IRC5-IRB6600 Prod Man 3HAC020938-001 References RevC en

Product manual (part 2 of 2), reference information
Articulated robot
IRB 6600 - 225/2.55 type A
IRB 6600 - 175/2.8 type A
IRB 6600 - 175/2.55 type A
IRB 6650 - 200/2.75 type A
IRB 6650 - 125/3.2 type A
M2000, M2004, M2000A

Product manual (part 2 of 2), reference information

IRB 6600 - 225/2.55 type A
IRB 6600 - 175/2.8 type A
IRB 6600 - 175/2.55 type A
IRB 6650 - 200/2.75 type A
IRB 6650 - 125/3.2 type A
M2000
M2000A
M2004
Document ID: 3HAC 020938-001
Revision: C
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABBs written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Vsters
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Reference information
11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Spare part / part list
25
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.2 Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.2 Rebuilding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.3 Part list, overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.4 Base incl frame ax 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3.5 Axis 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.6 Axis 3-4, Foundry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3.7 Wrist, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3.8 Wrist Foundry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.9 Wrist, insulated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3.10 Material set, manipulator, 3HAC 13263-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.11 Material set, axis 1-2, 3HAC 13264-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3.12 Material set, balancing device, 3HAC 13265-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3.13 Arm extension set, 250 mm, 3HAC 12311-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Exploded views
55
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2 Base incl. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.6 Wrist complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Circuit Diagram
61
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3HAC 020938-001 Revision: C
Table of Contents
Overview
Overview
About this manual
This manual contains reference information for all procedures described in the Product
manual, procedures .
Usage
This manual should be used during
installation
maintenance work
repair work.
Who should read this manual?

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

maintenance work.
Overview
Organization of chapters
The manual is organized in the following chapters:
Chapter
Contents
Reference information
Useful information when performing installation, maintenance or

repair work (lists of necessary tools, reference documents, safety
standards).
Spare part / Part list
Complete list of manipulator parts, shown in the exploded views

or foldouts.
Exploded views
Detailed illustrations of the robot with reference numbers to the

part list.
Circuit diagram
Circuit diagram of the robot.
Revisions
Revision
Description
First edition.
Replaces previous manuals:
Installation and Commssioning Manual
Maintenance Manual
Repair Manual, part 1
Repair Manual, part 2.
Changes made in the material from the previous manuals:
Various corrections due to technical revisions, changes in the toolkits
etc.
Model M2004 implemented.

Spare part list added to manual.
Section Document references is comleted with article for calibration

manuals.
New lubricating oil in the gearboxes. Changes made in the section Part
list on page 29.
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
Installation information
Repair information
Maintenance information
In addition, spare part information is supplied for the entire option.
Product documentation, M2004

General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
RAPID Overview: An overview of the RAPID programming language.
RAPID reference manual part 1: Description of all RAPID instructions.
RAPID reference manual part 2: Description of all RAPID functions and data types.
Technical reference manual - System parameters: Description of system

parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
The purpose of the application (what it does and when it is useful)
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
How to use the application
Examples of how to use the application
Operators manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
Operators manual - IRC5 with FlexPendant
Operators manual - RobotStudio Online
Trouble shooting manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)
10
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
11
1.2. Applicable Safety Standards
1.2. Applicable Safety Standards

Standards, general
The robot is designed in accordance with the requirements of:
EN 775 - Robot safety.
EN 292-1 - Basic terminology.
EN 292-2 - Technical principles.
EN 418 - Emergency stop.
EN 563 - Temperatures of surfaces.
EN 954-1 - Safety related parts of control systems.
EN 60204-1 - Electrical equipment of machines.
EN 1050 - Principles for risk assessment.
ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.
DIN 19258 - Interbus-S, International Standard
Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:
12
EN 953 - Fixed and moveable guards
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 349 - Minimum gaps to avoid crushing of parts of the human body.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
EN 1088 - Interlocking devices
EN 999 - The positioning of protective equipment in respect of approach speeds of the

human body.
ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing

systems.
1.3. Unit conversion
1.3. Unit conversion

Converter table
Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
14.5 psi
13
1.4. Screw joints
1.4. Screw joints

General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
14
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
1.4. Screw joints
Tightening torque
Before tightening any screw, note the following:
Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
Use the correct tightening torque for each type of screw joint.
Only use correctly calibrated torque keys.
Always tighten the joint by hand, and never use pneumatical tools.
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm)

Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Dimension
Tightening torque
(Nm)
Class 8.8, oillubricated
Tightening torque
(Nm)
Tightening torque
(Nm)
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension

Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
15
1.4. Screw joints
Dimension

Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M10
55
66
M12
96
115
M16
235
280
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
16
Dimension
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
1.5. Weight specifications
1.5. Weight specifications

Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
17
1.6. Standard toolkit
1.6. Standard toolkit

General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents, standard toolkit, 3HAC 15571-1
Qty Art. no. Tool
18
Rem.
Ring-open-end spanner 8-19mm
Socket head cap 5-17mm
Torx socket no:20-60
Box spanner set
Torque wrench 10-100Nm
Torque wrench 75-400Nm
Ratchet head for torque wrench 1/2
Hexagon-headed screw M10x100
Socket head cap no:14, socket 40mm bit L 100mm
Socket head cap no:14, socket 40mm bit L 20mm To be shorted to 12mm
1.7. Special tools
1.7. Special tools

General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in section Standard toolkit on page 18, and
of special tools, listed directly in the instructions and also gathered in this section.
Basic tools
The table below specifies the tools in the basic toolkit (3HAC 15571-3) that are used for the
current robot model. This toolkit is necessary primarly when removing and refitting the
motors.
The tools are also listed directly in the instructions.
Description
Qty
Art. no.
Bolts (M16 x 60) for Mech stop ax 3
3HAB 3409-86
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Guide pins M10 x 100
3HAC 15521-1
3HAC 15521-2
Lifting tool, wrist unit
3HAC 13605-1
Lifting tool, motor ax 1, 4, 5
3HAC 14459-1
Lifting tool, motor ax 2, 3, 4
3HAC 15534-1
Mech stop ax 3
3HAC 12708-1
Removal tool, motor M10x
3HAC 14972-1
Fits motors, axes 4, 5 and 6.
Removal tool, motor M12x
3HAC 14631-1
Fits motors axes 1, 2 and 3.
Rotation tool
3HAC 17105-1
Standard toolkit (content described in

section Standard toolkit on page 18)
3HAC 15571-1
Washers for mech stop axis 3
3HAA 1001-186
Special tools
The table below specifies the special tools required during several of the service procedures.
The tools may be ordered separately and are also specified directly in concerned instructions
in the Product manual, procedures.
Description
Qty
Art. no.
Fixture lower arm
3HAC 020584-001
Gearbox crank
3HAC 16488-1
3HAC 022637-001
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
3HAC 13120-5
19
1.7. Special tools
Description
Qty
Art. no.
Guide pins, sealing ax 2/3, 100mm
3HAC 14628-2
Guide pins, sealing ax 2/3, 80mm
3HAC 14628-1
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump, 80 MPa
3HAC 13086-1
Hydraulic pump, 150 MPa (Glycerin)
3HAC 021563-012
Lifting device, base
3HAC 15560-1
Lifting device, manipulator
3HAC 15607-1
Lifting device, upper arm
3HAC 15994-1
Lifting eye VLBG M12
3HAC 16131-1
Lifting eye M12
3HAC 14457-3
Lifting eye M16
3HAC 14457-4
Lifting tool (chain)
3HAC 15556-1
Lifting tool, gearbox axis 2
3HAC 13698-1
Measuring tool
6896 134-GN
Motor press pinion
3HAC 021883-001
Oil injector / max 500 MPa
3HAC 021590-001
Press tool, axis 2 bearing
3HAC 13527-1
Puller device, axis 2 shaft
3HAC 021563-001
Press device, axis 2 shaft
3HAC 021600-001
Press tool, balancing device
3HAC 020902-001
Press tool, balancing device shaft
3HAC 17129-1
Puller tool, balancing device shaft
3HAC 12475-1
Shackle, balancing device
3HAC 020997-1
Support, base
3HAC 15535-1
Tool set balancing device
3HAC 021984-001
Tools that may be rented

The table below specifies the tools that may be rented from ABB in order to perform certain
service procedures as described in the Product manual.
The special tools are also listed directly in the instructions.
20
Description
Art. no.
Note
Lifting tool, lower arm
3HAC 14691-1
Includes
guidings, 3HAC 14446-1
1.7. Special tools
Calibration equipment, Wyler

The table below specifies the calibration equipment required when calibrating the robot with
the Wyler method, using the Levelmeter 2000.
Description
Art. no.
Angel bracket
68080011-LP
Calibration bracket
3HAC 13908-9
Calibration tool ax1
3HAC 13908-4
Levelmeter 2000 kit
6369901-347
Measuring pin
3HAC 13908-5
Sensor fixture
68080011-GM
Sensor plate
3HAC 0392-1
Sync. adapter
3HAC 13908-1
Turn disk fixture
3HAC 68080011-GU
Note
Includes one sensor.
Calibration equipment, Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with
the Pendulum method.
Description
Art. no.
Note
CalPen (Calibration
Pendulum)
3HAC 15716-1
Complete kit that also includes user

instructions.
Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.
Description
Art. no.
Note
Oil exchange equipment
3HAC 021745-001
Includes
vacuum pump with
regulator, hose and coupling
couplings and adapters
pump (manual) with hose
and coupling
graduated measuring glass
oil gun
user instructions.
21
1.8. Document references

General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot
The product specification includes generic technical data. The specification listed below is
the English version.
Document name
Document ID
Product specification
3HAC 14064-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name
Document ID
Product manual, S4Cplus M2000
3HAC 021333-001
Product manual, S4Cplus M2000A
3HAC 021128-001
Product manual, IRC5 M2004
3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name
Document ID
Note
Users guide (S4Cplus)
3HAC 7793-1
Contains instructions for daily operation

of S4Cplus based robot systems.
Operators manual (IRC5)
3HAC 16590-1
Calibration manuals
22
Document name
Document ID
Note
Calibration Pendulum
Instruction
3HAC 16578-1
Enclosed with the Calibration

Pendulum Toolkit.
Instructions for Levelmeter

calibration (alternative method)
3HAC 022907-001
Enclosed with the Levelmeter 2000.
CalibWare 2.0 Users Guide
3HAC 16090-1
Manual for Absolute Accuracy

calibration.
Additional documentation
Document name
Document ID
External axes
3HAC 9299-1
Note
23
1.9. Lifting equipment and lifting instructions
1.9. Lifting equipment and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
24

2.1. Introduction

2.1. Introduction
Definitions
This chapter specifies all spare parts and replacement articles of the robot.
25

2.2.1. Introduction
2.2 Spare part list

2.2.1. Introduction
Overview
This section specifies all articles considered spare parts of the robot. The spare parts are also
specified as required equipment directly in the repair instruction of the current spare part.
26

2.2.2. Spare part list

Repair instructions
Each spare part is replaced as described in corresponding repair instruction in the Product
manual, procedures.
In addition to the spare part list in this section, there is also a part list with other replacement
articles for the robot in section Part list on page 29.
Robot overview
The figure below shows the location of all spare parts on the robot.
xx0400001022
Parts
Description
Spare part no.
Item in figure
Motor axis 1
3HAC 15879-2
Gearbox axis 1
3HAC 10828-8
Motor axis 2 (175/2.55)
3HAC 15882-2
27

28
Description
Spare part no.
Item in figure
Motor axis 2
(125/3.2, 175/2.8, 200/2.75, 225/2.55
3HAC 15885-2
Gearbox axis 2
3HAC 020043-001
Motor axis 3 (175/2.55)
3HAC 15882-2
Motor axis 3
(125/3.2, 175/2.8, 225/2.55, 200/2.75)
3HAC 15885-2
Gearbox axis 3
3HAC 021127-001
Motor axis 4 (175/2.55)
3HAC 15887-2
Motor axis 4
(125/3.2, 175/2.8, 225/2.55, 200/2.75)
3HAC 15889-2
SMB unit
3HAC 16014-1
Battery pack
3HAC 16831-1
Cable harness axis 1-4 (IRB 6600)
3HAC 14940-1
Cable harness axis 1-4

(IRB 6650)
3HAC 16331-1
Wrist (175/2.55)
3HAC 16627-1
Wrist (175/2.55, insulated turning disk)
3HAC 17372-1
Wrist
(125/3.2, 175/2.8, 225/2.55, 200/2.75)
3HAC 16626-2
Wrist (insulated turning disk)

(125/3.2, 175/2.8, 225/2.55, 200/2.75)
3HAC 16626-3
Cable harness axis 5
3HAC 14139-1
Motor axis 5 (175/2.55)
3HAC 17484-7
Motor axis 5
(125/3.2, 200/2.75, 175/2.8, 225/2.55)
3HAC 17484-10
VK-Cover VK 120x12
3HAA 2166-23
Turning disk, dia. 200 (175/2,55)
3HAC 9744-5
Turning disk, dia. 200

(125/3.2, 200/2.75, 175/2.8, 225/2.55)
3HAC 13752-1
Gearbox axis 6 (175/2.55)
3HAC 10828-10
Gearbox axis 6
(125/3.2, 200/2.75, 175/2.8, 225/2.55)
3HAC 10828-13
Motor axis 6 (175/2.55)
3HAC 15990-4
Motor axis 6
(125/3.2, 200/2.75, 175/2.8, 225/2.55)
3HAC 15991-4
Cable harness axes 5-6
3HAC 14140-1
Balancing device (IRB 6600)
3HAC 020691-001
Balancing device (IRB 6650)
3HAC 020692-001
Complete maintenance kit, balancing

device
3HAC 021592-001
Maintenance kit with bearings, balancing

device
3HAC 021593-001

2.3.1. Introduction
2.3 Part list

2.3.1. Introduction
Overview
This section specifies all the replacement articles of the robot. The parts are shown in
exploded views or in foldouts, either in this or in a separate chapter.
Specific spare parts are listed separately in a Spare part list.
29

2.3.2. Rebuilding parts

Overview
The IRB 6600/6650 has some rebuilding parts that differ from eachother, depending on the
version of the robot. This section is a general overview of which parts belong to which
versions.
The following section, Part list on page 29also gives further details of the parts specified
below.
Rebuilding parts
30
Art. no.
Part
3HAC 10746-1
Axis 3-4
3HAC 10746-3
Axis 3-4
3HAC 10746-6
Axis 3-4
3HAC 10746-7
Axis 3-4
2.55/
175
2.55/
225
2.75/
200
2.8/
175
3.2/
125
Type
Standard
Standard
Foundry
Foundry
3HAC 020049-001 Tube shaft 2.55 X
Standard
3HAC 020053-001 Tube shaft 2.55 X
Foundry
3HAC 10141-1
Lower arm
3HAC 13940-1
Lower arm
3HAC 14940-1
Harness ax. 1-4 X
3HAC 16331-1
Harness ax.1-4
3HAC 9760-3
Arm extender
250mm
Standard
3HAC 15859-2
Arm extender
250mm
Standard
and Foundry
3HAC 9760-7
Arm extender
450mm
Standard
3HAC 15859-3
Arm extender
450mm
Standard
and Foundry
3HAB 7700-69
Screw M12x50
12X
12X
3HAA 1001-134
Washer
13x19x1,5
12X
12X
9ABA 107-56
Parallel pin
10x20
9ADA 618-56
Screw M6x16
4X
6X
3HAC 9760-9
Cover 250mm
3HAC 9760-10
Cover 450mm
3HAC 15879-2
Motor axis 1
3HAC 15885-2
Motor axis 2
3HAC 15882-2
Motor axis 2
3HAC 15885-2
Motor axis 3
3HAC 15882-2
Motor axis 3
3HAC 15889-2
Motor axis 4
X
X
X
X
X
X
X
X

Art. no.
Part
2.55/
175
3HAC 15887-2
Motor axis 4
3HAC 16627-3
Wrist 175 kg
3HAC 16626-2
Wrist 225 kg
2.55/
225
2.75/
200
2.8/
175
3.2/
125
Type
31

2.3.3. Part list, overview

Part list
32
Item Qty
Art. number
Description
Note / Dimension
3HAC 17358-1
Mechanical stop ax 1,
assembly
101
3HAC 12685-1
Base incl frame ax 1
See section Base incl

frame ax 1 on page 34
102
3HAC 10746-1
Axis 3-4
See section Axis 3-4 on

page 35
102
3HAC 10746-3
Axis 3-4 (6600 - 175/2.55)
See section Axis 3-4 on

page 35.
102
3HAC 10746-4
Axis 3-4, Foundry
See section Axis 3-4,

Foundry on page 39
102
3HAC 10746-5
Axis 3-4, Foundry (6600 175/2.55)
See section Axis 3-4,

Foundry on page 39.
103
3HAC 8114-1
Wrist (6600 - 175/2.55)
See section Wrist,

standard on page 40.
103
3HAC 8114-3
Wrist
See section Wrist,

standard on page 40
103
3HAC 8114-5
Wrist, Foundry
See section Wrist

Foundry on page 45
103
3HAC 8114-6
Wrist, Foundry (6600 - 175/

2.55)
See section Wrist

Foundry on page 45.
103
3HAC 8114-7
Wrist, insulated (6600 - 175/ See section Wrist,

2.55)
insulated on page 46.
103
3HAC 8114-8
Wrist, insulated
104
3HAC 17117-2
Balancing Device A (6600225/2.55, 6600-175/2.8,

6600-175/2.55)
104
3HAC 17117-3
Balancing Device B (6650125/3.2, 6650-200/2.75)
105
3HAC 10141-1
Lower arm (6600 - 175/2.55,

6600-225/2.55, 6600-175/
2.8)
105
3HAC 13940-1
Lower arm (6650-125/3.2,

6650-200/2.75)
106
3HAC 14940-1
Cable harness, man. ax1-4

(6600-225/2.55, 6600-175/
2.8, 6600-175/2.55)
106
3HAC 16331-1
Cable harness, man ax 1-4

(6650-125/3.2, 6650-200/
2.75)
108
3HAC 13263-1
Material set manipulator
See section Wrist,

insulated on page 46.
See section Material set,

manipulator, 3HAC
13263-1 on page 48

Item Qty
Art. number
Description
Note / Dimension
109
3HAC 13264-1
Material set ax 1-2

axis 1-2, 3HAC 13264-1
on page 49
110
3HAC 13265-1
Mtrl.set balancing device

balancing device, 3HAC
13265-1 on page 52
111
3HAC 12311-4
Arm extension set 250mm

(175/2.8)
See section Arm

extension set, 250 mm,
3HAC 12311-4 on page
53
111
3HAC 12311-5
Arm extension set 450mm

(125/3.2)
See section Arm

extension set, 450 mm,
3HAC 12311-5.
112
2 or 1 3HAC 12129-1
Cover plate
t=1,5 mm
113
8 or 4 9ADA 618-56
Torx pan head screw
M6 x 16
114
3HAC 13416-1
Protection cover
Shell size 16
115
3HAC 18281-1
Cover
33

2.3.4. Base incl frame ax 1
2.3.4. Base incl frame ax 1

Part list
Item
Qty Art. number
Description
Note / Dimension
101.1
3HAC 17224-4
Base, machining
See block Base,

machining, 3HAC 172244.
101.2
3HAC 12684-1
Frame incl ax 1 gearbox
See block Frame incl ax

1 gearbox, 3HAC
020858-001.
101.3
3HAC 11732-2
Washer
T=3
101.4
18
3HAB 7700-5
Hex socket head cap screw
101.5
3HAC 11529-1
Rubber lined clip
101.6
3HAC 14453-1
Hose with flange
101.7
3HAC 14453-2
Plug
101.8
3HAC 4428-2
Hose Clip
D=23-27
101.9
9ADA 618-56
Torx pan head screw
M6 x 16
D=28
Base, machining
Item
Qty Art. number
Description
Dimension
101.1.1 1
3HAC 17224-2
Base, casting
101.1.2 5
3HAC 4836-7
Protection plug
101.1.3 1
3HAC 1383-2
Protection Cover compl.
101.1.4 1
3HAC 14024-1
Protection screw
16 x 12.3 x 9 x 7
Frame incl ax 1 gearbox

Item
34
Qty Art. number
Description
Dimension
101.2.1 1
3HAC 15866-1
Frame machining
101.2.2 1
3HAC 10828-8
101.2.3 24
3HAB 7700-73
Hex socket head cap screw M12 x 70
101.2.4 24
3HAA 1001-134
Washer
13 x 19 x 1.5

2.3.5. Axis 3-4
2.3.5. Axis 3-4

Overview
Item
Qty Art. number
Description
Note
102.1
3HAC 13350-1
Material set ax 4
See block Material set ax 4, 3HAC

13350-1.
102.2
3HAC 020049-001
Tube shaft 2,55
See block Tube shaft 2.55, 3HAC

020049-001.
102.3
3HAC 13351-1
Axis 3
See block Axis 3, 3HAC 13351-2/1.
102.4
3HAC 14753-1
Rot ac motor incl

gearbox (6600175/2.55)
See block Rot ac motor incl

gearbox, 3HAC 14752-1.
102.4
3HAC 14752-1
Rot ac motor incl

gearbox

Material set ax 4, 3HAC 13350-1

Item
Qty
Art. number
Description
102.1.1
3HAC 12261-1
Gear Z4 /4
102.1.3
9ADA 183-37
102.1.4
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
102.1.5
3HAC 12259-1
Wheel unit ax4 225kg
See sub-block Wheel unit

ax 4, 225 kg, 3HAC
12259-1.
102.1.6
3HAA 1001-99
Wedge
102.1.7
3HAC 12560-1
Stud bolt
M8 x 65
102.1.8
12
9ADA 334-7
Spring washer, conical
8.4 x 18 x 2
102.1.9
9ADA 267-7
Hexagon nut
M8
102.1.10 3
3HAB 3409-63
102.1.11 3
9ADA 334-8
10.5 x 23 x 2.5
102.1.12 1
3HAC 13564-1
Damper axis 4
See sub-block Damper,

axis 4, 3HAC 13564-1.
102.1.13 1
3HAA 1001-17
Stop, Axis 4, Casting
102.1.14 1
3HAC 11925-1
Mechanical stop head
102.1.15 2
3HAB 3409-81
102.1.16 1
3HAA 1001-98
Gasket
T=1
102.1.17 1
3HAC 12149-4
Cover ax4 with sealing
See sub-block Cover axis

4 with sealing, 3HAC
12149-4.
102.1.18 14
9ADA 618-56
Torx pan head screw
M6 x 16
102.1.20 1
3HAC 17218-1
Set of shims
102.1.21 1
3HAC 17219-2
Thrust washer
102.1.22 1
9ABA 135-45
Retaining ring, shaft
170
102.1.23 2
2213 253-5
Ball bearing
170 x 215 x 22
102.1.24 1
2216 261-18
Sealing
170 x 200 x 15
Dimension / Note
35

2.3.5. Axis 3-4
Item
Qty
Art. number
Description
Dimension / Note
102.1.25 1
2216 0086-4
Sealing (Nilos)
180 x 215 x 4
102.1.26 1
3HAB 4317-1
Sealing
102.1.27 1
3HAC 3774-7
Spacer ring
102.1.28 1
21522012-535
O-ring
169.3 x 5.7
102.1.29 1
9ABA 107-56
Parallel pin
10 x 20
102.1.30 8,100 1171 2016-604

ml
Lubricating oil
102.1.31 30 g
3HAB 3537-1
Bearing grease
102.1.32 1 ml
3HAB 7116-1
Locking liquid
102.1.33 1 ml
3HAB 7116-2
Locking liquid
102.1.34 1
3HAC 16721-1
Magnetic plug
R 1/2"
Wheel unit ax 4, 225 kg, 3HAC 12259-1

Item
Qty
Art. number
Description
Dimenstion / Note
102.1.5.1 1
3HAC 11742-1
Intermediate hub, machine
102.1.5.2 1
3HAC 12259-2
Gear unit Z2, 3/4
See sub-block below.
102.1.5.3 1
2126 2851-104
Lock nut
M20 X 1
102.1.5.4 1
2213 3802-11
Taper roller bearing
40 x 68 x 19
102.1.5.5 1
3HAA 1001-129
Taper roller bearing
102.1.5.6 1 ml
3HAB 7116-2
Locking liquid
Gear unit Z2, 3/4, 3HAC 12259-2

Item
Qty
Art. number
Description
102.1.5.2.0
3HAC 12259-3
Pinion Z3 /4
102.1.5.2.0
3HAC 12259-4
Gear Z2 /4
Item
Qty
Art. number
Description
102.1.12.2
3HAC 13564-2
Plate for damper
Dimension
Damper, axis 4, 3HAC 13564-1

Dimension
Cover axis 4 with sealing, 3HAC 12149-4

Item
Qty
Art. number
Description
Dimension
102.1.17.1
3HAC 12149-3
Cover ax4 with gasket
102.1.17.2
3HAA 1001-628
Sealing
Tube shaft 2.55, 3HAC 020049-001
36
Item
Qty
Art. number
Description
102.2.1
3HAC 10139-2
Tube shaft 2,55, casting
Note

2.3.5. Axis 3-4
Item
Qty
Art. number
Description
Note
102.2.2
3HAC 1383-2
Protection Cover compl. See sub-block Protection

cover compl., 3HAC 1383-2
Protection cover compl., 3HAC 1383-2

Item
Qty
Art. number
Description
Dimension
102.2.2.1 1
9ADA 624-69
Torx counters. head screw
M8 x 20
102.2.2.2 1
3HAB 3772-66
O-ring
8x2
102.2.2.3 1
3HAC 1383-1
Protection Cover
102.2.2.4 1
3HAC 1383-3
Gasket
Axis 3, 3HAC 13351-1

Item
Qty
Art. number
Description
102.3.1
3HAC 10133-1
Axis 4 housing
102.3.2
3HAC 021127-001 RV 410F-270,176

assembly
See sub-block RV 410F270, 176 assembly, 3HAC

021127-001
102.3.3
24
3HAB 3409-71
Hex socket head

cap screw
M12 x 60
102.3.4
24
3HAA 1001-134
Washer
13 x 19 x 1.5
102.3.5
3HAC 14750-1
Rot ac motor incl

pinion
See sub-block Rot ac

motor incl pinion, 3HAC
14750-1
102.3.6
3HAB 3409-50
Hex socket head

cap screw
M10 x 40
102.3.7
3HAB 4233-1
Washer
102.3.8
3HAC 16721-1
Magnetic plug
102.3.9
2,500 ml 3HAC 16843-1
102.3.9
2,500 ml 3HAC 021469-001 Lubricating oil, Shell Do not mix different types
Tivela S 150
of oil!
102.3.10
9ABA 142-92
Dimension / Note
R 1/2"
Lubricating oil, RMO Do not mix different types

150
of oil!
Spring pin, slotted
10 x 30
RV 410F-270, 176 assembly, 3HAC 021127-001

Item
Qty
Art. number
Description
102.3.2.1 1
3HAC 10828-11
RV 410F, i=270,176
102.3.2.2 1
3HAB 3772-68
O-ring
Dimension
276 x 3.53
Rot ac motor incl pinion, 3HAC 14750-1

Item
Qty
Art. number
Description
102.3.5.1
3HAC 17484-9
Rotational ac motor M9
102.3.5.2
3HAC 10122-15
Input gear
Dimension
37

2.3.5. Axis 3-4
Item
Qty
Art. number
Description
Dimension
102.3.5.3
2152 2012-430
O-ring
89.5 x 3
102.3.5.4
9ADA 183-444
M8 x 130
102.3.5.5
3 ml
3HAB 7116-1
Locking liquid
Rot ac motor incl gearbox
38
Item
Qty
Art. number
Description
Dimension
102.4.1
3HAC 17484-10
102.4.1
3HAC 17484-7
Rotational ac motor M7 (6600175/2.55)
102.4.2
3HAC 12260-1
Pinion Z1 /4
102.4.3
2152 2012-430
O-ring
89,5x3

2.3.6. Axis 3-4, Foundry
2.3.6. Axis 3-4, Foundry

Overview
Item
Qty
Art. number
Description
Note
102.1
3HAC 13350-1
Material set ax 4
See block Material set ax 4,

3HAC 13350-1 on page 35
102.2
3HAC 020053-001 Tube shaft 2,55 foundry
102.3
3HAC 13351-1
Axis 3
102.4
3HAC 14753-1
Rot ac motor incl gearbox See block Rot ac motor incl

(6600-175/2.55)
gearbox on page 38
102.4
3HAC 14752-1
Rot ac motor incl gearbox See block Rot ac motor incl

gearbox on page 38
See block Axis 3, 3HAC

13351-1 on page 37
39

2.3.7. Wrist, standard

Overview
Item
Qty
Art. number
Description
Dimension / Note
103.1
3HAC 8114-4
Material set
See block Material set, 3HAC

8114-4.
103.2
3HAC 7941-30
Rot ac motor incl

gearbox

103.2
3HAC 7941-29
Rot ac motor incl

gearbox (6600175/2.55)

gearbox on page 42.
103.3
10
3HAB 3409-89
Hex socket head

cap screw
M16 x 80
103.4
3HAC 13890-1
Axis 6 complete
See block Axis 6 complete, 3HAC

13890-1/2.
103.4
3HAC 9744-1
Axis 6 complete
(6600-175/2.55)
See block Axis 6 complete, 3HAC

9744-1, 3HAC 16032-1 on page
43.
103.5
3HAC 12732-1
Label (6600-175/
2.55)
103.5
3HAC 12732-3
Label
Item
Qty
Art. number
Description
103.1.1
3HAC 7956-1
Wrist housing, 225kg
103.1.2
3HAC 7941-28
Set of shim, motor
103.1.3
3HAC 7941-19
Set of shim, bevel gear
103.1.4
9ADA 183-37
103.1.5
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
103.1.6
3HAA 2166-11
VK-Cover
D=80 B=10
103.1.7
3HAC 4334-3
Cylindrical roll. bearing
50 x 90 x 20
103.1.8
3HAC 12560-1
Stud bolt
M8 x 65
103.1.9
1 ml
3HAB 7116-2
Locking liquid
103.1.10 16
9ADA 334-7
8.4 x 18 x 2
103.1.11 4
9ADA 267-7
Hexagon nut
M8
103.1.12 4
3HAA 1001-99
Wedge
103.1.13 1
3HAB 7299-1
Sealing
Di=115 Dy=140 B=12
103.1.14 1
3HAA 2166-23
VK-Cover
D=120, B=12
103.1.15 1
3HAC 7941-32
Support shaft incl bearing
See sub-block Support

shaft incl bearing, 3HAC
7941-32.
103.1.16 6
9ADA 183-39
103.1.17 2
3HAB 4337-2
Damper axis 5
103.1.18 1
3HAC 9953-1
Syncplate with nonie
Material set, 3HAC 8114-4
40
Dimension / Note
T=1.5

Item
Qty
Art. number
Description
Dimension / Note
103.1.19 1
3HAC 16721-1
Magnetic plug
R 1/2"
103.1.21 27
9ADA 618-56
Torx pan head screw
M6 x 16
103.1.22 2
9ADA 334-6
Plain washer
6.4 x 14 x 1.5
103.1.23 1 ml
3HAB 7116-1
Locking liquid
103.1.24 1
3HAC 14139-1
Manip. Harness ax 5
103.1.25 6,700 1171 2016-604

ml
Lubricating oil
103.1.26 1
3HAC 7941-6
Interm.wheel unit/5 225kg
See sub-block Interm.

wheel unit/5 225 kg,
3HAC 7941-6.
103.1.27 1
3HAA 1001-266
Screw
M16 x 60
103.1.28 1
3HAC 7941-21
Gear wheel unit z6/5 225
See sub-block Gear

wheel unit z6/5 225,
3HAC 7941-21
103.1.29 1
3HAC 8081-8
Cover with gasket, 225kg
103.1.30 1
3HAC 8081-3
Cable cover
103.1.31 1
3HAC 14140-1
Manip. Harn. ax 5/6
103.1.32 2
2166 2055-3
Cable straps, outdoors
4.8 x 208
103.1.33 5
3HAA 1001-106
Washer
D/d =15/6.4 t=3
Support shaft incl bearing, 3HAC 7941-32

Item
Qty
Art. number
Description
Dimension
103.1.15.1
3HAC 14731-1
Shaft
103.1.15.2
3HAB 3643-11
Groove ball bearing
130 x 165 x 18
103.1.15.3
9ADA 618-56
Torx pan head screw
M6 x 16
103.1.15.4
1 ml
3HAB 7116-1
Locking liquid
Interm. wheel unit/5 225 kg, 3HAC 7941-6

Item
Qty
Art. number
Description
Dimension / Note
103.1.26.1
3HAC 7946-1
Hub ax5, machining
103.1.26.2
3HAA 1001-130
Taper Roller Bearing
103.1.26.3
3HAC 7941-12
Gear Unit z4-z5/5 225kg
See sub-block below!
103.1.26.4
3HAC 13142-1
Washer
17 x 30 x 6
103.1.26.5
3HAC 7941-11
Locking Nut
103.1.26.6
1 ml
3HAB 7116-2
Locking liquid
Gear unit Z4-Z5/5 225 kg, 3HAC 7941-12

Item
Qty Art. number
Description
103.1.26.3.1
3HAC 7941-7
Pinion z5/5 225kg
103.1.26.3.2
3HAC 7941-5
Gear z4/5 225kg
Dimension
41

Gear wheel unit z6/5 225, 3HAC 7941-21

Item
Qty
Art. number
Description
Dimension
103.1.28.1
3HAC 7941-8
Gear z6/5 225kg
103.1.28.2
3HAB 4271-1
Groove ball bearing
103.1.28.3
3HAB 6686-1
Support ring
103.1.28.4
1 ml
3HAB 7116-2
Locking liquid
110 x 150 x 20

Item
Qty
Art. number
Description
Dimension
103.2.1
3HAC 17484-10
103.2.1
3HAC 17484-7
103.2.2
3HAC 7941-1
Bevelgear set unit z1-3/5
103.2.3
2152 2012-430
O-ring
89.5 x 3
Axis 6 complete, 3HAC 13890-1/2
42
Item
Qty
Art. number
Description
Dimension / Note
103.4.1
3HAC 13752-1
Turning disk
103.4.2
3HAC 10828-13
RV 70F-125,8 assembly
103.4.3
3HAC 11522-2
Tilt housing RV70
103.4.3
3HAC 16009-1
Tilt housing RV70, foundry
103.4.4
3HAC 14754-1
Rot ac motor incl pinion

motor incl. pinion, 3HAC
14754-1.
103.4.5
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
103.4.6
9ADA 183-37
Hex socket head cap

screw
M8 x 25
103.4.7
18
3HAA 1001-172
Washer
8.4 x 13 x 1.5
103.4.8
2522 122-1
Magnetic plug
R1/4"
103.4.9
450 ml 3HAC 16843-1
Lubricating oil, RMO 150
Do not mix different

types of oil!
103.4.9
450 ml 3HAC 021469001
Lubricating oil, Shell

Tivela S 150

types of oil!
103.4.10
2 ml
3HAB 7116-1
Locking liquid
103.4.11
3HAB 3772-64
O-ring
150.0 x 2.0
103.4.12
12
3HAB 3772-61
O-ring
13.1 x 1.6
103.4.13
3HAC 16862-1
Syncplate 175 kg
103.4.14
12
3HAB 7700-65
Hex socket head cap

screw
M12 x 30
103.4.15
18
3HAB 7700-55
Hex socket head cap

screw
M8 x 40
See sub-block RV 40E81 assembly, 3HAC

10828-13.

Item
Qty
Art. number
Description
Dimension / Note
103.4.18
9ADA 618-32
Torx pan head screw
M4 x 8
103.4.20
3HAC 14263-1
Protection Cover
103.4.21
9ADA 624-69
Torx counters. head screw M8 x 20
RV 70F-125,8 assembly, 3HAC 10828-13

Item
Qty
Art. number
Description
103.4.2.1
3HAC 10828-14
RV 70F, i=125,8
103.4.2.2
3HAB 3772-57
O-ring
Dimension
164.69 x 3.53
Rot ac motor incl. pinion, 3HAC 14754-1

Item
Qty
Art. number
Description
Dimension
103.4.4.1
3HAC 17484-8
103.4.4.2
3HAC 11173-3
Pinion RV 70F.125,8
103.4.4.3
2152 2012-430
O-ring
89.5 x 3
103.4.4.4
9ADA 183-415
M5 x 55
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
Axis 6 complete, 3HAC 9744-1, 3HAC 16032-1

Item
Qty
Art. number
Description
103.4.1
3HAC 9744-5
Turning disk
103.4.2
3HAC 10828-10
RV 40E-81 assembly
103.4.3
3HAC 9744-3
Tilt housing RV40
103.4.3
3HAC 16009-2
Tilt housing RV40, foundry
103.4.4
3HAC 14755-1

motor incl. pinion, 3HAC
14755-1 on page 44.
103.4.5
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
103.4.6
9ADA 183-37
Hex socket head cap

screw
M8 x 25
103.4.7
18
3HAA 1001-172
Washer
8.4 x 13 x 1.5
103.4.8
2522 122-1
Magnetic plug
R1/4"
103.4.9
300 ml 3HAC 16843-1
IRB 6600 - 175/2.55
103.4.9
450 ml 3HAC 16843-1
IRB 6600 - 225/2.55 175/2.8, IRB 6650

types of oil!
103.4.9
300 ml 3HAC 021469001

Tivela S 150
IRB 6600 - 175/2.55
Dimension / Note
See sub-block RV 40E81 assembly, 3HAC
10828-10 on page 44.
43

Item
Qty
103.4.9
Art. number
Description
Dimension / Note
450 ml 3HAC 021469001

Tivela S 150
IRB 6600 - 225/2.55 175/2.8, IRB 6650

types of oil!
103.4.10
2 ml
3HAB 7116-1
Locking liquid
103.4.11
3HAB 3772-65
O-ring
103.4.12
12
21520431-20
O-ring
103.4.13
3HAC 16862-2
Syncplate 175 kg
103.4.14
12
21212518-577
Hex socket head cap

screw
103.4.15
18
3HAB 7700-55
Hex socket head cap

screw
103.4.16
21520441-1
Washer
103.4.18
9ADA 618-32
Torx pan head screw
103.4.20
3HAC 14263-1
Protection Cover
103.4.21
9ADA 624-69
Torx counters. head screw M8 x 20
M8 x 40
M4 x 8
RV 40E-81 assembly, 3HAC 10828-10

Item
Qty
Art. number
Description
103.4.2.1
3HAC 10828-5
RV 40E, i=81
103.4.2.2
3HAB 3772-58
O-ring
Dimension
Rot ac motor incl. pinion, 3HAC 14755-1
44
Item
Qty
Art. number
Description
Dimension
103.4.4.1
3HAC 17484-8
103.4.4.2
3HAC 10122-24 Pinion RV 40E-81
103.4.4.3
2152 2012-430
O-ring
103.4.4.4
9ADA 183-20
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
89.5 x 3

2.3.8. Wrist Foundry
2.3.8. Wrist Foundry

Overview
Item
Qty
Art. number
Description
Dimension
103.1
3HAC 8114-4
Material set
See block Material set,

3HAC 8114-4 on page 40
103.2
3HAC 7941-30
See block Rot ac motor

incl gearbox on page 42
103.2
3HAC 7941-29

(6600-175/2.55)

incl gearbox on page 42.
103.3
10
3HAB 3409-89
103.4
3HAC 13890-2
Axis 6 complete Foundry
See block Axis 6

complete, 3HAC 13890-1/
2 on page 42
103.4
3HAC 16032-1
Axis 6 complete Foundry

(6600-175/2.55)
See block Axis 6

complete, 3HAC 9744-1,
3HAC 16032-1 on page
43.
103.5
3HAC 12732-2
Label
103.5
3HAC 12732-4
Label
45

2.3.9. Wrist, insulated

Overview
Item
Qty Art. no.
Description
Note/Dimension
103.1
3HAC 8114-4
Material set

8114-4 on page 40.
103.2
3HAC 7941-29

(6600-175/2.55)

8114-4 on page 40.
103.2
3HAC 7941-30

gearbox on page 42.
103.3
8
10
3HAB 3409-89
103.4
3HAC 17255-1
Ax 6 complete, insulated
(6600-175/2.55)
See block Ax 6 complete,

insulated, 3HAC 17255-1 on
page 46.
103.4
3HAC 17371-1
Ax 6 complete, insulated
See block Ax 6 complete,

insulated, 3HAC 17371-1 on
page 47.
103.5
3HAC 12732-5
Label
103.5
3HAC 12732-6
Label
Ax 6 complete, insulated, 3HAC 17255-1

Item
Qty
Art. no.
Description
103.4.1
3HAC 17098-1
Axis 6 insulated
103.4.2
3HAC 14755-1

motor incl pinon, 3HAC
14755-1 on page 46.
103.4.3
9ADA 312-7
Plain washer
M8
103.4.4
9ADA 183-37
103.4.5
300
ml
3HAC 021469001
Lubricating oil, Shell Tivela S

150
103.4.5
300
ml
3HAC 16843-1
103.4.6
1 ml
3HAB 7116-1
Locking liquid
103.4.7
3HAC 16862-2
Syncplate 175 kg
103.4.8
9ADA 618-32
Torx pan head screw
103.4.9
3HAC 14263-1
Protection cover
9ADA 624-69
Torx counters, head screw
103.4.10 1
Note/Dimension
Rot ac motor incl pinon, 3HAC 14755-1
46
Item
Qty
Art. no.
Description
Note
103.4.2.1
3HAC 17484-8
103.4.2.2
3HAC 10122-24
Pinion RV40E-81

Item
Qty
Art. no.
Description
103.4.2.3
21522012-430
O-ring
103.4.2.4
9ADA 183-20
Hex socket head screw
103.4.2.5
2 ml
3HAB 7116-1
Locking liquid
103.4.2.6
3HAC 12877-1
Gasket
Note
Ax 6 complete, insulated, 3HAC 17371-1

Item
Qty
Art. no.
Description
103.4.1
3HAC 17196-1
Axis 6 insulated
103.4.2
3HAC 14754-1

motor incl pinon, 3HAC
14754-1 on page 47.
103.4.3
9ADA 312-7
Plain washer
M8
103.4.4
9ADA 183-37
103.4.5
450
ml
3HAC 021469001
Lubricating oil, Shell Tivela S

150
103.4.5
450
ml
3HAC 16843-1
103.4.6
2 ml
3HAB 7116-1
Locking liquid
103.4.7
3HAC 16862-1
Syncplate 225 kg
103.4.8
9ADA 618-32
Torx pan head screw
103.4.9
3HAC 14263-1
Protection cover
9ADA 624-69
Torx counters, head screw
103.4.10 1
Note/Dimension
Rot ac motor incl pinon, 3HAC 14754-1

Item
Qty
Art. no.
Description
103.4.2.1
3HAC 17484-8
103.4.2.2
3HAC 11173-3
Pinion RV70F-125,8
103.4.2.3
21522012-430
O-ring
103.4.2.4
9ADA 183-415
Hex socket head screw
103.4.2.5
2 ml
3HAB 7116-1
Locking liquid
103.4.2.6
3HAC 12877-1
Gasket
Note
47

2.3.10. Material set, manipulator, 3HAC 13263-1
2.3.10. Material set, manipulator, 3HAC 13263-1

Overview
Item
48
Qty
Dimension /
Note
Art. number
Description
108.201 2
3HAC 17212-1
Sealing axis 2/3
108.202 66
3HAB 7700-69
108.203 3
3HAC 12703-1
Washer, axis 3
108.204 33
3HAA 1001-134
Washer
108.206 12
3HAB 7700-69
M12 x 50
108.207 12
3HAA 1001-134
Washer
13 x 19 x 1.5
108.210 1
3HAC 14300-1
Cable protector
108.211 1
3HAC020507-001
Lower arm cable protection

(IRB6650)
108.211 1
3HAC 16926-1
Lower arm cable protection

(IRB6600)
108.212 1
3HAC 11771-1
Cable guide, end part
108.213 1
3HAC 13960-1
Connection plate, ax3
108.214 2
3HAC 12320-1
Damper, axis 3
108.215 2
3HAC 12991-1
Damper, axis 2
108.216 2
9ADA 624-65
Torx counters. head screw
M6 x 60
108.217 2
9ADA 334-7
8.4 x 18 x 2
108.218 2
9ADA 618-57
Torx pan head screw
M6 x 20
108.220 2
3HAC 9953-1
Syncplate with vernier
T=1.5
108.222 1
3HAC 12719-1
Syncplate with vernier ax3
T=1.5
108.223 2
9ADA 183-48
M10 x 16
108.224 1
3HAC 12844-1
Cable cover
108.225 21
9ADA 618-56
Torx pan head screw
108.228 1
3HAC 3261-1
Cover
108.229 1
3HAC 15431-1
Cable protection
108.230 1
3HAC 14880-1
Cable fixing bracket
108.231 1
21520441-1
Washer
108.232 6
3HAC 16721-1
Magnetic plug
R 1/2"
108.233 1
2522122-1
Magnetic plug
G 1/4"
108.234 3
9ADA 618-56
Torx pan head screw
M6 x 16
108.235 1
3HAC 020958-001
Cable protection lower arm
M12 x 50
t = 4 mm
M6 x 16
t=3

2.3.11. Material set, axis 1-2, 3HAC 13264-1

Overview
Item
Qty
Art. number
Description
Dimension / Note
109.301
3HAC 021127-001
Reduction gear
See block Reduction

gear.
109.302
3HAC 16829-1
Cover, axis 2
109.303
3HAC 14699-1
Friction washer
294x333x1,0
109.304
24
3HAB 3409-71
Hex socket head cap

screw
M12 x 60
109.305
24
3HAA 1001-134
Washer
13 x 19 x 1.5
109.306
3HAC 14749-1

incl pinion, 3HAC
14749-1.
109.307
3HAC 14750-1

incl pinion, 3HAC
14750-1/ 14751-1 on
page 51.
109.307
3HAC 14751-1

(6600-175/2.55)

incl pinion, 3HAC
14750-1/ 14751-1 on
page 51.
109.308
3HAB 3409-50
Hex socket head cap

screw
M10 x 40
109.309
3HAB 4233-1
Washer
109.310
3HAC 12252-1
Bottom plate
T=3
109.311
3HAC 14131-1
Connection plate, base
t=3 mm
109.312
3HAC 11774-3
Adapter, complete
See block Adapter,

complete, 3HAC 117743.
109.313
3HAC 11769-1
Cable guide, ax.1
109.314
3HAC 16295-3
Cover
109.315
29
9ADA 183-39
Hex socket head cap

screw
M8 x 35
109.316
29
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
109.317
3HAB 3772-68
O-ring
276x3,53
109.318
3HAB 3772-69
O-ring
378x4
109.319
3HAB 3772-70
O-ring
340x3,5
109.320
3HAC 12671-5
Profile with sync scale
109.321
3HAC 12671-6
Block for calibration
109.322
3HAC 14024-1
Protection screw
See block Protection

screw, 3HAC 14024-1.
109.324
24
9ADA 618-56
Torx pan head screw
M6 x 16
109.325
9ADA 618-57
Torx pan head screw
M6 x 20
109.326
3HAC 16014-1
Serial measurement unit
109.327
3HAC 14692-3
Cover SMB and BRU
See block Cover SMB

and BRU.
49

Item
Qty
Art. number
Description
Dimension / Note
109.328
3HAC 16831-1
Battery pack
109.329
3HAC 13151-1
Cable battery/SMB
L=350 20
109.330
3HAC 11526-1
Stud screw
M6 x 150
109.332
3HAC 14791-3
Cover battery box
See block Cover,

battery box, 3HAC
14791-3.
109.334
9ADA 618-53
Torx pan head screw
M6 x 8
109.335
3HAA 2166-23
VK-Cover
D=120, B=12
109.336
3HAC 020745-001
Attachment plate
IRB 6600
109.337
3HAC 12625-1
Strap, Velcro
25 x 450
109.338
3HAC 14792-1
Bracket
T=3
109.339
3HAC 15619-1
Cable, FB7-SMB 1.7
109.341
7,300 3HAC16843-1
ml
Do not mix the types of

oil!
109.341
7,300 3HAC 021469-001

ml

Tivela S 150

oil!
109.342
4,600 3HAC 16843-1

ml

oil!
109.342
4,600 3HAC 021469-001

ml

Tivela S 150

oil!
109.344
1 ml
3HAB 7116-1
Locking liquid
109.345
9ADA 267-6
Hexagon nut
109.346
3HAC 16035-1
BU w. buttons DSQC 563
109.347
3HAC 6499-1
Push button guard
109.348
9ADA 629-56
Torx pan head roll. screw M6 x 16
109.349
9ADA 618-58
Torx pan head screw
109.350
3HAC 4813-1
Cover, push button guard
109.351
10
9ADA 618-44
Torx pan head screw
Art. number
Description
109.301.1 1
3HAC 10828-11
Reduction gear
109.301.2 1
3HAB 3772-68
O-ring
M6
M6 x 25
M5 x 12
Reduction gear
Item
Qty
Dimension
Rot ac motor incl pinion, 3HAC 14749-1

Item
50
Qty
Art. number
Description
Dimension
109.306.1 1
3HAC 17484-6
109.306.2 1
3HAC 11350-1
Pinion RV 500C & RV 320C
109.306.3 1
2152 2012-430
O-ring
89.5 x 3

Rot ac motor incl pinion, 3HAC 14750-1/ 14751-1

Item
Qty
Art. number
Description
109.307.1 1
3HAC 17484-9
109.307.1 1
3HAC 17484-6
109.307.2 1
3HAC 10122-15
Input gear
109.307.3 1
21522012-430
O-ring
109.307.4 1
9ADA 183-444
Hexagon socket head screw
109.307.5 1 ml
3HAB 7116-1
Locking liquid
Art. number
Description
109.312.1 1
3HAC 11774-1
Adapter, machined
109.312.2 2
2152 2012-428
O-ring
109.312.3 1 ml
1234 0011-125
Acrylate adhesive
Dimension
89.5 x 3
Adapter, complete, 3HAC 11774-3

Item
Qty
Dimension
79.5 x 3
Protection screw, 3HAC 14024-1

Item
Qty
Art. number
Description
Dimension
109.322.1 1
3HAC 13582-1
Protection screw
109.322.2 1
3HAB 3772-32
O-ring
17 x 3
Item
Art. number
Description
Dimension
109.327.1 1
3HAC 14692-1
Cover
109.327.2 1
3HAC 14692-2
Gasket
109.327.3 1
3HAC 14692-4
Rubber cloth
Art. number
Description
Dimension
109.332.1 1
3HAC 14791-1
Cover
T=4
109.332.2 1
3HAC 14791-2
Gasket
T=3
109.332.3 1
3HAC 16977-1
Warning label battery
Cover SMB and BRU

Qty
Cover, battery box, 3HAC 14791-3

Item
Qty
51

2.3.12. Material set, balancing device, 3HAC 13265-1
2.3.12. Material set, balancing device, 3HAC 13265-1

Overview
52
Item
Qty
Art. number
Description
Dimension
110.401
3HAC 12441-2
Spherical roller bearing
65 x 120 x 38
110.402
3HAC 12481-1
Thrust washer
110.403
3HAC 12627-1
Bushing
110.404
9ABA 135-31
Retaining ring, shaft
110.405
3HAC 12480-1
Shaft
110.406
3HAC 4836-7
Protection plug
16 x 12.3 x 9 x 7
110.407
3HAB 7700-5
M16 x 70
110.408
9ABA 107-56
Parallel pin
10 x 20
110.409
3HAC 12548-1
Protection washer
T=1
110.410
3HAC 12534-1
Shaft, balancing device
110.411
3HAA 1001-186
Washer
110.412
50 ml 3HAA 1001-294
Grease
110.413
3HAC 4836-1
Protection plug
20 x 14.6 x 7.5 x 5.5
110.414
9ADA 183-490
M16 x 180
110.415
9ADA 312-10
Plain washer
17 x 30 x 3
65
17 x 25 x 3

2.3.13. Arm extension set, 250 mm, 3HAC 12311-4

Overview
Item
Qty
Art. number
Description
111.501
3HAC 9760-3
Arm extender 250mm
111.501
3HAC 15859-2
Arm extender 250mm, Foundry
111.503
12
3HAB 7700-69
M12 x 50
111.504
12
3HAA 1001-134
Washer
13 x 19 x 1.5
111.505
9ABA 107-56
Parallel pin
10 x 20
111.506
3HAC 9760-9
Cable cover 250mm
111.507
9ADA 618-56
Torx pan head screw
Dimension
M6 x 16
53

54
3 Exploded views
3.1. Introduction
3 Exploded views
3.1. Introduction
Definitions
This chapter contains detailed views of the components on the manipulator.
The numbered details are specified with item numbers in the Part List.
The exploded views are divided into:
Base, incl. frame
Frame-Lower arm 1
Frame-Lower arm 2
Upper arm
Wrist complete
55
3 Exploded views
3.2. Base incl. Frame
3.2. Base incl. Frame
xx0200000329
56
3 Exploded views
3.3. Frame-Lower arm 1

Exploded view
xx0200000334
57
3 Exploded views
xx0200000335
58
3 Exploded views
3.5. Upper arm
3.5. Upper arm
xx0200000337
59
3 Exploded views
3.6. Wrist complete
3.6. Wrist complete
xx0200000336
60
4 Circuit Diagram
4.1. Introduction
4 Circuit Diagram
4.1. Introduction
Overview
This chapter includes the circuit diagram of the robot.
61
Circuit Diagram 3HAC 13347-1 / Rev. 02

CONTENTS
Sheet
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 6............................................................................................................................111
Switches axis 1 .............................................................................................................113
Switches/Fan axis 2 ......................................................................................................114
Switches/Fan axis 3 ......................................................................................................115
Axis 5 (IRB 6600) ........................................................................................................901
Design changes, note 1.1 ..............................................................................................905
Design changes, note 2.1-2.7 ........................................................................................906
Contents
101
02
Circuit Diagram 3HAC 13347-1
Revision
sheet
Connection Point Location
102
Revision
02
sheet
02
Legend
103
Revision
sheet
sheet
104
Revision
02
Brake Release Unit
Serial Measurement Board
105
Revision
02
sheet
Axis 1
106
02
Revision
sheet
Axis 2
107
02
Revision
sheet
Axis 3
108
02
Revision
sheet
109
02
Revision
sheet
Axis 4
sheet
110
Revision
02
Axis 5 (IRB 7600)
Axis 6
111
02
Revision
sheet
Switches axis 1
113
Revision
02
sheet
Switches/Fan axis 2
114
Revision
02
sheet
Switches/Fan axis 3
115
Revision
02
sheet
sheet
Revision
901
02
Axis 5 (IRB 6600)
Revision
905
02
Design changes, note 1.1
sheet
Revision
906
02
Design changes, note 2.1-2.7
sheet

IRC5-IRB6600 Prod Man 3HAC020938-001 References RevC en

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Product manual (part 2 of 2), reference information

Product manual (part 2 of 2), reference information

Copyright 2004 ABB All right reserved.

3HAC 020938-001 Revision: C

3HAC 020938-001 Revision: C

Who should read this manual?

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/

3HAC 020938-001 Revision: C

Useful information when performing installation, maintenance or

Spare part / Part list

Complete list of manipulator parts, shown in the exploded views

Detailed illustrations of the robot with reference numbers to the

Circuit diagram of the robot.

Model M2004 implemented.

Section Document references is comleted with article for calibration

3HAC 020938-001 Revision: C

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views

In addition, spare part information is supplied for the entire option.

3HAC 020938-001 Revision: C

Product documentation, M2004

Product documentation, M2004

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views

RAPID Overview: An overview of the RAPID programming language.

RAPID reference manual part 1: Description of all RAPID instructions.

Technical reference manual - System parameters: Description of system

3HAC 020938-001 Revision: C

Product documentation, M2004

The purpose of the application (what it does and when it is useful)

How to use the application

Examples of how to use the application

Operators manual - IRC5 with FlexPendant

Operators manual - RobotStudio Online

Trouble shooting manual for the controller and robot

3HAC 020938-001 Revision: C

Robot fundamentals (describing the fundamental aspects, functions, concept and

Product documentation, M2004

3HAC 020938-001 Revision: C

3HAC 020938-001 Revision: C

1.2. Applicable Safety Standards

EN 775 - Robot safety.

EN 292-1 - Basic terminology.

EN 292-2 - Technical principles.

EN 418 - Emergency stop.

EN 563 - Temperatures of surfaces.

EN 954-1 - Safety related parts of control systems.

EN 60204-1 - Electrical equipment of machines.

EN 1050 - Principles for risk assessment.

ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.