S4CPlus-Maintenance Manual IRB6600

Maintenance Manual
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Maintenance Manual, IRB 6600/6650, M2000A

3HAC 16246-1
Revision A
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.
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 2003 ABB All rights reserved.

ABB Automation Technology Products AB
Robotics
SE-721 68 Vsters
Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 1: Safety, service
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Section 1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.3 Emergency release of the manipulators arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.5 Risk of disabling function "Reduced speed 250 mm/s". . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.3.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chapter 2: Reference information
13
2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Section 2.1: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.1.1 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.1.2 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.1.3 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.1.4 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.1.5 Special tools, IRB 6600/6650/7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.1.6 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.1.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Chapter 3: Service Information System (SIS)
23
3.0.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.0.2 Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.0.3 Defining the SIS input parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.0.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.0.5 Reading the SIS output logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.0.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Chapter 4: Maintenance schedules and intervals
37
4.0.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

4.0.2 Maintenance schedule, IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.0.3 Expected component life, IRB 6600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.0.4 Maintenance schedule, controller S4CPlus M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3HAC 16246-1
Table of Contents
Chapter 5: Maintenance activities, manipulator
43
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 5.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.1.5 Inspection, oil level, gearbox axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.1.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1.9 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1.10 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1.11 Inspection, mechanical stop, axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1.12 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1.13 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.1.14 Inspection, UL signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Section 5.2: Changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2.1 Oil change, gearbox axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

5.2.3 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Section 5.3: Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.3.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Section 5.4: Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.4.1 Cleaning, manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Chapter 6: Maintenance activities, controller cabinet
93
6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Section 6.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1.1 Inspection of controller cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Section 6.2: Replacement activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.2.1 Replacement of battery unit, controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Section 6.3: Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3.1 Cleaning of controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

6.3.2 Cleaning computer fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.3.3 Cleaning Drive units and air outlet device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.3.4 Cleaning Air outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.3.5 Cleaning Drain filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
ii
3HAC 16246-1
0.0.1 Overview
0.0.1 Overview
About This
Manual
This information product is a manual containing instructions for maintenance of the complete
robot system, mechanically as well as electrically.
Usage
This manual should be used during maintenance work.
Who Should Read

This Manual?
This manual is intended for:
Prerequisites
Organization of
Chapters
maintenance personnel in the user's organization.
maintenance personnel in other organizations.
The reader should...
be a trained maintenance craftsman
have the required knowledge of mechanical maintenance work OR
have the required knowledge of electrical maintenance work.
The information product is organized in the following chapters:
Chapter
Contents
Safety, service
Reference information
Service Information System (SIS)
Maintenance Schedules
Maintenance activities
Maintenance activities for options
References
Reference
Document Id
Circuit diagram, Manipulator
3HAC 13347-1
Circuit diagram, Controller
3HAC 5582-2
Revisions
Revision
Description
First edition
3HAC 16246-1
Various corrections in text and in figures due to reconstructions, new spare part numbers, new tools, etc.
Manual completed with references to pagenumbers and numbering of sections (manipulator sections).
Manual completed with version IRB 6650.
0.0.1 Overview
3HAC 16246-1
0.0.2 Product Documentation
General
The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and
Commissioning
Manual
The Installation and Commissioning Manual contains the following information:
Repair Manual
Maintenance
Manual
Safety, Service
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Installation of controller software
System directory structure
Calibration
If there is any, model specific information
The Repair Manual contains the following information:
Safety, Service
Remove/Refitting instructions for all manipulator details considered spare parts
Remove/Refitting instructions for all controller cabinet details considered spare parts
The Maintenance Manual contains the following information:
Safety, Service
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the controller, respectively.
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 Robotics.
3HAC 16246-1
Hardware option
manual
Each hardware option is supplied with its own documentation. Each document set contains
the types of information specified above:
Installation information
Repair information
Maintenance information
In addition, spare part information is supplied for the complete option.
3HAC 16246-1
1 Safety, service
1.0.1 Introduction
Chapter 1: Safety, service

1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
The chapter "Safety, service" is divided into the following sections:

1. General information contains lists of:
Safety, service -general
Limitation of liability
Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16246-1
1 Safety, service
1.1.1 Safety, service - General
Section 1.1: General information

1.1.1 Safety, service - General
Validity and
responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of
external safety
devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
1.1.2 Limitation of Liability
General
Any information given in this information product regarding safety, must not be construed as
a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if
all safety instructions have been complied with.
1.1.3 Related information
General
The list below specifies documents which contain useful information:
Documents
Type of information
Detailed in document
Installation of safety devices
Installation and Commissioning

Manual
Changing robot modes
Users Guide
Restricting the working space Installation and Commissioning

Manual
Section
Start-up
On-site installation Manipulator
3HAC 16246-1
1 Safety, service
1.2.1 Safety risks related to gripper
Section 1.2: Safety risks

1.2.1 Safety risks related to gripper
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
1.2.2 Safety risks related to tools/workpieces
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
1.2.3 Safety risks related to pneumatic/hydraulic systems
General
Residual energy
Safe design
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
1.2.4 Safety risks during operational disturbances
General
Qualified personnel
Extraordinary
risks
3HAC 16246-1
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Care must be taken at all times.
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.
1 Safety, service
1.2.5 Safety risks during installation and service
1.2.5 Safety risks during installation and service
General risks during installation

and service
Nation/region
specific regulations
Non-voltage
related risks
To be observed
by the supplier of
the complete system
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available
for the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
tie rod.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
When dismantling/assembling mechanical units, watch out for falling objects.
Be aware of stored heat energy in the controller.
Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
1.2.6 Risks associated with live electric parts
Voltage related
risks, general
Voltage related
risks, controller
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
A danger of high voltage is associated with the following parts:
Be aware of stored electrical energy (DC link) in the controller.
3HAC 16246-1
1 Safety, service
1.2.6 Risks associated with live electric parts
Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.
The mains supply/mains switch
The power unit
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The drive unit (700 VDC)
The service outlets (115/230 VAC)
The power supply unit for tools, or special power supply units for the machining process
The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
Additional connections
Voltage related
risks, manipulator
A danger of high voltage is associated with the manipulator in:
Voltage related
risks, tools, material handling
devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be damaged.
3HAC 16246-1
The power supply for the motors (up to 800 VDC)
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
1 Safety, service
1.3.1 Safety fence dimensions
Section 1.3: Safety actions

1.3.1 Safety fence dimensions
General
Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator
or controller)!
1.3.3 Emergency release of the manipulators arm
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, which may further increase any injury!
1.3.4 Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
10
3HAC 16246-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit
or a PC. This will affect the safety function Reduced speed 250 mm/s.
1.3.6 Safe use of the Teach Pendant Unit

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device
is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
During programming and testing, the enabling device must be released as soon as there is no
need for the robot to move.
The programmer must always bring the Teach Pendant Unit with him/her, when entering the
robots working space. This is to prevent anyone else taking control over the robot without the
programmer knowing.
1.3.7 Work inside the manipulators working range

If work must be carried out within the robots work envelope, the following points must be
observed:
- The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
- The robots speed is limited to max. 250 mm/s when the operating mode selector is in position
< 250 mm/s. This should be the normal position when entering the working space. The position
100% full speedmay only be used by trained personnel who are aware of the risks that this
entails.
- Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not
to get entangled with hair or clothing. Also be aware of any danger that may be caused by
rotating tools or other devices mounted on the manipulator or inside the cell.
- Test the motor brake on each axis, according to section Brake testing on page 10.
3HAC 16246-1
11
1 Safety, service
1.3.7 Work inside the manipulators working range
12
3HAC 16246-1
2 Reference information
2.0.1 Introduction
Chapter 2: Reference information

2.0.1 Introduction
General
3HAC 16246-1
This chapter presents generic pieces of information, complementing the more specific information in the following chapters.
13
2.1.1 Applicable Safety Standards
Section 2.1: Reference information

2.1.1 Applicable Safety Standards
Standards,
general
Standards,
robot cell
14
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
The following standards are applicable when the robot is part of a robot cell:
EN 953 - Fixed and moveable guards
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 349 - Minimum gaps to avoid crushing of parts of the human body.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
EN 1088 - Interlocking devices
EN 999 - The positioning of protective equipment in respect of approach speeds of the

human body.
ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing systems.
3HAC 16246-1
2.1.2 Screw joints
2.1.2 Screw joints
General
This section details how to tighten the various types of screw joints on the manipulator as well
as the controller.
The instructions and torque values are valid for screw joints comprising metallic materials
and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type
screw joints.
UNBRAKO
screws
UNBRAKO is a special type of screw recommended by ABB in 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 screw 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 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate 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.
Tightening torque
3HAC 16246-1
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
Below are tables specifying the torque values for different screw joint types:
15
2.1.2 Screw joints
Screws with
slotted or cross
recess head
Dimension
Tightening torque (Nm)

Class 4.8 "dry"
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Tightening torque
(Nm)
Class 8.8 "dry"
Tightening torque
(Nm)
Class 10.9 "dry"
Tightening torque
(Nm)
Class 12.9 "dry"
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
Dimension

Class 10.9

Class 12.9
M8
28
34
M10
55
66
M12
96
115
M16
235
280
Screws with
hexagon socket
head, dry
Screws with
hexagon socket
head, lubricated
16
3HAC 16246-1
2.1.3 Weight specifications
2.1.3 Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
ABB recommends the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.
Example
Below is an example of how a weight specification is presented:

The motor weighs 65 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16246-1
17
2.1.4 Standard toolkit
2.1.4 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
18
Qty
Art. no.
Tool
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
Socket head cap no:6, socket 40mm bit L 145mm
3HAC 16246-1
2.1.5 Special tools, IRB 6600/6650/7600
General
All service (repairs, maintenance and installation) 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 the table below.
Special tools, IRB

6600/6650/7600
The table below is an overview of all the special tools required when performing service
activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
3HAC 16246-1
Description
IRB 66X0/ IRB 7600/

Art. no.
Qty
Qty
Angel bracket
68080011-LP
Bolts (M16 x 60) for Mech stop ax 3
3HAB 3409-86
Bolts (M16 x 80) for Mech stop ax 3
3HAB 3409-89
Cal. tool
68080011-GM
Calibration bracket
3HAC 13908-9
Calibration tool ax1
3HAC 13908-4
CalPen (Calibration Pendulum)
3HAC 15716-1
Extension 300mm for bits 1/2"
3HAC 12342-1
Fixture lower arm
3HAC 13659-1
Fixture lower arm
3HAC 13660-1
Gearbox crank
3HAC 16488-1
Guide pins M12 x 150
3HAC 13056-2
3HAC 13056-3
3HAC 13056-4
Guide pins M8 x 100
3HAC 15520-1
Guide pins M8 x 150
3HAC 15520-2
Guide pins sealing
3HAC 14445-1
Guide pins sealing
3HAC 14446-1
3HAC 15521-1
3HAC 15521-2
3HAC 13120-2
3HAC 13120-3
3HAC 13120-4
3HAC 13120-5
Guide pins sealing ax 2, 3, 100mm
3HAC 14628-2
3HAC 14628-1
3HAC 14627-3
3HAC 14627-2
Hydraulic cylinder
3HAC 11731-1
19
Description
IRB 66X0/ IRB 7600/

Art. no.
Qty
Qty
Hydraulic pump 80Mpa
3HAC 13086-1
Hydraulic pump 80Mpa (Glycerin)
3HAC 13086-2
Levelmeter 2000 kit
6369901-348
Lifting device, base
3HAC 15560-1
Lifting device, manipulator
3HAC 15607-1
Lifting device, upper arm
3HAC 15994-1
Lifting device, upper arm
3HAC 15536-1
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 ax 2
3HAC 13698-1
Lifting tool, gearbox ax 2
3HAC 12731-1
Lifting tool, lower arm
3HAC 14691-1
Lifting tool, motor ax 1, 4, 5
3HAC 14459-1
Lifting tool, motor ax 2, 3, 4
3HAC 15534-1
Lifting tool, wrist unit
3HAC 13605-1
Lifting tool, wrist unit
3HAC 12734-1
Measuring pin
3HAC 13908-5
Mech stop ax 3
3HAC 12708-1
Mech stop ax 3
3HAC 12708-2
Press tool, ax 2 bearing
3HAC 13527-1
Press tool, ax 2 bearing
3HAC 13453-1
Press tool, ax 2 shaft
3HAC 13452-1
Press tool, balancing device shaft
3HAC 17129-1
Press tool, balancing device
3HAC 15767-1
Puller tool, balancing device shaft
3HAC 12475-1
Removal tool, wheel unit
3HAC 15814-1
Removal tool, motor M10x
3HAC 14972-1
3HAC 14631-1
3HAC 14973-1
Rotation tool
3HAC 17105-1
Sensor plate
3HAC 0392-1
Support, base
3HAC 15535-1
Sync. adapter
3HAC 13908-1
Tool set balancing device
3HAC 15943-2
Tool set balancing device
3HAC 15943-1
Turn disk fixture
3HAC 68080011-GU
Washers for Mech stop axis 3
3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
20
3HAC 16246-1
2.1.6 Performing a leak-down test
2.1.6 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Spare part no. Art. no.
Leakdown tester
Note
3HAC 0207-1
Leak detection spray
Procedure
Step
3HAC 16246-1
Action
Note/Illustration
1.
Finish the refitting procedure of the motor or gear in

question.
2.
Remove the topmost oil plug on the gear in question, Art. no. specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3.
Apply compressed air, and raise the pressure with

the knob until the correct value is shown on the
manometer.
4.
Disconnect the compressed air supply.
5.
Wait for approx. 8-10 minutes. No pressure loss

must be detected.
6.
Was any pressure drop evident?

Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7.
Spray suspected leak areas with leak detection

spray .
Bubbles indicate a leak.
8.
When the leak has been localized: take the necessary measures to correct the leak.
Recommended value: 0.2 0.25 bar (20 - 25 kPa)
If the compressed air is significantly colder or warmer than

the gearbox to be tested, a
slight pressure increase or
decrease respectively may
occur. This is quite normal.
Art. no. specified above!
21
2.1.7 Lifting equipment and lifting instructions
2.1.7 Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
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.
22
3HAC 16246-1
3 Service Information System (SIS)

3.0.1 Using the SIS system
Chapter 3: Service Information System (SIS)

3.0.1 Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS. Details may be
found in:
Service Information System, SIS
Defining the SIS input parameters
Setting the SIS parameters
Importing/exporting SIS data
Reading the SIS output logs
Basic procedure
Step
3HAC 16246-1
Action
Reference
1.
Determine which of the system function

you require.
These are described in Service Information System (SIS) on page 24.
2.
Define what values are adequate and

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

these are given in Defining the SIS input
parameters on page 30.
Maintenance intervals recommended by
ABB are specified in section "Maintenance Schedule" in the Maintenance
Manual.
3.
Enter these parameters in the system.
How to do this is detailed in Setting the

SIS parameters on page 33.
4.
Run the robot in normal operation.
5.
Reset the counter if a repair has to be

The TPU displays for resetting any SIS
made, or if a counter for any other reason value are shown in Service Information
has to be restarted.
System (SIS) on page 24.
6.
When a time limit, set in the parameters, How to access this is detailed in Reading
is exceeded, a message may be read on the SIS output logs on page 35.
the 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
data on page 36.
SIS parameters are to be entered from
an external PC, a set of software tools
are available to build such an application.
23

3.0.2 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.
Supervised functions
The following counters may be set:
Calendar time counter, a general alarm based on calendar time
Operation time counter, a general alarm based on operational time
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
interval
interval
interval
The figure below show the different selections possible:
xx0200000034
x OK
24
"OK" indicates that no service interval limit has been exceeded by that counter.
If any such limit was exceeded, the counter name would be followed by "NOK".
3HAC 16246-1

Calendar time
This is a clock within the control system that enables you to set a specific service interval,
based on calendar time:
xx0200000035
After this time, a message is accessible on the Tech Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
Operation time
Prev service
Date when the counter was reset last time, i.e. after the last service. This
date was entered manually as detailed in section Setting the SIS parameters on page 33.
Elapsed time
Elapsed time since the counter was reset the last time.
Next service
Date when next scheduled service is planned. This date is entered manually as detailed in section Setting the SIS parameters on page 33.
Remaining time
Remaining time to next scheduled service date.
This is a function within the control system that counts the amount of time the "MOTORS
ON" signal is active, i.e. the amount of time the robot is in the operational mode.
xx0200000036
After this time, a message is accessible on the Teach Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
3HAC 16246-1
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 33.
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.
25

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 35.
en0200000037
Axis x OK
Service status for axis x, i.e. the automatically calculated time parameter
has not been exceeded.
Axis x NOK
The service interval for the axis in question has been reached.
Axis x N/A
No service time parameter calculation available.

Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
en0200000038
This example shows the window for axis 1, but is also valid for the other axes.
26
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.
3HAC 16246-1

Reset values
All counters may be reset at any time.
en0200000040
When resetting, both variables sisRestartDate and sisCalendarT are reset!

The variables are described in section Exporting the SIS data on page 36!
Yes
Resets the counter to zero.
No
Does not reset the counter, but returns to the previous menu.
en0200000041
When resetting, variable sisRunT is reset!

3HAC 16246-1
Yes
No
27

en0200000039
When resetting, both variables sisL10h_x and sisL10h_Time_x are reset!

Service interval
exceeded
Yes
No
When the service time has been exceeded for the selection made, a message (Service interval
exceeded!) is displayed below the data of the counter in question:
en0200000044
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
In addition to this view, an error message is also displayed on the TPU when the service
interval is exceeded!
28
3HAC 16246-1

No data available
When no data is available for the selection made, a message (No data available!) is displayed
below the function in question:
en0200000043
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
Exit
en0200000042
3HAC 16246-1
Yes
Exits the Service Information System.
No
Returns to the Service Information System.
29

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

E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating
the alarm, not counting the percentage described below.
en0200000054
30
3HAC 16246-1

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.
en0200000053
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.
en0200000050
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.
en0200000051
3HAC 16246-1
31

Gearbox warning
A percentage of the gearbox service interval as calculated by the system.

E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service
interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate the
expected service interval of each gearbox. This is done by extrapolating data from earlier
operation into a function of time, using a formula including:
input and output torque
gearbox spindle speed
other variables
en0200000052
32
3HAC 16246-1

3.0.4 Setting the SIS parameters
General
If the SIS system is to function properly, a number of parameters must be set. How to do this
is detailed below.
Procedure
This is an instruction of how to enter SIS parameters to the robot system.
Step
Action
Rem.
1.
Open "System parameters" using the

TPU.
Detailed in the Users Guide.
2.
Go to "System parameters/Manipulator/
types 2".
xx0200000045
en0200000046
3.
Select "0 SIS parameters" and press

"Enter".
en0200000047
xx0100000200
3HAC 16246-1
33

Step
4.
Action
Rem.
Select the required system

The parameter list is displayed.
en0200000048
en0200000049
5.
34
Select the required parameters by step- Available parameters are described in

ping up and down through the parame- Defining the SIS input parameters on page
ter list.
30!
3HAC 16246-1

3.0.5 Reading the SIS output logs
3.0.5 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 any log and show its contents is detailed in the "Users Guide", chapter "Service".
Available messages
The following messages may be shown:
Available in:
3HAC 16246-1
SIS message in
Operational log
Meaning
Calendar time
Service Message
Service is due!
X calendar days since
last service.
The manually set calendar time limit has expired.

How to set the limit is detailed in section Setting
the SIS parameters on page 33.
Proceed with the required service as detailed in
the Repair Manual or Maintenance Manual
depending on which type of service.
Calendar time
Service Message
X calendar days to
next service.
X number of calendar days remain until the manually set calendar time limit expires.
How to set the value determining when the message is to be shown, is detailed in section Setting
Operation time
Service Message
Service is due!
X production hours
since last service.
The manually set operation time limit has expired.

How to set the limit is detailed in section Setting
Operation time
Service Message
X production hours to
next service.
X number of operation hours remain until the manually set operation time limit expires.
Gearbox time
Service Message
Gearbox x requires
service!
The automatically calculated gearbox time limit

has expired.
Gearbox time
Service Message
X% of the service interval has expired for
gearbox x!
X percent of gearbox hours remain until the automatically calculated gearbox time limit expires.
35

3.0.6 Exporting the SIS data
3.0.6 Exporting the SIS data
General
This section describes the available variables for entering SIS parameters as well as showing
any messages of exceeded time limits as detected by the SIS counters on an external PC using
"Webware SDK".
How to access these variables and how to perform the actual programming sequences are
detailed in the robot system Users Guide.
Definitions
36
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
sisRestartDate
sec
Calendar time
The date on which the supervision was started/

reset last time.
Expressed in seconds starting 1/1 1970 (in accordance with ANSI c-standard).
sisCalendarT
sec
Calendar time
The number of seconds since start/last reset.
sisTotRunT
sec
Operation time Total number of operation seconds since the system was started. Corresponds to the operating
time counter on the control cabinet.
sisRunT
sec
Operation time The number of operation seconds since start/last

reset of the operation time counter. Corresponds
to the operating time counter on the control cabinet.
sisL10h_1
hrs
Gearbox time
Estimated life of gearbox axis 1
sisL10h_Time_1 sec
Gearbox time
Operation time of gearbox axis 1
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2 sec
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3 sec
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6 sec
Gearbox time
Function
3HAC 16246-1
4 Maintenance schedules and intervals

4.0.1 Specification of maintenance intervals
Chapter 4: Maintenance schedules and intervals

4.0.1 Specification of maintenance intervals
Description
3HAC 16246-1
The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot:
Calendar time: specified in months regardless of whether the robot system is run or
not.
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
SIS: specified by the robot's Service Information System (SIS). How to access this
information is detailed in section "Access to SIS information". A typical value is given
for a typical work cycle, but the value will differ depending on how hard each part is
run.
37

4.0.2 Maintenance schedule, IRB 6600/6650
General
The robot, consisting of manipulator and controller cabinet, must be maintained regularly to
ensure its function. The maintenance activities and their respective intervals are specified in
the table below.
Non-predictable situations also give rise to inspections of the robot. If damage is discovered,
attend to it immediately!
The inspection intervals do not specify the life of each component. Values for these are specified in Expected component life, IRB 6600 on page 41.
Activities and
intervals, standard equipment
38
The section referred to in the table can be found in the different chapters for every maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
Equipment
activity
Interval
Note
Inspection
Axis 1 gear, oil

level
12 mths
Ambient tempera- "Inspection, oil level,

ture below 50 C 1 gearbox axis 1"
Inspection
Axis 2 gear, oil

level
12 mths

Inspection
Axis 3 gear, oil

level
12 mths

Inspection
Axis 4 gear, oil

level
12 mths
"Inspection, oil level

gearbox axis 4"
Inspection
Axis 5 gear, oil

level
12 mths
"Inspection, oil level

gearbox axis 5"
Inspection
Axis 6 gear, oil

level
12 mths
Ambient tempera- "Inspection, oil level

Inspection
Balancing device 12 mths
"Inspection, balancing
device"
Inspection
Manipulator har- 12 mths

ness
"Inspection, cable harness"
Inspection
Information
labels
"Inspection, information labels"
Inspection
Damper axes 2-5 12 mths
"Inspection damper,
axes 2-5"
Inspection
Mechanical stop, 12 mths

axis 1
"Inspection mechanical stop, axis 1"
Changing
Axis 1 gear, oil
48 mths
Ambient tempera- "Oil change, gearbox

ture below 50 C 1 axis 1"
Changing
Axis 2 gear, oil
48 mths

Changing
Axis 3 gear, oil
48 mths

Changing
Axis 4 gear, oil
48 mths

Changing
Axis 5 gear, oil
48 mths

12 mths
Detailed in section
3HAC 16246-1

Maintenance
Equipment
activity
Interval
Note
Changing
Axis 6 gear, oil
48 mths

Replacement
Axis 1 gear, oil
As specified by the
SIS, or typically 96
mths
"Remove/Refit, gearbox axis 1" in Repair

Manual
Replacement
Axis 2 gear, oil
As specified by the
mths

Manual
Replacement
Axis 3 gear, oil
As specified by the
mths

Manual
Replacement
Axis 4 gear
96 mths 2
"Remove/Refit, upper
arm without wrist unit"
in Repair Manual
Replacement
Axis 5 gear
96 mths 2
"Remove/Refit, complete wrist unit" in

Repair Manual
Replacement
Axis 6 gear
As specified by the
mths

Manual
Replacement
Manipulator har- See note

ness
below 3
"Remove/Refit, cable
harness" in Repair
Manual
Replacement
SMB Battery
pack
"Removal/Refitting of
SMB related equipment" in Repair Manual
Lubrication
Balancing device 48 mths 4

bearing
36 mths
Detailed in section
"Lubrication, balancing
device bearing"
1)
If the robot is run at temperatures higher than 50 C, the manipulator may require maintenance more frequently.
2) The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see expected life
in section Expected component life, IRB 6600 on page 41.
3)
Replace when damage is detected or when approaching life limit as specified in Expected
component life, IRB 6600 on page 41.
4)
The interval is the same as the interval for changing axis 2 gear oil because of the similarity
of the type and degree of operation.
Activities and
intervals, optional
equipment
3HAC 16246-1
The table below specifies the required maintenance activities and intervals for common
optional equipment. Maintenance of other external equipment for the robot is detailed in separate documentation.
39

Maintenance
Equipment
activity
40
Interval Note
Inspection
UL-lamp
Inspection
Mechanical stop
axes 1-3
12 mths
Inspection
Position switches,
axes 1-3
12 mths
Detailed in
section
"Inspection, ULlamp"
Mechanical stops in "Inspection,

addition to the fixed mechanical stop,
stops
axes 1-3"
"Inspection, position
switches, axes 1-3"
3HAC 16246-1

4.0.3 Expected component life, IRB 6600
4.0.3 Expected component life, IRB 6600
General
The expected life of a component can vary greatly depending on how hard it is run
Expected life
Component
Expected life
Note
Manipulator harness
2,000,000 cycles
See note 1)
Cabling for position switch and fan
2,000,000 cycles
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000h
See note 3)
1)
The expected life can also be affected by assemblage of cabling other than standard options.
The given life is based on a test cycle that for every axis starts from the calibration position
to minimum angle to maximum angle and back to the calibration position. Deviations from
this cycle will result in differences in expected life!
2)
The given life for the balancing device is based on a test cycle that starts from the initial
position and goes to maximum extension, and back. Deviations from this cycle will result in
differences in expected life!
3)
The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spot
welding application. Depending on the actual application, the life of individual gearboxes
may vary greatly from this specification. The SIS (Service Information System) integrated in
the robot software, keeps track of the gearbox life in each individual case and will notify the
user when a service is due. The SIS is described in "SIS, Service Information System".
3HAC 16246-1
41

4.0.4 Maintenance schedule, controller S4CPlus M2000A
4.0.4 Maintenance schedule, controller S4CPlus M2000A
General
The robot controller must be maintained at regular intervals to ensure its function. The maintenance activities and their respective intervals are specified in the table below:
Intervals
Maintenance
Equipment
activity
Interval
Detailed in section
Inspection
Controller cabinet
6 mths
"Inspection, controller cabinet"
Cleaning
Controller cabinet
Replacement
Battery unit
12 000 h/36
mths 1
"Replacement, battery unit"
Replacement
System fan unit
60 mths
"Replacement, system fan unit".
1)
42
"Cleaning of controller cabinet"
Hours denote operational time while months denote the actual calender time.
3HAC 16246-1
5 Maintenance activities, manipulator

5.0.1 Introduction
Chapter 5: Maintenance activities, manipulator

5.0.1 Introduction
General
3HAC 16246-1
This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
43

5.1.1 Inspection, oil level gearbox axis 1
Section 5.1: Inspection activities

Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
C
D
A
xx0200000228
Gearbox axis 1
Oil plug, inspection
Motor, axis 1
Oil plug, filling
Required equipment
Equipment
Lubricating oil
3HAC 16843-1
Optimol Optigear RMO 150
Standard toolkit
3HAC 15571-1
The contents are defined in

section Standard toolkit on
page 18!
Other tools and procedures may be required.

See references to these
procedures in the stepby-step instructions
below.
44
Note
These procedures include references to the tools required.
3HAC 16246-1

Inspection, oil
level gearbox
The procedure below details how to inspect the oil level in gearbox axis 1.
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!
Step
3HAC 16246-1
Action
Note/Illustration
1.
Open the oil plug, inspection.
Shown in the figure Location of gearbox on page

44!
2.
Required oil level: max. 10 mm

below the oil plug hole!
3.
Add oil if required.
Art. no. specified in Required equipment on

page 44!
Detailed in section Oil change, gearbox axis 1
on page 75.
4.
Refit the oil plug, inspection.
Tightening torque: 24 Nm.
45

Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The correct oil level varies, depending on the design of the motor attachment.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
A
D
B
xx0200000229
Gearbox axis 2 (behind motor attachment and cover)
Oil plug, filling
Oil plug, draining
Vent hole, gearbox axis 2
Required equipment
Equipment etc.
Lubricating oil
46
Note
3HAC 16843-1 Optimol Optigear RMO 150
3HAC 16246-1

Equipment etc.
Standard toolkit
3HAC 15571-1 The contents are defined in

page 18!

below.
Inspection, oil
level
Note
motors or gears!
Step
3HAC 16246-1
Action
Note/Illustration
1.
Open the oil plug, filling.
Shown in the figure Location of gearbox on page 46!
2.
Measure the oil level at the oil plug, filling.

Required oil level with the early design of the
motor attachment: approx. 65 mm 5 mm.
Required oil level with the later design of the
motor attachment: max. 10 mm below the oil
plug hole.

Read more about the variations in
design in Different designs on page
46.
3.
Art. no. specified in Required equipment on page 46!

Detailed in section Oil change, gearbox axis 2 on page 78.
4.
Refit the oil plug, filling.
47

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A
B
C
xx0200000230
Gearbox axis 3
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Lubricating oil
3HAC 16843-1 Optimol Optigear RMO 150
Standard toolkit

page 18!

procedures in the step-bystep instructions below.
48
Note
These procedures include

references to the tools
required.
3HAC 16246-1

Inspection, oil
level gearbox 3
The procedure below details how to inspect the oil level in the gearbox axis 3.
motors or gears!
Step
3HAC 16246-1
Action
Note/Illustration
1.
Run the manipulator to the calibration

position.
Detailed in "Calibration" in the Installation

Manual.
2.
Shown in the figure Location of gearbox

on page 48!
3.
Required oil level: max 10 mm below the

oil plug hole.
4.
Art. no. specified in Required equipment

on page 48!
Detailed in section Oil change, gearbox,
axis 3 on page 81.
5.
49

Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
A
B
xx0200000231
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Lubricating oil
1171 2016-604 BP Energol GR-XP 320

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

page 18!

below.
Inspection, oil
level gearbox 4
Note
motors or gears!
50
3HAC 16246-1

Step
3HAC 16246-1
Action
Note/Illustration
1.
Run the manipulator to the calibration

position.
Shown in "Calibration" in the Installation

Manual!
2.
Shown in the figure Location of gearbox on

page 50!
3.
Required oil level: max 10 mm below

the oil plug hole.
4.

on page 50.
axis 4 on page 83.
5.
Refit the oil plug.
51

5.1.5 Inspection, oil level, gearbox axis 5
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
B
xx0200000232
Oil plug, filling
Oil plug, draining
Required equipment
Equipment etc.
Lubricating oil
1171 2016-604 BP Energol GR-XP 320

This is a common oil that can be
replaced with an equivalent oil
from another manufacturer!
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Other tools and procedures may be

required. See references to these procedures in the step-bystep instructions
below.
Inspection, oil
level gearbox 5
Note
motors or gears!
52
3HAC 16246-1

Step
3HAC 16246-1
Action
Note/Illustration
1.
Turn the wrist unit so that both oil plugs

face upwards.
2.
3.
Measure the oil level.

Required oil level: 30 mm to the oil plug
hole.
4.

on page 52.
axis 5 on page 85.
5.
Refit the oil plug.

on page 52!
53

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
B
A
C
xx0200000233
Gearbox axis 6
Oil plug, filling
Oil plug, draining
Required equipment
Equipment
Lubricating oil
3HAC 16843-1 Optimol Optigear RMO 150.
Standard toolkit

page 18!

Inspection, oil
level gearbox 6
Note

required.
motors or gears!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
54
3HAC 16246-1

Step
3HAC 16246-1
Action
Note/Illustration
1.
Make sure the oil plug, filling is facing

upwards and open it.

on page 54!
2.
Measure the oil level.

Required oil level: 55 mm 5 mm to oil
plug hole, filling.
3.

Detailed in section Oil change, gearbox
axis 6 on page 87.
4.
55

5.1.7 Inspection, balancing device
Location of balancing device
The balancing device is located at the top rear of the frame as shown in the figure below.
If damage is detected during inspection, a maintenance or an upgrade must be performed,
depending on version of balancing device! Balancing device 3HAC 14678-1 and 3HAC
16189-1 requires maintenance, while 3HAC 12604-1 requires an upgrade.
C
A, B
E
F
xx0200000110
Balancing device
Piston rod (inside the cylinder)
Shaft, including securing screw
Ear with spherical roller bearing inside
Bearing attachment
Rear cover
Required equipment -general
56
Equipment, etc.
Note
Balancing device
3HAC 16198-1
IRB 6600.
Includes balancing device
3HAC 14678-1!
3HAC 16246-1

Equipment, etc.
Note
Balancing device
3HAC 16907-1
IRB 6650.
Includes balancing device
3HAC 16189-1!
Standard toolkit

See references to
these procedures in
the step-by-step
instructions below.
Depending on whether maintenance or upgrade is to be performed, use also equipment as

specified below!
Required equipment -maintenance
Required equipment -upgrade
If detecting damage when inspecting balancing device, version 3HAC 14678-1, 3HAC
16189-1 maintenance must be performed!
The table below specifies the equipment required when maintaining the balancing device!
Equipment, etc. Spare part no. Art. no.
Note
Maintenance kit
3HAC 16195-1
Includes complete kit 3HAC

16192-1 and instructions for maintenance, 3HAC 15864-5.
Maintenance kit
3HAC 16194-1
Includes kit with bearings and

seals only, 3HAC 16190-1, plus
instructions for maintenance,
3HAC 15864-4.
Documentation for
maintenance
3HAC 15864-5
3HAC 15864-4
See difference above!
Toolkit for maintenance
3HAC 15943-2
Puller for separator
4552-2 (Bahco) Used for dismounting the spherical roller bearings.
Separator
4551-C (Bahco) Used for dismounting the spherical roller bearings.
If detecting damage when inspecting balancing device, version 3HAC 12604-1, an upgrade
must be performed!
The table below specifies equipment required when upgrading the balancing device!
3HAC 16246-1
Note
Upgrade kit
3HAC 16196-1 Includes kit with piston rod, support

shaft etc., 3HAC 16193-1, plus
instruction for conversion, 3HAC
15864-6.
Documentation in
upgrade kit
3HAC 15864-6 Instruction for conversion from balancing device, 3HAC 12604-1 to
3HAC 14678-1.
57

Inspection, balancing device
The procedure below details how to inspect the balancing device.
motors or gears!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
58
Action
Note
1.
Check for dissonance from bearings, gear or Shown in the figure Location of balshaft.
ancing device on page 56.
Make sure the securing screw in the shaft is
positioned correctly and undamaged.
(M16x180, tightening torque: 50 Nm.)
At detected dissonance: Carry out an overhaul as detailed in Maintenance kit or
Upgrade kit, depending on the version of balancing device.
2.
Check for dissonance from the cylinder.

Replacing balancing device is
The springs inside the cylinder can cause a detailed in "Remove/Refit balancing
tapping sound. Replace the balancing device device" in the Repair Manual.
or consult ABB Robotics.
3.
Check for dissonance from the piston rod.

Squeaking can indicate worn plain bearings,
internal contamination or insufficient lubrication.
At detected dissonance: Carry out an overhaul as detailed in Maintenance kit or
Upgrade kit, depending on the version of balancing device.
4.
Check if the piston rod is scratched, worn or

has an uneven surface.
At detected damage: Carry out an overhaul
as detailed in Maintenance kit or Upgrade kit,
depending on the version of balancing
device.
5.
If any damage or dissonance is detected, follow the notes above!

Carry out the overhaul as detailed in the
enclosed instruction in the Maintenance kit or
upgrade as detailed in the instruction in the
Upgrade kit.
Art. no. specified in Required equipment -maintenance on page 57/

Required equipment -upgrade on
page 57!
3HAC 16246-1

5.1.8 Inspection, cable harness
Location of
cabling axes 1-4
The manipulator cable harness, axes 1-4, is located as shown in the figure below.
C
A
D
xx0200000097
Lower arm
Cables attached with velcro straps and mounting plate
Connectors at cable harness division point, R2.M5/6
Connectors at base
Required equipment
3HAC 16246-1
Equipment, etc.
Note
Harness manipulator 1-4
3HAC 14940-1
IRB 6600
Harness manipulator 1-4
3HAC 16331-1
IRB 6650
Cable harness ax. 5-6
3HAC 14140-1
Cable harness axis 5
3HAC 14139-1
Circuit diagram
3HAC 13347-1 Included in the Repair Manual, part 2.
Standard toolkit

page 18!
59

Equipment, etc.

Inspection, cable
harness 1-4
Note
required.
The procedure below details how to inspect the cable harness of axes 1-4.
motors or gears!
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Step
60
Action
Note/Illustration
1.
Make an overall visual inspection of the

cable harness, in order to detect wear and
damage.
2.
Check the connectors at the division point

and at the base.
Shown in the figure Location of

cabling axes 1-4 on page 59!
3.
Check that velcro straps and the mounting

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

of cabling axes 1-4 on page 59!
A certain wear of the hose at the
entrance to the lower arm is natural.
4.
Replace the cable harness if wear or damage is detected.

Removal and refitting of cable harness is detailed in the Repair Manual!
3HAC 16246-1

Location of
cabling axes 5-6
The manipulator cable harness, axes 5-6, is located as shown in the figure below.
C
xx0200000234
Inspection, cable
harness, axes 5-6
Connectors at cable harness division point, R2.M5/6
Cable attachment, rear of upper arm
Cable attachment, upper arm tube
The procedure below details how to inspect the cable harness of axes 5-6.
motors or gears!
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Step
1.
3HAC 16246-1
Action
Note
Make an overall visual inspection of the cable harness,

in order to detect wear and damage.
61

Step
62
Action
Note
2.
Check the attachments at the rear of the upper arm and Shown in the figure Locain the upper arm tube.
tion of cabling axes 5-6 on
page 61!
Check the connectors at the cable harness division.
Make sure the attachment plate is not bent or in other
way damaged.
3.
Replace the cable harness if wear or damage is

detected.
Art. no. specified in

Required equipment on
page 59!
Removal and refitting of
cable harness is detailed
in the Repair Manual!
3HAC 16246-1

5.1.9 Inspection, information labels
Location of labels
The figures below show the location of the information labels to be inspected.
A
B
Warning
A
D
Warning
C
B
A
B
X-X
xx0200000236
3HAC 16246-1
Warning label "High temperature", 3HAC 4431-1
Warning sign, a symbol of a lightning flash (located on motor cover), 3HAC 1589-1
Instruction label "Safety instructions", 3HAC 4591-1
Warning label "Brake release", 3HAC 15334-1
63

E
G
Liftin g of robot
H
Warning
Warning
F
xx0200000101
Instruction label "Lifting the robot", 3HAC 16420-1
Warning label "Robot can tip forward...", 3HAC 9191-1
Foundry logotype, 3HAC 8256-1
Warning label "Stored energy", 3HAC 9526-1
Required equipment
Equipment, etc.
Labels and plate set
Note
3HAC 8711-1
Inspection, labels
Step
64
Action
Note/Illustration
1.
Check the labels, located as shown in the figures

Location of labels on page 63.
2.
Replace any missing or damaged labels.
Art. no. specified in Required

equipment on page 64!
3HAC 16246-1

5.1.10 Inspection, mechanical stop, axis 1
5.1.10 Inspection, mechanical stop, axis 1
Location of
mechanical stop
The mechanical stop axis 1 is located at the base as shown in the figure below.
A
xx0200000151
Mechanical stop (stop pin)
Required equipment
Equipment, etc.
Inspection,
mechanical stop
Note
Mechanical stop ax 1
3HAC 12812-2 To be replaced when damaged.

Includes spring pin.
Standard toolkit
The procedure below details how to inspect the mechanical stop axis 1.
motors or gears!
Step
3HAC 16246-1
Action
Note/Illustration
1.
Inspect the mechanical stop, axis 1.

mechanical stop on page 65!
2.
Make sure the mechanical stop can move in both

directions.
3.
If the stop pin is bent or damaged, it must be

replaced!

65

5.1.11 Inspection, mechanical stop, axes 1, 2 and 3
Location of
mechanical stops
The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3
(IRB 7600 shown).
B
A
B
A
xx0200000150
Additional stop
Fixed stop
Required equipment
Equipment etc.
66
Note
3HAC 11076-1 Limits the robot working range by

7,5.
3HAC 11076-2 Limits the robot working range by

15.
3HAC 13787-1
3HAC 13128-2
Standard toolkit
3HAC 15571-1 The contents are defined in section Standard toolkit!
3HAC 16246-1

Inspection,
mechanical stops
The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and
3.
motors or gears!
Step
3HAC 16246-1
Action
Note/Illustration
1.
Check the additional stops on axes 1, 2 and 3 for Shown in the figure Location of
damage.
mechanical stops on page 66!
2.
Make sure the stops are properly attached.

Correct tightening torque: 115 Nm.
3.
If any damage is detected, the mechanical stops Art. no. specified in Required
must be replaced!
Correct attachment screws (lubricated with Molycote 1000):
Axis 1: M16 x 35
Axis 2: M16 x 50
Axis 3: M16 x 60
67

5.1.12 Inspection, damper axes 2-5
Location of
dampers
The figure below shows the location of all the dampers to be inspected.
B
A
xx0300000040
Damper, axis 2 (2 pcs)
Damper, axis 4 (1 pc)
Required equipment
Equipment
68
Note
Damper axis 2
3HAC 12991-1
To be replaced if damaged!
Damper axis 3
3HAC 12320-1
Damper axis 4
3HAC 13564-1
Damper axis 5
3HAB 4337-2
Standard toolkit
3HAC 15571-1
The contents are defined in section

Standard toolkit on page 18!
3HAC 16246-1

Inspection, dampers
The procedure below details how to inspect the dampers, axes 2-5
motors or gears!
Step
3HAC 16246-1
Action
Note/Illustration
1.
Check all dampers for damage, and for cracks or Shown in the figure Location of
existing impressions larger than 1 mm.
dampers on page 68!
To inspect the damper, axis 4, remove the two
covers on top of the upper arm!
2.
Check attachment screws for deformation.
3.
If any damage is detected, the damper must be

replaced with a new one!

69

5.1.13 Inspection, position switch axes 1, 2 and 3
Location of position switches
The illustration below shows the position switch for axis 1.
A
F
C
E
xx0100000158
Position switch, axis 1
Cam
Set screw, cam
Protection sheet
Rail
Rail attachment
E
B
C
F
xx0100000159
70
3HAC 16246-1

Cam
Set screw, cam
Rail
Rail attachment
C
B
xx0100000160
Cam
Set screw, cam
Rail
Rail attachment
Required equipment
Equipment, etc.
3HAC 16246-1
Note
3HAC 15715-1
To be replaced in case of
detected damage
3HAC 16418-1
detected damage
3HAC 16417-1
detected damage
71

Equipment, etc.
Standard toolkit
3HAC 15571-1

See references to
these procedures in the
step-by-step instructions below.
Inspection, position switches
Note
The contents are defined in
page 18!
The procedure below details how to inspect the position switch, axes 1, 2 and 3.
See figure above to locate the different components to be inspected.
motors or gears!
Step
Action
1.
Check the position switch!

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

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

Check that the rollers has not caused any
impressions on the cams.
4.
Check that the cams are clean. Wipe them if

necessary!
Check that the set screws holding the cams

in position are firmly attached.
Check the protection sheets on axis 1!

Check that the three sheets are in position
and not damaged. Deformation can result in
rubbing against the cams!
5.
72
Note/Illustration
Check that the area inside of the sheets is

clean enough not to interfere the function of
the position switch.
If any damage is detected, the position switch must Art. no. specified in Required
be replaced!
3HAC 16246-1

5.1.14 Inspection, UL signal lamp
Location of UL
lamp
The UL-lamp is located as shown in the figure below. Note that the position can differ
depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on
the current harness for alternative positioning.
There are two different article numbers for the UL-lamp. The difference is due to the accompanying motor cover, which is either flat or vaulted.
A
D
C
B
xx0200000240
UL signal lamp
Clamp
Position for cable gland
Warning label on motor cover
Warning sign on motor cover
Required equipment
Equipment, etc.
3HAC 16246-1
Note
Signal lamp
3HAC 10830-1 To be replaced in case of

detected damage.
(Includes vaulted motor cover.)
Signal lamp
3HAC 13097-1 To be replaced in case of

detected damage.
(Includes flat motor cover.)
Standard toolkit

page 18!
73

Equipment, etc.

See references to
Inspection, ULlamp
Note
The procedure below details how to inspect the function of the UL-lamp.
motors or gears!
Step
74
Action
Note/Illustration
1.
Check that the UL-lamp is lit, when the motors are put in
operation ("motors ON").
2.
If the lamp is not lit, trace the fault by:

Checking whether the ul-lamp is broken. If so,
replace it.
Checking the cable connections.
Measuring the voltage in connectors motor axis 3

(=24V).
Checking the cabling. Replace cabling if a fault is

detected.
Art. no. specified in

Required equipment on
page 73!
3HAC 16246-1

5.2.1 Oil change, gearbox axis 1
Section 5.2: Changing activities

Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
C
D
A
xx0200000228
Gearbox axis 1
Oil plug, inspection
Motor axis 1
Oil plug, filling
Required equipment
Equipment, etc.
Lubricating oil
Note

Total amount: 7,300 ml.
Oil collecting vessel
Capacity: 8,000 ml.
Standard toolkit
3HAC 15571-1 The contents are defined in section

The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
3HAC 16246-1
75

Changing, oil
The procedure below details how to change the oil in gearbox axis 1.
motors or gears!
Step
Action
Note/Illustration
1.
Remove the rear cover on the base by

unscrewing its attachment screws.
2.
Pull the oil draining hose out of the rear of

the base.
xx0200000237
The hose is located beneath the base,

as shown in the figure with a view from
below.
A: Oil draining hose
76
3.
Place an oil vessel close to the hose end. Vessel capacity specified in Required
4.
Remove the oil plug, filling, in order to

drain the oil quicker!
5.
Open the hose end and drain the oil into

the vessel.
6.
Close the oil drain hose, and put it back

inside the base.
Notice! The draining is time-consuming. Elapsed time depends on the temperature of the oil.
3HAC 16246-1

Step
3HAC 16246-1
Action
Note/Illustration
7.
Close the rear cover by securing it with its

attachment screws.
8.
9.
Refill the gearbox with lubricating oil.

Art. no. and the total amount are speciThe amount of oil to be refilled depends on fied in Required equipment on page 75!
the amount previously being drained. The
correct oil level is detailed in section
Inspection, oil level gearbox axis 1 on
page 44.
10.

on page 75!
77

Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two different designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws (only some versions of IRB 6600).
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The correct amount oil varies, depending on the design of the motor attachment.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment.
The figure below shows the later design of the motor attachment.
A
D
B
xx0200000229
78
Gearbox axis 2
Oil plug, filling
Oil plug, draining
Vent hole, gearbox axis 2
3HAC 16246-1

Required equipment
Equipment, etc.
Lubricating oil
Note

Total amount with early design of
motor attachment: 1,800 ml.
Total amount with later design of
motor attachment: 4,300 ml.
Capacity: 5,000 ml.
Hose with nipple
1/2".
Standard toolkit
Changing, oil
The procedure below details how to change the oil in gearbox axis 2.
motors or gears!
Step
1.
3HAC 16246-1
Action
Note/Illustration
Remove the plug of the vent hole (later

design).

on page 78!
79

Step
80
Action
Note/Illustration
2.
Remove the oil plug, draining, and drain

the gearbox oil using a hose with nipple
and an oil collecting vessel.

on page 78!
Vessel capacity specified above!
Draining is time-consuming. Elapsed
time varies depending on the temperature of the oil.
3.
Refit the oil plug.
4.
Remove the oil plug, filling.

on page 78!
5.

The amount of oil to be refilled depends
on the amount previously being drained.
The correct oil level is detailed in section
page 46.
Art. no. and total amount specified in

Required equipment on page 79!
6.
Refit the oil plug and the plug in the vent

hole.
3HAC 16246-1

5.2.3 Oil change, gearbox, axis 3
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A
B
C
xx0200000230
Gearbox axis 3
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Lubricating oil
Note

Capacity: 3,000 ml.
Hose with nipple
1/2".
Standard toolkit
The contents are defined in section Standard toolkit on page 18!
3HAC 16246-1
81

Changing, oil
The procedure below details how to change the oil in gearbox, axis 3.
motors or gears!
Step
82
Action
Note/Illustration
1.
Remove the oil plug, draining, and drain

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

Vessel capacity specified in Required
Draining is time-consuming. Elapsed
time varies depending on the temperature of the oil.
2.
Refit the oil plug.
3.
4.

The amount of oil to be refilled depends on Required equipment on page 81!
page 48.
5.
Refit the oil plug.
3HAC 16246-1

Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
B
xx0200000231
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Lubricating oil
1171 2016-604
Note
BP Energol GR-XP 320.
Capacity: 9,000 ml.
Standard toolkit
3HAC 15571-1
3HAC 16246-1
83

Changing, oil
motors or gears!
Step
84
Action
Note/Illustration
1.
Run the upper arm -45from the calibration

position.
2.
Open the oil plug, draining.

Shown in the figure Location of gearRemove the oil plug, filling in order to drain box on page 83!
the oil quicker!
3.
Drain the oil from the gearbox.

4.
Run the upper arm back to its calibration

position (horizontal position).
Detailed in "Calibration" in the Installation Manual.
5.
Refit the oil plug, draining.
6.
Refill the gearbox with lubricating oil

through the oil plug, filling.
The amount of oil to be refilled depends on
Inspection, oil level gearbox axis 4 on page
50.

Required equipment on page 83.
7.
3HAC 16246-1

Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
B
xx0200000232
Oil plug, filling
Oil plug, draining
Required equipment
Equipment, etc.
Lubricating oil
Note
1171 2016-604 BP Energol GR-XP 320.

Capacity: 7,000 ml.
Standard toolkit
3HAC 15571-1
Changing, oil
motors or gears!
3HAC 16246-1
85

Step
86
Action
Note/Illustration
1.
Run axis 4 to a position where the oil plug,

draining, is facing downwards.
2.
Open the oil plug, draining.

Shown in the figure Location of gearRemove the oil plug, filling in order to drain box on page 85!
the oil quicker!
3.
Drain the oil from the gearbox.

4.
5.
Run axis 4 back to the calibration position.
6.
Refill the gearbox with lubricating oil

through the oil plug, filling.
The amount of oil to be refilled depends on
Inspection, oil level, gearbox axis 5 on page
52.

Required equipment on page 85.
7.
3HAC 16246-1

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions have different gearbox designs. The amount of oil in the gearbox
therefore varies depending on robot version.
B
A
C
xx0200000233
Gearbox axis 6
Oil plug, filling
Oil plug, draining
Required equipment
Lubricating oil
Note
3HAC 16843-1 Optimal Optigear RMO 150.

Total amount for robot v. 175/2.25:
300 ml.
Total amount for robot v. 225/2.55,
175/2.8, 125/3.2 and 200/2.75: 450
ml.
Vessel capacity: 500 ml.
Standard toolkit
3HAC 15571-1 The contents are defined in section

3HAC 16246-1
87

Changing, oil
The procedure below details how to change oil in gearbox, axis 6.

motors or gears!
Step
88
Action
Note/Illustration
1.
Run the robot to a position where the oil plug,

draining of axis 6 gearbox is facing downwards.

gearbox on page 87!
2.
Drain the oil from gearbox 6 by removing the oil Vessel capacity specified in
plug. Collect the oil with a suitable vessel.
Required equipment on page 87!
3.
4.

gearbox on page 87!
5.

Art. no. and the total amount are
The amount of oil to be refilled depends on the specified in Required equipment
amount previously being drained. The correct on page 87!
oil level is detailed in section Inspection, oil
level gearbox axis 6 on page 54.
6.
Refit the oil plug.
3HAC 16246-1

5.3.1 Lubrication, balancing device bearing
Section 5.3: Lubrication activities

Location of bearing
The figure below shows the location of the lubrication nipple etc.
Note! The balancing device must be mounted on the manipulator when lubricating the bearing!
xx0200000109
Ear (spherical roller bearing located inside)
Lubrication nipple
Sealing spacer
Hole through which the shaft is pressed
Required equipment
Note
Grease
Optimol PDO, max. 80 ml.

For lubrication of the spherical
roller bearing.
3HAA 1001-294
Grease pump
3HAC 16246-1
89

Lubrication, balancing device

bearing
The procedure below details how to lubricate the spherical roller bearing.
motors or gears!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
1.
90
Action
Note/Illustration
Lubricate the spherical roller bearing through

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

bearing on page 89!
The balancing device must be
mounted on the manipulator!
3HAC 16246-1

5.4.1 Cleaning, manipulator
Section 5.4: Cleaning activities

General
The protection class is IP 67, i.e. the manipulator is watertight.
Activities
This instruction specifies how to clean the manipulator.
Periodicity
The periodicity of cleaning the manipulator varies a great deal depending on the actual environment and function of the robot. Clean a contamined manipulator as required.
Special points
Special points to be observed are shown in the figure below:

C
B
A
xx0200000239
3HAC 16246-1
Spiral cables to motor 6
Inside of upper arm tube
Rear of upper arm tube
Inside of lower arm
Inside of base/axis 1
91

Required equipment
Equipment, etc.
Steam cleaner
High pressure water

cleaner
Dos and donts!
Always!
Never!
Foundry versions
92
Note
Water pressure at nozzle: max. 2,500 kN/m 2 (25 bar)
Type of nozzle: fan jet, min. 45spread
Flow: max. 100 litres/min.
Water temperature: max. 80C
Max. water pressure on enclosures: 50 kN/m 2 (0.5 bar)
Fan jet nozzle should be used, min. 45spread
Flow: max. 100 litres/min.
The section below specifies some special considerations when cleaning the manipulator.
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never point the water jet at bearing seals, contacts, and other seals!
Never spray from a distance closer than 0.4 m!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 6 spiral cable (item A in the figure Special points on page 91)!
Although the manipulator is watertight, avoid spraying connectors and similar items
with a high pressure cleaner!
In working environments, e.g. foundries, where the manipulator may be exposed to fluids that
dry to make a crusty surface, e.g. release agents, clean the cable harnesses to prevent the crust
damaging the cables:
Clean the spiral wound cables to motor 6 (item A in the figure Special points on page
91) with water and a cloth!
Clean the remaining sections of the cable harnesses as detailed above!
3HAC 16246-1
6 Maintenance activities, controller cabinet

6.0.1 Introduction
Chapter 6: Maintenance activities, controller cabinet

6.0.1 Introduction
General
3HAC 16246-1
This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
93

6.1.1 Inspection of controller cabinet, S4Cplus M2000A
Section 6.1: Inspection activities

6.1.1 Inspection of controller cabinet, S4Cplus M2000A
Inspection
The procedure below details how to inspect the controller cabinet.
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supplies to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
Step Action
94
Note/Illustration
1.
Inspect the cabinet interior to make sure there is no Replace any faulty seals as
contamination.
required.
If any contamination is found, the cabinet interior
must be cleaned and all gaskets and seals to the
cabinet inspected.
2.
Inspect all sealing joints and cable glands to make

sure they are airtight in order to prevent dust and dirt
from being sucked into the cabinet.
3.
Inspect connectors and cabling to make sure they

are securely fastened and cabling not damaged.
4.
Inspect any fans to make sure they function correctly.
Replace any malfunctioning

fans as detailed in the Repairs
manual.
3HAC 16246-1

6.2.1 Replacement of battery unit, controller
Section 6.2: Replacement activities

Location of battery unit
The battery unit is located at the bottom of the controller.
X1
X1
X1
X1
X1
X2
X2
X2
X2
X2
X3
Rectifier
A0
xx0200000103
Battery unit
Required equipment
Equipment, etc.
Spare part no. Art no.
Note
Battery unit
3HAC 5393-2
To be replaced as a complete
unit

See references to
Removal, battery
unit
The procedure below details how to remove the battery unit.
3HAC 16246-1
95

Step Action
Note/Illustration
1. Remove the battery unit by unscrewing its attachment screws (1).

X1
X1
X1
X1
X2
X2
X2
X2
X1
X2
X3
Rectifier
A0
xx0200000004
2. Pull the battery unit out.

3. Disconnect the three cables from the
battery unit.
xx0200000005
Refitting, battery
unit
The procedure below details how to refit the battery unit.
Step Action
Note/Illustration
1. Place the battery unit close to its position.
Art. no. is specified above!

See illustration above!
2. Reconnect the cables and push the unit into position. See illustration above!
3. Secure it with the attachment screws.
96
See illustration above!
3HAC 16246-1

6.3.1 Cleaning of controller cabinet
Section 6.3: Cleaning activities

6.3.1 Cleaning of controller cabinet
Required equipment
Equipment, etc.
Internal cleaning
Art. no.
Note
Vacuum cleaner
ESD Safe
Cleaning agent, exterior cleaning
Use rag with alcohol, for example, if

necessary
The procedure below details how to clean the interior of the controller cabinet.
Step
1.
Dos and donts!
Always!
Never!
3HAC 16246-1
Action
Note/Illustration
Clean the cabinet interior with a vacuum cleaner if necessary.
The section below specifies special considerations when cleaning the controller cabinet.
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the controller before cleaning!
Never remove any covers or other protective devices before cleaning the controller!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure water cleaner!
97

6.3.2 Cleaning computer fans
Location of computer fans
The fans are located as shown in the figure below:
xx0200000002
Cover
Fan
Screw
Required equipment
Equipment, etc.
Note
Vacuum cleaner
Cleaning
ESD Safe
The following procedures details how to clean the computer fans.

Please observe the following before commencing any repair work:
Turn off all electric power supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. securing the lower arm with fixtures before removing the gearbox, axis 2.
Step
1.
98
Action
Note/Illustration
Loosen the screws on both sides of the cover, see

illustration pos 1.
3HAC 16246-1

Step
3HAC 16246-1
Action
Note/Illustration
2.
Remove the covers.
3.
Clean the fans with an ESD safe vacuum cleaner.
4.
Remount the covers.
99

6.3.3 Cleaning Drive units and air outlet device
Location of drive
units
The illustration below shows the location of the drive units and air outlet device.
1
Drive units
Air outlet device
Required equipment
Equipment, etc.
Vacuum cleaner
Cleaning
Note
ESD Safe
The following procedures detail how to clean the drive units, bleeder resistor and air outlet
device.
Step
1.
2.
100
Action
Illustration/Note
Loosen the M5 screws (pos B) to the

air outlet device.
Remove the air outlet
3HAC 16246-1

Step
Refitting
Action
Illustration/Note
3.
Remove the bleeder resistor.
Detailed in Repairs Manual section

Replacement of bleeder resistor.
4.
Clean the Inside of the air outlet.
Use an ESD safe vacuum cleaner.
5.
Clean the back side of the drive units. See Note above.
6.
Clean the bleeder resistor.
See Note above.
7.
Clean the drive unit fans.
See Note above.
The procedure below details how to refit the bleeder resistor.

Step Action
Note/Illustration
1. Fit the bleeder resistor into position and secure it with the Art. no. is specified above!
spring.
Also see the figure above!
2. Secure the cable disconnected during disassembly.
3. Refit the air outlet device.
4. Tighten the M5 screws.
3HAC 16246-1
101

6.3.4 Cleaning Air outlet
Location of air
outlet
The illustration below shows the location of the air outlet shaft
Air outlet
Required equipment
Equipment, etc.
Vacuum cleaner
Cleaning
Note
ESD Safe
The following procedures detail how to clean the air outlet shaft.
102
1.
Remove the drive units.
Detailed in Repairs Manual, section

Replacement of drive units and
rectifier.
2.
Remove the Bleeder resistor and system fan

unit.

Replacement of system fan unit.
3.
Use an ESD safe vacuum cleaner to clean the

shaft
4.
Clean also the space around the transformer

from the front of the cabinet, see illustration.
3HAC 16246-1

Refitting
The procedure below details how to refit the Drive units, bleeder resistor and system fan unit.
Step Action
Note/Illustration
1. Refit the drive units.

Replacement of drive units and rectifier.
2. Refit the Bleeder resistor and system fan unit. Detailed in Repairs Manual, section
Replacement of system fan unit.
3. Refit the air outlet device.
4. Tighten the M5 screws.
3HAC 16246-1
103

6.3.5 Cleaning Drain filter
Location of drain
filter
The illustration below shows the location of the drain filter.
Filter holder
M5 screw
Drain filter
Required equipment
Equipment, etc.
Spare part no. Art no.
Filter
3HAC 5393-2
Standard toolkit
3HAC 15571-1 The contents are defined in section "Standard toolkit"!

See references to
Removal
Note
The procedure below details how to remove the drain filter.

104
3HAC 16246-1

Step Action
Note/Illustration
1. Place the computer unit in the service position.
Detailed in Repairs Manual, section,

Putting the computer unit in service
position.
2. Loosen the M5 screw, pos. 2 in illustration.
3. Remove the filter holder, pos. 1 in previous

illustration.
4. Clean or replace the filter.
Refitting
The procedure below details how to refit the Drain filter.

Step Action
Note/Illustration
1. Fit the cleaned or new filter, pos 3
2. Fit the filter holder, (pos.1) and secure it with the See the figure above!
M5 screw, (pos. 2).
3. Put the computer system back in the regular
operation position.
3HAC 16246-1
Detailed in section "Putting the

computer in the service position".
105

106
3HAC 16246-1

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Maintenance Manual

Maintenance Manual, IRB 6600/6650, M2000A

The information in this manual is subject to change without notice and

Copyright 2003 ABB All rights reserved.

1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.1.1 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.0.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.0.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Chapter 5: Maintenance activities, manipulator

5.1.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.2.1 Oil change, gearbox axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

5.3.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.4.1 Cleaning, manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

6.1.1 Inspection of controller cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

6.2.1 Replacement of battery unit, controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6.3.1 Cleaning of controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

This manual should be used during maintenance work.

Who Should Read

This manual is intended for:

maintenance personnel in the user's organization.

maintenance personnel in other organizations.

The reader should...

be a trained maintenance craftsman

have the required knowledge of mechanical maintenance work OR

have the required knowledge of electrical maintenance work.

The information product is organized in the following chapters:

Service Information System (SIS)

Maintenance activities for options

Circuit diagram, Manipulator

Circuit diagram, Controller

Manual completed with version IRB 6650.

0.0.2 Product Documentation

0.0.2 Product Documentation

The Installation and Commissioning Manual contains the following information:

Installation of controller software

System directory structure

If there is any, model specific information

The Repair Manual contains the following information:

Remove/Refitting instructions for all manipulator details considered spare parts

If there is any, model specific information

The Maintenance Manual contains the following information:

If there is any, model specific information

0.0.2 Product Documentation

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

Chapter 1: Safety, service

The chapter "Safety, service" is divided into the following sections:

Section 1.1: General information

1.1.2 Limitation of Liability

1.1.3 Related information

The list below specifies documents which contain useful information:

Installation of safety devices

Installation and Commissioning

Changing robot modes

Restricting the working space Installation and Commissioning

Section 1.2: Safety risks

1.2.2 Safety risks related to tools/workpieces

1.2.3 Safety risks related to pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.

Dump valves should be used in case of emergency.

1.2.4 Safety risks during operational disturbances

Care must be taken at all times.