 Nm.
on the front of the motor attachment. Reused screws may be used,
Remove the guide pins and tighten the remaining providing they are lubricated as de-
two screws. tailed in section Screw joints on
13 Remove the guide pins and tighten the remaining
two screws as above.

4 Repair
Continued
Action Note
14 Insert and secure 28 of the 30 attachment screws
on the inside of the lower arm.
xx0300000064

providing they are lubricated as de-
tailed in section Screw joints on
15 Remove the guide pins, sealing axis 2/3 and
tighten the remaining two screws as above.
16 Refit the motor. Detailed in section Refitting, motor
on page 299.
17 Perform a leak-down test. Detailed in section Performing a
leak-down test on page 206.
18 Refill the gearbox with oil. Detailed in section Filling, oil on
page 170.
19 Restore the balancing device. Detailed in section Restoring the
balancing device on page 284.
DANGER

injury.
the tool.
20 Remove the fixture, lower arm.

21 Remove the locking screw, lower arm.
22 Refit any mechanical stops if such were removed
during disassembly.
23 Refit any equipment to the turning disc if such
was removed during assembly.
ration tools.
method on page 385.
page 373.

4 Repair
Continued
Action Note
25
DANGER


4 Repair
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the
figure below.
xx0100000137
A Gearbox, axis 3
B Attachment screws, gearbox
C Oil plug, filling
D Oil plug, draining
E Motor, axis 3
F Attachment screws, upper arm
G Attachment screws, motor
H Sealing, axis 2/3 (between lower arm and gearbox 3)

4 Repair
Continued
Required equipment

Gearbox For spare part number, Includes
see Spare part lists on • gearbox
page 427. • o-ring.
Does not include the sealing, axis
2/3!
O-ring 3HAB3772-51 1 pc on the gearbox.
Replace if damaged.
Grease 3HAC042536-001 For lubricating the o-rings.
Sealing, axis 3 3HAC17213-1 A new sealing must be used on
each assembly!
Mechanical stop axis 3 3HAC12708-2 Used to secure the upper arm.
Use attachment screws
3HAB3409-86 (M16 x 60).
Washers (for mechanical stop 3HAA1001-186
axis 3)
Bolt, M16x60 (for mechanical 3HAB3409-86
stop axis 3)
Lifting accessory, axis-2 and 3HAC032723-001
axis-3 gear
Use guides in pairs!
Use guides in pairs!
Guide pins, sealing ax 2/3, 3HAC14627-2 For guiding the axis-3 sealing.
80mm Use guides in pairs!
Guide pins, sealing ax 2/3, 3HAC14627-3 For guiding the axis-3 sealing.
100mm Use guides in pairs!
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes
operating manual.
the robot.
Calibration tools.
valid calibration method for the
robot.
below.

4 Repair
Continued

Action Note
calibration:

Action Note
1 Decide which calibration routine
to use, and take actions accord-
ingly prior to beginning the repair
procedure.
2
DANGER
Turn off all:

robot
to the robot
• air pressure supply to the
robot
area.
3 Secure the upper arm in a horizont- Art. no. is specified in Required equipment on
al position using round slings. page 350.

4 Repair
Continued
Action Note
4 Remove the motor, axis 3. Detailed in section Removal, motor on page 304.
Note
When removing the motor axis 3, the brake on axis

3 is released. Make sure the upper arm is secured
and disabled to move!
5 Remove the upper arm. Detailed in section Removal, upper arm on

page 243.
6 Remove the sealing, axis 2/3 On reassembly a new sealing must be used! Art.
between the gearbox and lower no. is specified in Required equipment on page 350.
arm.
7 Place the upper arm safely on a
workbench, in a fixture or similar.
8 Remove the attachment screws, Shown in the figure Location of gearbox on
gearbox. page 349.
9 Fit the two guide pins in 180° rela- Art. no. is specified in Required equipment on
tion to each other in the gearbox page 350.
attachment screw holes.
10 Fit the Lifting accessory RV2 ac-
cording to figure.
xx0900000113
11 If required, use screws in the holes

(A) shown in the figure to the right
to press the gearbox free.
xx0200000033
• A: M16 holed for pressing the gearbox out

4 Repair
Continued
Action Note
12
CAUTION
The gearbox weighs 125 kg! All

lifting accessories used must be
sized accordingly!
13 Remove the gearbox, with guid-

ance from the guide pins, using an
overhead crane or similar.

The procedure below details how to refit gearbox, axis 3.
Action Note
1
DANGER
Turn off all:

• electric power supply to
the robot
to the robot
• air pressure supply to the
robot
Before entering the robot work-
ing area.
2 Turn the upper arm in such a

position that the gear mating
surface faces upwards.
3 Fit two guide pins in 180° rela- Art. no. is specified in Required equipment on
tion to each other in the holes in page 350.
the upper arm, used for the
gearbox attachment screws.
4
CAUTION
The gearbox weighs 125 kg! All

lifting accessories used must be
sized accordingly!

4 Repair
Continued
Action Note
5 Fit the lifting accessory RV2 ac-
cording to figure.
xx0900000113
6 Make sure the o-ring is fitted to Art. no. is specified in Required equipment on
the rear of the gearbox. Apply page 350.
grease to it to make sure it sticks
in its groove during assembly!
Replace if damaged!
xx0100000136
• A: O-ring, gearbox axis 3

7 Lift the gearbox to its mounting
position.
8 Turn the gearbox to align the at-
tachment screw holes with those
in the upper arm.
9 Fit the gearbox onto the guide Make sure the o-rings are seated properly and the
pins and slide it into position. gearbox correctly oriented!
10 Remove the lifting tool.
11 Secure the gearbox with 18 of 20 pcs: M16 x 90; 12.9 quality UNBRAKO, tightening
the 20 gearbox attachment torque: 300 Nm.
screws. Reused screws may be used, providing they are
Remove the guide pins and lubricated as detailed in section Screw joints on
tighten the remaining two page 417 before fitting.
screws.

4 Repair
Continued
Action Note
12 Refit the upper arm with a new Art. no. is specified in Required equipment on
sealing, axis 2/3 . page 350.
Detailed in section Refitting, upper arm on page 244.
13 Refit the motor. Detailed in section Refitting, motor on page 306.
14 Recalibrate the robot! Pendulum Calibration is described in Operating
manual - Calibration Pendulum, enclosed with the
calibration tools.
Axis Calibration is described in Calibrating with Axis
Calibration method on page 385.
General calibration information is included in section
Calibration on page 373.
15
DANGER
Make sure all safety require-

ments are met when performing
the first test run. See Test run
after installation, maintenance,
or repair on page 116.

4 Repair
Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure
below.
xx0100000144
A Upper arm housing

B Gearbox, axis 4
C Cover, axis 4 gearbox
D Attachment screws, cover axis 4
E Oil plug, filling, secondary gearbox
F Oil plug, draining, secondary gearbox
G Gear, Z3
H Gear attachment screws
I Motor, axis 4
J Motor flange
K Oil plug, filling, primary gearbox (draining not shown in figure)

4 Repair
Continued
Required equipment

Gear axis 4 3HAC17810-1 Includes all o-rings!
Friction washer 3HAC10122-27 2 pcs. Must be replaced at
assembly!
Gasket, cover axis 4 3HAC11423-3
Grease 3HAC042536- For lubrication of gearbox,
001 motor and motor attachment
mating surfaces.
Guide pins M10 x 100 3HAC15521-1 Always use the guide pins
in pairs!
Guide pins M10 x 150 3HAC15521-2 Always use the guide pins
in pairs!
Required if Calibration Pen-
dulum is the valid calibration
Calibration tool box, Axis 3HAC055412- Delivered as a set of calibra-
Calibration 001 tion tools.
is the valid calibration meth-
od for the robot.
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures quired.
tions below.

Action Note

4 Repair
Continued
Action Note
calibration:

Action Note
procedure.
2
DANGER
Turn off all:

3 Drain the oil from the primary gearbox through the Detailed further in section
oil plug, draining. Changing oil, axis-4 gearbox on
page 175.
4 Drain the oil from the secondary gearbox through Shown in the figure Location of
the oil plug, draining. gearbox on page 356.
Draining is further detailed in
section Changing oil, axis-4
5 Remove the plastic housing from the cover, axis 4
gearbox.
6 Remove the cover, axis 4 gearbox by unscrewing Shown in the figure Location of
its attachment screws. gearbox on page 356.
7 Loosen the gear attachment screws but do not re- Shown in the figure Location of
move the gear Z3. gearbox on page 356.
8 Remove the motor, axis 4. Detailed in section Removal,
motor axis 4 on page 311.
9 Remove gear Z3 from the gearbox by unscrewing Shown in the figure Location of
the 15 gear attachment screws. gearbox on page 356.
If required, insert screws into three holes in gear Z3
to press it out.

4 Repair
Continued
Action Note
10 Remove the motor flange attachment screws and Shown in the figure Location of
plain washers. gearbox on page 356.
11 Pull the motor flange and gearbox, axis 4 out along M10.
with the friction washers.
If required, insert screws into two holes in the gear-
box to press it out.

The procedure below details how to refit the gearbox of axis 4.
Action Note
1
DANGER
Turn off all:

2 Make sure the two o-rings on the circumference Art. no. is specified in Required
of the gearbox are seated properly in their equipment on page 357.
grooves respectively. Lightly lubricate the o-
rings with grease.
3 Lubricate the gearbox, motor and motor attach- Art. no. is specified in Required
ment mating surfaces with grease. equipment on page 357.
4 Fit four guide pins symmetrically in the attach-
ment holes in the upper arm housing.
xx0200000067
A Attachment holes for guide

pins, M10
5 Fit two new friction washers onto the guide pins. Spare part no. is specified in Required
Note
Make sure the surface beneath the

friction washers is clean and dry!

4 Repair
Continued
Action Note
6 Push in the gearbox, axis 4, and the motor Shown in the figure Location of gear-
flange. box on page 356.
If necessary, use screws in the attachment
holes to press in the motor flange. Note
Make sure the motor flange is oriented

correctly by observing the oil plugs as
shown in the figure Replacement of
gearbox, axis 4 on page 356.
7 Secure the motor flange to the upper arm 18 pcs: M10 x 40; tightening torque:
housing with 16 of the 18 washers and attach- 65 Nm.
ment screws.
Secure with locking liquid.
8 Remove the guide pins and secure the remain-
ing two attachment screws as specified in pre-
vious step.
axis 4 on page 312.
10 Refit gear Z3 to the gearbox with its gear attach- Shown in the figure Location of gear-
ment screws. box on page 356.
9 pcs: M12 x 50; tightening torque:
115 Nm.
6 pcs: M16 x 60: tightening torque:
300 Nm.
11 Replace the gasket, cover axis 4. Art. no. is specified in Required
12 Refit the cover, axis 4 gearbox with its attach- Tightening torque: 10 Nm.
ment screws and secure with locking liquid. Shown in the figure Location of gear-
box on page 356.
14 Refill the primary gearbox with oil. This is detailed in section Filling, oil,
gearbox axis 4 on page 177.
15 Refill the secondary gearbox with oil. This is detailed in section Filling, oil,
lum, enclosed with the calibration
tools.
rating with Axis Calibration method on
page 385.
page 373.
17
DANGER


4 Repair
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0100000146
A Wrist housing
B Cover, axis 5 gearbox
C Attachment screws, cover axis 5
D Oil plug, secondary, filling
E Oil plug, secondary, draining
F Gear, Z3
G Wheel unit
H Attachment screws, gear Z3
K Gearbox, axis 5
L Oil plug, primary, filling (draining plug on the opposite side of the wrist housing,
not shown in figure)
N VK-cover

4 Repair
Continued
O Attachment screws, bearing washer, M6 x 16
Required equipment

Gear axis 5 3HAC17810-1 Includes all o-rings!
Friction washer 3HAC10122-27 2 pcs. Must be replaced at
assembly!
VK-cover 3HAA2166-24 Must be replaced!
Gasket, cover 3HAC 11409-5
Grease 3HAC042536- For lubricating the o-rings
001 and the packing box.
Locking liquid 3HAB7116-1 Loctite 243
Isopropanol 11771012-208 To clean surface beneath VK-
cover.
Lifting eye M12 3HAC14457-3 2 pcs required!
For lifting the gearbox.
Removal tool, wheel unit 3HAC15814-1 For removing and lifting the
wheel unit.
pairs!
pairs!
Calibration tool box, Axis 3HAC055412- Delivered as a set of calibra-
Calibration 001 tion tools.
is the valid calibration method
for the robot.
See references to these quired.
procedures in the step-
by-step instructions be-
low.

4 Repair
Continued

Action Note
calibration:
Removal, gearbox
The procedure below details how to remove the gearbox, axis 5.
Action Note
procedure.
2
DANGER
Turn off all:

3 Drain the oil from the primary gearbox. Detailed in section Changing oil,
4 Drain the oil from the secondary gearbox. Detailed in section Changing oil,
5 Remove the motor, axis 5. Detailed in section Replacement
of motor, axis 5 on page 316.
6 Remove the cover, axis 5 gearbox by unscrewing its Shown in the figure Location of
attachment screws. gearbox on page 361!

4 Repair
Continued
Action Note
7 Remove gear Z3 from the gearbox by unscrewing its Shown in the figure Location of
attachment screws (let axis 6 turn to the stop). gearbox on page 361!
If necessary, insert screws into the three holes in 6 pcs: M16 x 60.
gear Z3 to remove it.
9 pcs: M12 x 50.
8 Remove the wheel unit. Detailed in following section
(Removal, wheel unit on
page 364).
9 Remove the gearbox, axis 5 by unscrewing its attach- Shown in the figure Location of
ment screws and removing the washers. gearbox on page 361!
18 pcs: M10 x 40.
10 Apply two lifting eyes to the gearbox, axis 5, in op- Art. no. is specified in Required
posite positions. equipment on page 362!
11 Remove the gearbox by gently lifting it straight out.
12 Remove the friction washers, located beneath the
gearbox, from the wrist housing.
Removal, wheel unit

The procedure below details how to remove the wheel unit.
Action Note
1 Drain the oil from the secondary gearbox. Detailed in section Changing oil,
2 Remove the cover, axis 5 gearbox by unscrewing Shown in the figure Location of
its attachment screws. gearbox on page 361!
3 Make a short cut in the center of the VK-cover Shown in the figure Location of
and remove it from the wheel unit by bending it gearbox on page 361!
off.
Note
Avoid damaging screws or surfaces

beneath, when removing the cover!
4 Unscrew the attachment screws, bearing washer Shown in the figure Location of
located beneath gear Z4. gearbox on page 361 and in the fig-
Turn the gear Z4 in order to reach all the srews. ure below!
7 pcs: M6 x 16.

4 Repair
Continued
Action Note
5 Remove the attachment screws, gear Z4.
xx0200000068
A Gear Z4
B Surface beneath VK-cover
C VK-cover
D Attachment screws, gear Z4,
21 pcs: M16
E Attachment screws, bearing
washer, 7 pcs: M6
6 Apply the removal tool to the center hole of gear Art. no. is specified in Required
Z4 to press the wheel unit free. equipment on page 362!
7 Remove the wheel unit by gently lifting it straight
out.
Action Note
1
DANGER
Turn off all:

2 Make sure the two o-rings on the circumference of Art. no. is specified in Required
the gearbox are seated properly in their grooves equipment on page 362.
respectively. Lightly lubricate the o-rings with
grease.
3 Fit two guide pins in the housing. Art. no. is specified in Required
4 Refit the two new friction washers (2 pcs) in the Art. no. is specified in Required
wrist housing. equipment on page 362.
5 Apply two lifting eyes to the gearbox, axis 5 , in Art. no. is specified in Required
opposite positions. equipment on page 362.
6 Refit the gearbox, axis 5 to the wrist housing, by Shown in the figure Location of
gently lowering it straight down, using the guide gearbox on page 361.
pins.

4 Repair
Continued
Action Note
7 Secure the gearbox with 16 of the 18 attachment 18 pcs: M10 x 40: tightening
screws and washers. torque: 65 Nm.
8 Remove the guide pins and fit the remaining two
attachment screws as specified in the previous step.
9 Refit the gear Z3 to the gearbox, axis 5 with its at- 9 pcs: M12 x 50; 12.9 quality UN-
tachment screws. BRAKO, tightening torque: 115
Nm.
6 pcs: M16 x 60: tightening
torque: 300 Nm.
10 Refit the wheel unit. Detailed in the following proced-
ures (Refitting, wheel unit on
page 367).
11 Replace the gasket. Art. no. is specified in Required
12 Refit the cover, axis 5 gearbox with its attachment 14 pcs, tightening torque: 10 Nm.
screws and secure with locking liquid. Shown in the figure Location of
axis 5 on page 319.
14 Perform a leak-down test. Detailed in section Performing a
leak-down test on page 206.
15 Refill the primary gearbox with oil. Detailed further in section Filling
16 Refill the secondary gearbox with oil. Detailed further in section Filling
17 Recalibrate the robot. Pendulum Calibration is described
ibration tools.
method on page 385.
page 373.
18
DANGER


4 Repair
Continued
Refitting, wheel unit

The procedure below details how to refit the wheel unit.
Action Note
1 Clean the wheel unit and the tube mating surfaces.
2 Lubricate packing box with grease. Art. no. is specified in Required
3 Apply removal tool to the center hole of the gear Art. no. is specified in Required
Z4. equipment on page 362.
4 Refit wheel unit by gently lowering it straight down.
5 Gently knock on the wheel unit with a plastic mallet,
to press it all the way down. Note
Make sure the bearing reaches

the bottom, before continuing the
mounting!
6 Fasten the bearing washer with its attachment

screws and secure with locking liquid .
Turn the gear Z4 in order to reach all the screws.
xx0200000068
A Gear Z4
B Surface beneath VK-cover
C VK-cover
D Attachment screws, gear
Z4, 21 pcs: M16
E Attachment screws, bear-
ing washer, 7 pcs: M6
7 Clean the surface beneath the VK-cover with isop-
ropanol.
8 Secure the wheel unit with attachment screws, gear 21 pcs: M16 x 90; 12.9 quality
Z4. UNBRAKO, tightening torque: 300
Nm.
9 Refit the VK-cover. Art. no. is specified in Required
10 Proceed with step 11 in the refitting detailed in the
previous procedure (procedure Refitting, gearbox
axis 5 on page 365).

4 Repair
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure
below.
xx0100000131
A Gearbox, axis 6
B Attachment screws, gearbox
C Washers
D Oil plug, filling
E Oil plug, draining (can be located on the turning disk instead)
- O-ring (not shown in the figure)
Required equipment

Gearbox For spare part number, Includes o-ring 3HAB3772-49
see Spare part lists on
page 427.
Washers 3HAC10122-13 Not included in the gearbox. Re-
place if damaged.

4 Repair
Continued

O-ring 3HAB3772-83 Located between the gearbox and
the turning disk.
Must be replaced when reas-
sembling gearbox.
Flange sealant 12340011-116 Loctite 574
erating manual.
the robot.
Calibration tools.
bot.
tions below.

Action Note
calibration:

4 Repair
Continued
Removal, gearbox
Action Note
repair procedure.
2
DANGER
Turn off all:

3 Drain the oil from gearbox, axis 6. Detailed in the section Draining oil,
4 Remove the turning disc. Detailed in the section Removing turn-
ing disk on page 233.
5 Remove the gearbox by unscrewing its attach- Shown in the figure Location of gearbox
ment screws. on page 368.
6 If required, apply M10 screws to the holes
shown in the figure to the right, to press the
gearbox out.
xx0200000220
• A: M10 holes for pressing out the

gearbox
Foundry Plus:
Remove old Loctite 574 flange sealant residues
and other contamination from the contact sur-
faces.
xx1400001123

4 Repair
Continued
Action Note
7 Remove the gearbox axis 6 by lifting it out Be careful not to damage the motor
carefully. pinion!
Refitting, gearbox
The procedure below details how to refit gearbox, axis 6.
Action Note
1
DANGER
Turn off all:

bot
2 Make sure the o-ring is fitted to the rear of Article number is specified in Required
the gearbox. Lubricate the o-ring with equipment on page 368.
grease.
xx0200000221
• A: O-ring, gearbox axis 6

3 Release the holding brake of motor axis 6. Detailed in the section Manually releasing
the brakes on page 73.
4 Foundry Plus:
Apply Loctite 574 flange sealant on the
contact surface.
xx1400001122

4 Repair
Continued
Action Note
5 Insert the gearbox, axis 6 into the wrist Article number is specified in Required
unit. equipment on page 368.
Shown in the figure Location of gearbox on
page 368.
Make sure the gears of the gearbox mate
with the gears of the motor!
6 Fit the both washers and secure the gear- Shown in the figure Location of gearbox on
box with the attachment screws. page 368.
18 pcs: M10 x 50; 12.9 quality Gleitmo,
7 Refit the turning disc. Detailed in the section Refitting turning disk
on page 234.
8 Perform a leak-down test. Detailed in the section Performing a leak-
9 Refill the gearbox with oil. Detailed in the section Filling oil, gearbox
axis 6 on page 184.
10 Re-calibrate the robot. Pendulum Calibration is described in Oper-
ating manual - Calibration Pendulum, en-
closed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 385.
11
DANGER

run after installation, maintenance, or re-
pair on page 116.

5 Calibration
5.1.1 Introduction and calibration terminology
5 Calibration
5.1 Introduction to calibration
5.1.1 Introduction and calibration terminology
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 385.
Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.
Calibration terminology
Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.

5 Calibration
5.1.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration or Cal-
position. ibration Pendulum i
Standard calibration data is found on the SMB Levelmeter calibration
(serial measurement board) or EIB in the robot. (alternative method)
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the serial measurement board (SMB) or
other robot memory.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with Absolute accuracy has
a sticker next to the identification plate of the
robot (IRC5).
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.
xx0400001197

5 Calibration
Continued
Type of calibration Description Calibration method

Optimization Optimization of TCP reorientation perform- Wrist Optimization
ance. The purpose is to improve reorientation
accuracy for continuous processes like weld-
ing and gluing.
Wrist optimization will update standard calib-
ration data for axes 4 and 5.
i The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use
the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration
menu on the FlexPendant.
If no data is found related to standard calibration, contact the local ABB Service.
Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of many of
ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).
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 - Calibration Pendulum, which describes
the method and the different routines further.
Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 7600. It is
the recommended method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
with Axis Calibration method on page 385.
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Wrist Optimization method

Wrist Optimization is a method for improving reorientation accuracy for continuous
processes like welding and gluing and is a complement to the standard calibration
method.
The actual instructions of how to perform the wrist optimization procedure is given
on the FlexPendant.

5 Calibration
Continued
Levelmeter calibration - alternative method

Levelmeter calibration is referred to as the alternative method for calibration of
ABB robots because of the less accurate values obtained during calibration. The
method uses the same principles as Calibration Pendulum, but does not have as
good of mechanical tolerances to the toolkit parts as the standard method with
Calibration Pendulum.
This method may, after calibration, require modifications in the robot program and
is therefore not recommended.
The calibration equipment (Levelmeter 2000) for levelmeter calibration is ordered
as separate parts for each robot, and includes the Operating manual - Levelmeter
Calibration, which describes the method and the different routines further.
CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after replacements that do not include taking apart the robot
structure, standard calibration is sufficient.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 422.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

5 Calibration
5.1.3 When to calibrate
5.1.3 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed

If resolver values are changed, the robot must be re-calibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate 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 the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 380. 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 reachability of a robot
is changed, it needs to be re-calibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
5.2 Synchronization marks and axis movement directions
5.2.1 Synchronization marks and synchronization position for axes
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 7600

The figure shows IRB 6600, but the scales and their positions are the same.
xx0200000176
A1 Synchronization mark, axis 1 (early design)

A2 Synchronization mark, axis 1 (later design)
B1 Synchronization mark, axis 2 (early design)
B2 Synchronization mark, axis 2 (later design)
C1 Synchronization mark, axis 3 (early design)
C2 Synchronization mark, axis 3 (later design)
D Synchronization mark, axis 4
E Synchronization mark, axis 5
F Synchronization mark, axis 6
Synchronization marks at axes 2 and 3

The synchronization 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 synchronization position. One of the marks is more narrow
than the other and should be positioned within the limits of the wider mark.

5 Calibration
5.2.2 Calibration movement directions for all axes
5.2.2 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
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
Manual movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!
xx0200000089

5 Calibration
5.3.1 Updating revolution counters on IRC5 robots
5.3 Updating revolution counters
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 378.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the TPU on page 381 (BaseWare 4.0).
Step 2 - Updating the revolution counter
with the FlexPendant on page 382.
Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position. Do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 7600 Yes Yes
If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).

5 Calibration
Continued
Step 2 - Updating the revolution counter with the TPU

Use this procedure to update the revolution counter with the TPU (BaseWare 4.0).
Action Note
1 Press the button Miscellaneous then ENTER to select the service
window.
xx0100000194
2 Select Calibration from the View menu.

The Calibration window appears.
If there is more than one unit connected to the manipulator, they will
be listed in the window.
xx0100000201
3 Select the desired unit and choose Rev Counter Update from the Calib
menu.
The Revolution Counter Update window appears.
xx0100000202
4 Select the desired axis and press Incl to include it (it will be marked
with an x) or press All to select all axes.
5 Press OK when all axes that are to be updated are marked with an x.
CANCEL returns to the Calibration window.
6 Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.

5 Calibration
Continued
Action Note
7 At this point, it is recommended that the revolution counter values are Not required.
saved to a diskette.
8
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect

manipulator positioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update.
How to perform the check is detailed in section Checking the synchron-
ization position on page 401.
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.
xx1500000942

5 Calibration
Continued
Action
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
3 This step is valid for RobotWare 6.02 and later.

Calibration method used at factory for each axis is shown, as well as calibration
method used during last field calibration.
Tap Manual Method (Advanced).
xx1500000944

5 Calibration
Continued
Action
4 A screen is displayed, tap Rev. Counters.
en0400000771
5 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.
6 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.
7 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 selected revolution counters and removes the tick from
the list of axes.
8
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 401.

5 Calibration
5.4.1 Description of Axis Calibration
5.4 Calibrating with Axis Calibration method
Instructions for Axis Calibration procedure given on the FlexPendant

This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.
Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
A fixed calibration pin/bushing is installed on each robot axis at delivery.
The Axis Calibration procedure described roughly:
1 A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
2 During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.
3 The axis position is stored in RobotWare with an active choice from the
operator.

5 Calibration
Continued
Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.
Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.
Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
Note
When using reference calibration with some tools, typically large or flexible tools,
oscillations in the robot can cause issues leading to failure of the calibration.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
Position of robot axes

The robot axes should be positioned close to 0 degrees before commencing the
calibration program. The axis chosen for calibration is then automatically run by
the calibration program to its exact calibration position during the calibration
procedure.
It is possible to position some of the other axes in positions different from 0 degrees.
Information about which axes are allowed to be jogged is given on the FlexPendant.

5 Calibration
Continued
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
Requirements for axis positioning during calibration
Axis to calibrate
Required Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
position of
axis
Axis 1 - * * * * *
Axis 2 0 - 0 * * *
Axis 3 0 0 - * * *
Axis 4 * * * - * *
Axis 5 * * * * - *
Axis 6 * * * * * -
- Axis to be calibrated
* Unrestricted. Axis is allowed to be jogged to other position than 0 degrees.
0 Axis must be put in position 0 degrees.
System containing SafeMove

SafeMove will lose its synchronization to the controller if a new calibration is done.
New calibration values have to be downloaded to SafeMove, and a new SafeMove
calibration has to be done. Make sure that the user rights admit to change the
safety settings and to synchronize SafeMove.
For robots with EPS, the same applies as for SafeMove.

5 Calibration
5.4.2 Calibration tools for Axis Calibration
Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. There is no risk for bad calibrations as long as the
calibration tool is in one piece.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration bushings may cause severe damage to
the robot and/or personnel.

Calibration tool box, 3HAC055412-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot.
Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.
WARNING
If any part is missing or damaged, the tool must be replaced immediately.
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring

5 Calibration
Continued
Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.
xx1500000951
A Outer diameter
Identifying the calibrating tools

It is possible to make the calibration tool identifiable with, for example, an RFID
chip. The procedure of how to install an RFID chip is described below.
Note
The tool identifier is NOT delivered from ABB, it is a customized solution.
Action Note
1 It is possible to use any RFID solution, with the
correct dimensions. ABB has verifed function on
some suppliers fulfilling the requirements of NFC
compatible devices (13.56 Mhz) according to ISO
14443 or ISO 15693.
Note
The maximum dimensions on the RFID chip must

not exceed Ø7.9 mm x 8.0 mm, Ø5.9 mm x 8.0
mm or Ø3.9 mm x 8.0 mm (depending on calibra-
tion tool size).
2 There is a cavity on one end of the calibration tool

in which the RFID chip can be installed.
Install the RFID chip according to supplier instruc-
tions.
Install the chip in flush with the tool end.

5 Calibration
5.4.3 Installation locations for the calibration tools
5.4.3 Installation locations for the calibration tools
Location of fixed calibration items

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
xx1500000894
The fixed calibration pin for axis 1 is installed on a removable tower. The tower will
need to be removed if electronic position switches are fitted to the robot. Keep the
tower in a safe location for future recalibration needs and mark it with robot serial
number to ensure that the correct one is refitted.
Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new.
Spare part Article number Note
Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.

5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration holes may cause severe damage to the
robot and/or personnel.

Calibration tool box, Axis 3HAC055412-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
Spare part Article number Note

Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure.
After the calibration method has been started on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 386.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.
4 Validate the synchronization marks.
5 The robot moves to preparation position.
6 Remove the protective cover from the fixed pin and the protection plug from
the bushing, if any, and install the calibration tool.

5 Calibration
Continued
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER
While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robot's working area is empty,
as the robot can make unpredictable movements.
2 Wipe the calibration tool clean. Use a clean cloth.
Note
The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.
3 Check if the standard calibration data for axes 4 If the data is optimized, the calibra-
or 5 are updated with wrist optimization. tion routine Wrist Optimization
This is shown in the calibration overview/summary must be re-run after standard calib-
window on the FlexPendant. ration.
See Calibrating with Wrist Optimiza-
tion method on page 398.
Starting the calibration procedure

Use this procedure to start the Axis Calibration routine on the FlexPendant.
Action Note
1 Tap the calibration icon and enter the calibration
main page.
2 All mechanical units connected to the system are
shown with their calibration status.
Tap the mechanical unit in question.
3 The calibration method used at ABB factory for The FlexPendant will give all inform-
each axis is shown, as well as calibration method ation needed to proceed with Axis
used for the robot during last field calibration. Calibration.
4 Valid for RobotWare 6
Tap Call Calibration Method. The software will
automatically call for the procedure for the valid
calibration method. If not, tap Call Routine and
then tap Axis calibration.

5 Calibration
Continued
Action Note
5 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 391.
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
The three-position enabling device on the Press and hold the three-position enabling
FlexPendant has been released during robot device and press Play.
movement.
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 379
Axis Calibration with SafeMove option

To be able to run Axis Calibration, SafeMove needs to be unsynchronized. The
Axis Calibration routine recognizes if the robot is equipped with SafeMove and will
force SafeMove to unsynchronize automatically.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine. When a warning message is displayed, tap Acknowledge
to confirm the unsynchronized state and continue Axis Calibration procedure.
CAUTION
SafeMove must be synchronized after the calibration is completed.

5 Calibration
Continued
After calibration
Action Note
1 Check the o-ring on the fixed calibration pin.
Replace if damaged or missing.
2 Reinstall the protective cover on the fixed calibra-
tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.
xx1600002102
Protection cover and plug set:

3HAC056806-001.
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. Ensure that the sealing is not
damaged.
Replace the plug and the sealing with new spare
part, if missing or damaged.
xx1500000952
Protection cover and plug set:

3HAC056806-001.
4 If the standard calibration data for axes 4, 5 or 6 See Calibrating with Wrist Optimiz-
should be updated with wrist optimization, run the ation method on page 398.
calibration routine Wrist Optimization.

5 Calibration
5.4.5 Reference calibration
Brief introduction to Reference Calibration

Reference calibration is a faster method compared to Fine calibration, as it refers
to a previously made calibration.
1 Create a backup of the current robot system.
2 Check that the active calibration offset values corresponds to the values on
the silver label (on the lower arm or the base).
3 Jog the manipulator so that all axes are in zero position (ex use MoveAbsJ
instruction). Check that all axis scales are aligned with calibration marks.
4 If the scales differ from calibration marks it might depend on wrong turns of
the revolution counters. Make a marker line on the corresponding axis to be
able to validate the result of the calibration. If more than one motor revolutions
are wrong, the calibration will fail.
5 Use a verification position. This is especially recommended if all axes were
not aligned with the synchronization marks (step 3). Reuse an existing
position that is suitable and accurate so it can be used to validate the repair.
Use a position where a deviation in axis calibration gives a big deviation in
positioning. Note! Check the position after each repair in one axis.
6 Use Reference calibration to save reference values for all axes that is to be
replaced. Make sure that the values are saved in RobotStudio or FTP program.
The files are located in "Active system folder name/HOME/RefCalibFiles".
7 Perform the repair.
8 Make sure that the tooling and process equipment are the same as when
creating the reference. Use Reference calibration to update the system with
new calibration offset value for the repaired axis.
9 Check the position against the verification position (step 5).
10 Proceed with the repair of the next axis, if necessary, and repeat (step 8-9)
for every axis.
11 (For system containing SafeMove or EPS) Download new calibration values
to SafeMove. Use Visual SafeMove in RobotStudio.
12 (For system containing SafeMove or EPS) Synchronize SafeMove to activate
SafeMove.
13 Perform test run.
14 Update the label for resolver values with new calibration values.
Manual tuning of calibration offset

Manual tuning of calibration offset is normally not needed, but can be useful in
some situations. The requirement to do manual tuning is that there is a known
accurate position, that worked accurately before the repair (step 5, see Brief
introduction to Reference Calibration on page 395).
Example "Adjust axis 4":
1 Create a backup.

5 Calibration
Continued
2 Run the manipulator to the verification position. (The manipulator position

is now deviating from the verification position.)
3 Read and note current axis 4 value in degrees (example: 96.3 degrees).
4 Manually jog, only axis 4, so that the manipulator is correctly positioned to
the verification position.
5 Read and note current axis 4 value in degrees (example: 94.2 degrees).
6 Move the manipulator to its calibration position.
7 Calculate the angle difference (ie 96.3-94.2=2.1 degrees).
8 Manually jog axis 4 the calculated angle difference (-2.1). NOTE! The direction
+/- shall be the same direction as the direction used when axis 4 was manually
jogged to coincide with the verification process. In the example -2.1 degrees.
9 Make a new manual fine calibration of axis 4 with axis in -2.1 degrees position.
10 Check again against the verification position.
11 Repeat the manual tuning if needed.
12 Create a new reference if the intention is to use the reference in the future.

5 Calibration
5.5 Calibrating with Calibration Pendulum method
5.5 Calibrating with Calibration Pendulum method
Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.

5 Calibration
5.6 Calibrating with Wrist Optimization method
When to run Wrist Optimization

Wrist Optimization routine is run to improve TCP reorientation performance.
Calibrating the robot with standard calibration method overwrites the optimized
positions of axes 4, 5. Re-run the Wrist Optimization routine after standard
calibration to re-achieve the optimized positions of the wrist axes.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine Wrist Optimization.
2 Modify targets for 4-point tool frame definition, in Wrist Optimization routine.
Tip
Select positions with large reorientations around the TCP. For best results,
make sure that axis 4 and 5 have large movements.
a Jog the robot to an appropriate position,
A, for the first approach point.
Use small increments to accurately posi-
tion the tool tip as close to the reference
point as possible.
b Tap Modify Position to define the point.
c Repeat for each approach point to be
defined, positions B, C, and D.
Jog away from the fixed world point to
achieve the best result. Just changing the
tool orientation will not give as good a
result.
en0400000906
3 Improved calibration data to the wrist axes is identified and presented.

4 Optimized positions for the wrist axes are presented.

5 Calibration
Continued
5 The robot moves to the optimized positions for the wrist axes and
automatically overwrites previous calibration data.
WARNING
Robot moves automatically when pressing Calibrate.
6 Wrist optimization is finished.

7 Redefine / verify TCP for all tools.

5 Calibration
5.7 Verifying the calibration
5.7 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 401.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 378.
3 Write down the values on a new label and stick it on top
of the calibration label.
The label is located on the lower arm.

5 Calibration
5.8 Checking the synchronization position
Introduction
Check the synchronization position of the robot 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 FlexPendant.
Using a MoveAbsJ instruction on the TPU, S4Cplus

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 Create the following program:
MoveAbsJ [[0,0,0,0,0,0], [9E9,
9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, z50, Tool0
2 Run the program in manual mode.

3 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolution synchronization position for axes
counters. on page 378 and Updating revolution
counters on IRC5 robots on
page 380.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization 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, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 378 and Updating revolution
counters on page 380.

5 Calibration
Continued
Using the jogging window on the TPU, S4Cplus

Use this procedure to jog the robot to synchronization position of all axes.
Action Illustration/Note
1 Open the Jogging window.
xx0100000195
2 Select running axes-by-axes.
xx0100000196
3 Manually run the robot axes to a position

where the axis position value read on the
TPU, is equal to zero.
4 Check that the synchronization marks for the See Synchronization marks and syn-
axes align correctly. If they do not, update chronization position for axes on page 378
the revolution counters. and Updating revolution counters on
IRC5 robots on page 380.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis 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 synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 378 and
date the revolution counters. Updating revolution counters on page 380.

6 Decommissioning
6.1 Introduction to decommissioning
6 Decommissioning
6.1 Introduction to decommissioning
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
Note
The decommissioning process shall be preceded by a risk assessment.
Disposal of materials used in the robot

All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
See also Environmental information on page 404.
Transportation
Prepare the robot or parts before transport, this to avoid hazards.

6 Decommissioning
6.2 Environmental information
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Materials used in the product

The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Covers, synchronization brackets

Batteries, Lithium Serial measurement board
Cast iron/nodular iron Base, lower arm, upper arm
Copper Cables, motors
Neodymium Brakes, motors
Nickel Turning disc (foundry)
Oil, grease Gearboxes
Plastic/rubber Cables, connectors, drive belts, and so on.
Steel Gears, screws, base frame, and so on.

6 Decommissioning
Continued
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:
• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

6 Decommissioning
6.3 Scrapping of robot
6.3 Scrapping of robot
Note
The decommissioning process shall be preceded by a risk assessment.
Important when scrapping the robot
DANGER
The risk assessment should consider hazards arising in the decommissioning,

such as, but not limited to:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.
• A used robot does not have the same performance as on delivery. Springs,
brakes, bearings, and other parts might be worn or broken.

6 Decommissioning
6.4 Decommissioning of balancing device
General
There is much energy stored in the balancing device. Therefore a special procedure
is required to dismantle it. The coil springs inside the balancing device exert a
potentially lethal force unless dismantled properly.
The device must be dismantled by a decommissioning company.
Required equipment

tools on page 421.
Protective clothing that also covers - Must protect against spatter of sparks
face and hands and flames.
Cutting torch with a long shaft - For opening housing and cutting coils.
The long shaft is a safety requirement.
Other tools and procedures may be These procedures include references
required. See references to these to the tools required.
procedures in the step-by-step in-
structions below.
DANGER
Do not under any circumstances, deal with the balancing device in any other
way than that detailed in the product documentation! For example, attempting
to open the balancing device is potentially lethal!
Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing
device is to be decommissioned.
Action Note
1 Remove the balancing device from the robot. Detailed in section Replacing the balan-
2 Send the device to a decommissioning Make sure the decommissioning com-
company. pany is well informed about the stored
energy built up by high tensioned com-
pression springs and that the device
contains some grease.
The following procedure contains useful
information about decommissioning.

6 Decommissioning
Continued
Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact
ABB Robotics for further consultation.
Action Note
1
DANGER
There is stored energy built up by high

tensioned compression springs inside the
balancing device! When a coil is cut the
released tension creates a spatter of
sparks and flames.
The working area must be free of flam-
mable materials. Position the balancing
device so that the spatter will be directed
away from personnel.
2 Clamp the device at the working location.

Place the device at ground level so that
the hole and spring coils are cut from a
more safe distance.
3
DANGER
The hole must be cut as specified in the

figure. Pieces can be ejected from the cyl-
inder at high speed if the hole is cut larger
than specified!
4 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft.
figure. The measurements shown below are maxim-
um values!
xx0200000082

6 Decommissioning
Continued
Action Note
5
DANGER
There is stored energy built up by high

tensioned compression springs inside the
balancing device! When a coil is cut the
released tension creates a spatter of
sparks and flames.
The working area must be free of flam-
mable materials. Position the balancing
device so that the spatter will be directed
away from personnel.
6 Cut the coils of the springs inside the Use a cutting torch with a long shaft.
housing as specified below:
• Outer spring: cut at least five coils!
• Middle spring: cut at least four coils!
• Inner spring: cut at least four coils!
7 Double-check the number of coils cut and
make sure all the tension in the springs
are removed.

7 Robot description
7.1 Type A vs type B motors
7 Robot description
Identifying the motor visually

Type B motors include evacuation on the motor flange to indicate failure of primary
sealing between the gearbox and the motor. Robots with protection type Foundry
Plus have a sight glass installed in the evacuation holes.
Use the images to identify which type of motor is installed on each robot axis.
Type A motor Type B motor
xx1500001058 xx1500001057
No evacuation on type A motors. The type B motor include evacuation on the

motor flange.
Identifying the motor by article number

Use the table to identify which type of motor is installed on each robot axis by
article number. The article numbers specified are found in WebConfig.
Contact ABB Service for further assistance regarding which motor type is installed
on the robot, if needed.
The columns for reach refer to the robot variant designation.
Note
The article numbers in the table can not be used for ordering spare parts. The
numbers are only used for identification of installed motors.
See Product manual, spare parts - IRB 7600 for spare part numbers.
Robot Article number Article number 500 500 400 340 325 150
axis Type A motor Type B motor 2.55 2.3 2.55 2.80 /3.10 3.50
1 3HAC057539-001 3HAC062338-001 X X X X X X
3HAC060565-001 N/A X
(Foundry Prime)
2 3HAC057540-001 3HAC062339-001 X X X X
3HAC057541-001 3HAC062340-001 X X
3HAC060566-001 N/A X
(Foundry Prime)

7 Robot description
Continued
Robot Article number Article number 500 500 400 340 325 150
axis Type A motor Type B motor 2.55 2.3 2.55 2.80 /3.10 3.50
3 3HAC057540-001 3HAC062339-001 X X X X X X
3HAC060566-001 N/A X
(Foundry Prime)
4 3HAC057543-001 3HAC062341-001 X X X X X X
3HAC036644-002 N/A X
(Foundry Prime)
5 3HAC057543-001 3HAC062341-001 X X X X X X
3HAC060567-001 N/A X
(Foundry Prime)
6 3HAC057544-001 3HAC062342-001 X X X X X X
3HAC060568-001 N/A X
(Foundry Prime)
Interchangeable parts
Use the table to see if type A and type B motors are interchangeable on each robot
axis.
Robot axis Motor replacement from Requirements/notes for replacing type A motor
type A to type B with type B motor
1 Fully interchangeable.
5 Partly interchangeable. Replacement to type B requires replacement of
the left hand side wrist cover. Spare part number
for the cover that fits the type B motor:
3HAC062450-005 (ABB Orange) / 3HAC062450-
004 (Graphite White).
xx1800000129
6 Not interchangeable. The complete wrist unit must be replaced.

8 Reference information
8.1 Introduction
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

8.2 Applicable standards
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
General
The product is designed in accordance with ISO 10218-1:2011, Robots for industrial
environments - Safety requirements -Part 1 Robots, and applicable parts in the
normative references, as referred to from ISO 10218-1:2011. In case of deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.
Normative standards as referred to from ISO 10218-1
Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
Deviations from ISO 10218-1:2011 for IRC5 with MultiMove

A deviation exists towards ISO 10218-1:2011, paragraph 5.9 Control of simultaneous
motion, for the option MultiMove. See the application manual for MultiMove.
Region specific standards and regulations
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
ments
Other standards used in design
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments

Continued
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13732-1:2006 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.

8.3 Unit conversion
8.3 Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

8.4 Screw joints
8.4 Screw joints
General
This section describes how to tighten the various types of screw joints on ABB
robots.
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. It is recommended by ABB for M6-M20 screw joints. 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.
Generally, screws are lubricated with Gleitmo 603 mixed with Geomet 500 or
Geomet 702 in proportion 1:3. Geomet thickness varies according to screw
dimensions, refer to the following.
Dimension Lubricant Geomet thickness
M6-M20 (any length except Gleitmo 603 + Geomet 500 3-5 μm
M20x60)
M6-M20 (any length except Gleitmo 603 + Geomet 720 3-5 μm
M20x60)
M20x60 Gleitmo 603 + Geomet 500 8-12 μm
M20x60 Gleitmo 603 + Geomet 720 6-10 μm
Screws lubricated in other ways

Screws lubricated with Molykote 1000 or Molykote P1900 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 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.

8.4 Screw joints
Continued
Lubricant Article number

Molykote 1000 (molybdenum disulphide grease) 3HAC042472-001
Molykote P1900 (molybdenum disulphide grease) 3HAC070875-001
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 following tables. 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 pneumatic 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%!
Tightening torque for oil-lubricated screws with slotted or cross-recess head screws
The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Tightening torque for oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670

8.4 Screw joints
Continued
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M24 680 960 1150
Tightening torque for lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M5 8
M6 14
M8 28 35
M10 55 70
M12 96 120
M16 235 300
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent
Water and air connectors

water and air connectors when one or both connectors are made of brass.
Note

Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -

Nominal Min. 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

8.5 Weight specifications
8.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
The arm weighs 25 kg.

All lifting accessories used must be sized accord-
ingly.

8.6 Standard tools
8.6 Standard tools
General
All service (repairs, maintenance, and installation) procedures contains 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 following table.
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 Hex bit socket head cap no. 14 socket 40 mm L=100 mm
1 Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm
1 Hex bit socket head cap no. 6 socket 40 mm L=145 mm
1 Hex bit socket head cap no. 6 socket 40mm bit L=220 mm

8.7 Special tools
8.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 421, and of special tools, listed directly in the instructions
and also gathered in this section.
Basic tools
The following table specifies the tools in the basic toolkit (3HAC15571-3) that are
used for the current robot model. This toolkit is necessary primary when removing
and refitting the motors.
The tools are also listed directly in the instructions.
Description Qty Art. no.
Extension 300mm for bits 1/2" 1 3HAC12342-1
Guide pins M8 x 100 2 3HAC15520-1
Lifting tool, wrist unit 1 3HAC12734-1
Lifting tool, motor ax 1, 4, 5 1 3HAC14459-1
Lifting tool, motor ax 2, 3, 4 1 3HAC15534-1
Removal tool, motor M10x 2 3HAC14972-1
Removal tool, motor M12x 1 3HAC14973-1
Fits motors, axes 1, 2, 3, 4 and 5.
Rotation tool 1 3HAC17105-1
Mechanical stop axis 3 2 3HAC12708-2
Bolts M16 x 80 (for mechanical stop axis 3) 2 3HAB3409-89
Washers (for mechanical stop axis 3) 2 3HAA1001-186
Standard toolkit (content described in section 1 3HAC15571-1
Standard tools on page 421)
Special tools
The following table specifies the special tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly
in concerned instructions in the product manual.
Fixture lower arm 1 3HAC13660-1
Guide pins M12 x 130 2 3HAC022637-001

8.7 Special tools
Continued

Guide pins, sealing ax 2/3, 100mm 1 3HAC14627-3
Guide pins, sealing ax 2/3, 80mm 1 3HAC14627-2
Holder for bits (Stahlwille 736/40 S 5/16") 1 3HAC029090-001
Hydraulic cylinder 1 3HAC11731-1
Hydraulic pump, 80 MPa 1 3HAC13086-1
Hydraulic pump, 150 MPa (Glycerin) 1 3HAC021563-012
Lifting accessory, base 1 3HAC15560-1
Lifting accessory, robot 1 3HAC15607-1
Lifting accessory, upper arm 1 3HAC15536-1
Lifting eye VLBG M12 1 3HAC16131-1
Lifting eye M12 2 3HAC14457-3
Lifting eye M16 2 3HAC14457-4
Lifting tool (chain) 1 3HAC15556-1
Lifting tool, gearbox axis 2 and axis 3 1 3HAC032723-001
Measuring tool 1 6896134-GN
Oil injector / max 500 MPa 1 3HAC021590-001
Press tool, axis 2 bearing 1 3HAC076203-001
Puller device, axis 2 shaft 1 3HAC075427-001
Press device, axis 2 shaft 1 3HAC076203-001
Press equipment, balancing device 1 3HAC074411-001
Adapter 1 3HAC078221-001
Used together with press equipment for balan-
cing devices from 2002 and older.
Press equipment, balancing device shaft 1 3HAC076202-001
Removal tool, wheel unit 1 3HAC15814-1
Support, base 1 3HAC15535-1
Tool set balancing device 1 3HAC15943-1
Tools that may be rented

The following table specifies the tools that may be rented from ABB in order to
perform certain service procedures as described in the Product manual.
The special tools are also listed directly in the instructions.
Description Art. no. Note
Lifting tool, lower arm 3HAC14691-1 Includes
• Guidances, 3HAC14445-1

8.7 Special tools
Continued
Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating
the robot with the alternative method, Levelmeter Calibration.
Angle bracket 68080011-LP
Calibration bracket 3HAC13908-9
Calibration tool ax1 3HAC13908-4
Measuring pin 3HAC13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC0392-1
Sync. adapter 3HAC13908-1
Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating
manual.
Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating
the robot with the Axis Calibration method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Calibration tool box, Axis Cal- 3HAC055412- Delivered as a set of calibration tools.
ibration 001 Required if Axis Calibration is the valid

8.7 Special tools
Continued
Oil exchange equipment

The following table specifies the recommended equipment for oil exchange.
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.

8.8 Lifting accessories and lifting instructions
8.8 Lifting accessories and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction delivered with each piece of lifting accessories.
The instructions delivered with the lifting accessories should be stored for later
reference.

9 Spare part lists
9.1 Spare part lists and illustrations
9 Spare part lists

9.1 Spare part lists and illustrations
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document for registered users on myABB Business Portal,
www.abb.com/myABB.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.

10 Circuit diagram
10.1 Circuit diagrams
10 Circuit diagram
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.abb.com/myABB.
See the article numbers in the tables below.
Controllers
Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Manipulators

Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
3HAC029940-001

10 Circuit diagram
Continued

Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
3HAC025744-001
Circuit diagram - IRB 910SC 3HAC056159-002

10 Circuit diagram
10.2 Validity of circuit diagram 3HAC025744-1
Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the
robot.
Check the article number of the cable harness fitted to the robot and see page 3
of the circuit diagram in order to determine if the diagram is valid for the harness
or not.
Where to find the article number Action
Label on the cable harness The label is located at the connectors in the base.
Remove the rear cover plate to see the label.
WebConfig

10 Circuit diagram
Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the
robot.
Check the article number of the cable harness fitted to the robot.
Where to find the article number Action
Label on the cable harness The label is located at the connectors in the base.
Remove the rear cover plate to see the label.
WebConfig -
This circuit diagram is valid for the following cable harness assemblies:
Robot Cable harness Revision
IRB 6600 3HAC 14940-1 all
IRB 6650, IRB 6650S 3HAC 16331-1 all
IRB 7600 3HAC 14940-1 revision 0-2
For remaining cable harness assemblies, see section Validity of circuit diagram
3HAC025744-1 on page 431.

Index
Index jogging to, 402

jogging to, TPU, 402
scales, 378
A calibration scales, 378
Absolute Accuracy, calibration, 376
CalibWare, 374
allergenic material, 34
carbon dioxide extinguisher, 35
aluminum
cast iron
disposal, 404
disposal, 404
ambient humidity
cleaning, 194
operation, 55
climbing on robot, 38
storage, 55
Cold environments, 115
ambient temperature
connecting the robot and controller, cabling, 111
operation, 55
copper
storage, 55
disposal, 404
assembly instructions, 45
assessment of hazards and risks, 34 D
Axis Calibration, 385 damage to mechanical stop, 153
calibration tool dimensions
article number, 388, 391 frame, 86
examining, 388 lower arm, 84
installation position, 390 upper arm, 85
overview of method, 385 direction of axes, 379
procedure on FlexPendant, 391, 398
protective cover and protection plug, 390–391 E
environmental information, 404
B EPS, 101
balancing device, replacement, 279 equipment on robot, 84
balancing device bearing, replacement, 274 ESD
base plate damage elimination, 62
guide pins, 76 sensitive equipment, 62
securing, 76 expected life, 123
batteries extended working range, 101
disposal, 404 extended working range, axis 1, 101
battery extra equipment
replacing, 185, 264 frame, 86
battery pack lower arm, 84
replacing, interval, 122 robot, 84
battery shutdown upper arm, 85
service routine, 185, 264
brakes F
testing function, 42 fire extinguishing, 35
fitting equipment on robot, 84
C FlexPendant
cabinet lock, 35 jogging to calibration position, 402
cable harness axes 1-4, replacement, 214 MoveAbsJ instruction, 401
cabling, robot, 112 updating revolution counters, 382
cabling, robot axes 1-4, 215 fork lift, 63
cabling, robot axes 5-6, 224 foundation
cabling between robot and controller, 111 requirements, 55
calibrating frame
robot, 385 dimensions, 86
roughly, 380
calibrating robot, 385, 397–398 G
calibration gearbox axis 1, replacement, 328
Absolute Accuracy type, 374 gearbox axis 3, replacement, 349
alternative method, 376 gearbox axis 6, replacement, 368
Levelmeter calibration, 376 gearboxes
rough, 380 location of, 163
standard type, 374 grease, 38
verification, 400 disposal, 404
when to calibrate, 377 guide pins, base plate, 76
calibration, Absolute Accuracy, 376
calibration manuals, 376 H
calibration marks, 378 hanging
Calibration Pendulum installed hanging, 34
overview of method, 397 hazard levels, 25
calibration position hazardous material, 404

Index
height motor axis 6, replacement, 321

installed at a height, 34 motor brakes
hot surfaces, 38 releasing, 73
HRA, 34 motor seal
humidity inspecting, 124
operation, 55 MoveAbsJ instruction, 401
storage, 55 TPU, 401
I N
information labels location, 159 national regulations, 34
inspecting negative directions, axes, 379
information labels, 159 neodymium
mechanical stop, 153 disposal, 404
motor seal, 124 nodular iron
inspecting oil levels disposal, 404
axis-6, 141
axis-5, 138 O
axis-4, 135 oil, 38
axis-3, 132 amount in gearboxes, 163
axis-2, 129 disposal, 404
axis-1, 126 type of oil, 163
installation oil level
mechanical stop axis 1, 104 gearbox axis-6, 141
installing equipment on robot, 84 gearbox axis-3, 132
instructions for assembly, 45 gearbox axis-2, 129
integrator responsibility, 34 gearbox axis-1, 126
intervals for maintenance, 119 operating conditions, 55
option
L Extended working range, 101
labels original spare parts, 23
robot, 27
leak-down test, 206 P
Levelmeter calibration, 376 pedestal
lifting accessory, 420 installed on pedestal, 34
lifting accessory, robot, 69 personnel
lifting robot requirements, 24
with fork lift, 63 plastic
with lifting accessory, 69 disposal, 404
with roundslings, 71 positive directions, axes, 379
limitation of liability, 23 PPE, 24
Lithium product standards, 414
disposal, 404 protection classes, 56
loads on foundation, 54 protection type, 56
lock and tag, 35 protective equipment, 24
lower arm protective wear, 24
dimensions, 84
lower arm shaft, replacement, 256 R
lubricants, 38 recycling, 404
lubrication regional regulations, 34
amount in gearboxes, 163 release brakes, 41
type of lubrication, 163 releasing motor brakes, 73
replacement
M balancing device, 279
magnesium bearing, balancing device, 274
disposal, 404 cable harness axes 1-4, 214
maintenance schedule, 119 gearbox axis 1, 328
mechanical stop gearbox axis 3, 349
axis 1, 104 gearbox axis 6, 368
axis 2, 106 lower arm shaft, 256
axis 3, 108 motor axis 1, 291
mechanical stop location, 153 motor axis 2, 296
motor axis 1, replacement, 291 motor axis 3, 302
motor axis 4, replacement, 309 replacements, report, 205

Index
report replacements, 205 ANSI, 414

requirements on foundation, 55 CAN, 414
responsibility and validity, 23 EN IEC, 414
restricting EN ISO, 414
working range axis 1, 101, 104 start of robot in cold environments, 115
working range axis 2, 106 steel
working range axis 3, 108 disposal, 404
revolution counters storage conditions, 55
storing on FlexPendant, 382 symbols
storing on TPU, 381 safety, 25
updating, 380 synchronization position, 380
risk of burns, 38 sync marks, 378
risk of tipping, 61 system integrator requirements, 34
robot
labels, 27 T
protection class, 56 temperatures
protection types, 56 operation, 55
symbols, 27 storage, 55
roundslings attached to robot, 71 testing
rubber brakes, 42
disposal, 404 tightening torque
mechanical stop axis 2, 107
S tools
safety Axis Calibration, 424
brake testing, 42 calibration equipment, Levelmeter, 424
ESD, 62 Calibration Pendulum, 424
fire extinguishing, 35 for service, 422
release robot axes, 41 oil exchange equipment, 425
signal lamp, 100 torques on foundation, 54
signals, 25 TPU
signals in manual, 25 jogging to calibration position, 402
symbols, 25 MoveAbsJ instruction, 401
symbols on robot, 27 updating revolution counters, 381
test run, 116 transportation, 403
safety devices, 35 transporting the robot, 50
safety equipment transport support, 50
mechanical stop, 104 troubleshooting
mechanical stop axis 2, 106 oil spills, 194
mechanical stop axis 3, 108 safety, 43
safety hazard type A motors, 411
hydraulic system, 36 type B motors, 411
pneumatic system, 36
safety signals U
in manual, 25 upcycling, 404
safety standards, 414 updating revolution counters, 380
scales on robot, 378 upper arm
schedule for maintenance, 119 dimensions, 85
screw joints, 417 users
securing requirements, 24
base plate, 76
securing, robot, 81 V
securing, upper arm, 304 validity and responsibility, 23
securing the robot to foundation, attachment screws, 81 velocity
shipping, 403 adjusting, 115
signal lamp, 100 verifying calibration, 400
signals
safety, 25 W
SMB weight, 53
replacing, 264 balancing device, 282, 286
SMB battery base plate, 75, 80
extension of lifetime, 185, 264 complete arm system, 229–230
replacing, 185, 264 gearbox, 344, 353
special tools, 422 lower arm, 251, 253
speed motor, 312–313, 318–319
adjusting, 115 robot, 68, 70, 72, 331, 333, 335, 338
stability, 61 upper arm, 243–244
standards, 414 wrist unit, 238–239

Index
working range restricting axis 2, 106

IRB 7600 - 150/3.5, 57 restricting axis 3, 108
IRB 7600 - 340/2.8, 58 Wrist Optimization
IRB 7600 - 400/2.55, 59 overview of method, 398
IRB 7600 - 500/2.3, 60
IRB 7600 - 500/2.55, 59 Z
restricting axis 1, 104 zero position
checking, 401

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 10-732 50 00
ABB AS
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC022033-001, Rev AG, en


3HAC022033 PM IRB 7600-En (Replace Gearbox)

Uploaded by

Copyright:

Available Formats

3HAC022033 PM IRB 7600-En (Replace Gearbox)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3HAC022033 PM IRB 7600-En (Replace Gearbox)

Uploaded by

Copyright:

Available Formats

ROBOTICS

Document ID: 3HAC022033-001

© Copyright 2007 - 2023 ABB. All rights reserved.

© Copyright 2007 - 2023 ABB. All rights reserved.

2 Installation and commissioning 45

Product manual - IRB 7600 5

2.7 Electrical connections ........................................................................................ 111

6 Product manual - IRB 7600

4.3.3 Replacement of complete arm system ......................................................... 227

7 Robot description 411

Product manual - IRB 7600 7

8 Reference information 413

9 Spare part lists 427

10 Circuit diagram 429

8 Product manual - IRB 7600

Overview of this manual

Who should read this manual?

Product manual scope

Continues on next page

Continues on next page

Document name Document ID Note

Additional document references

Document name Document ID

Continues on next page

Continues on next page

Continues on next page

Continues on next page

Continues on next page

Continues on next page

Product manual - IRB 7600 17

Product documentation, M2000/M2000A

Controller hardware option manual

18 Product manual - IRB 7600

Product documentation, IRC5

All documents can be found via myABB Business Portal, www.abb.com/myABB.

Technical reference manuals

Continues on next page

• Examples of how to use the application.

20 Product manual - IRB 7600

How to read the product manual

References to required equipment

Product manual - IRB 7600 21

1.1.1 Limitation of liability

Spare parts and equipment

Product manual - IRB 7600 23

1.1.2 Requirements on personnel

Personal protective equipment

24 Product manual - IRB 7600

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

WARNING Signal word used to indicate a potentially hazardous

ELECTRICAL Signal word used to indicate a potentially hazardous

CAUTION Signal word used to indicate a potentially hazardous

ELECTROSTATIC Signal word used to indicate a potentially hazardous

NOTE Signal word used to indicate important facts and

Continues on next page

Symbol Designation Significance

26 Product manual - IRB 7600