IRC5-IRB6600 Prod Man 3HAC020938-001 - References - Revc - en PDF

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

Product manual (part 2 of 2), reference information
IRB 6600 - 225/2.55 type A
IRB 6600 - 175/2.8 type A
IRB 6600 - 175/2.55 type A
IRB 6650 - 200/2.75 type A
IRB 6650 - 125/3.2 type A
M2000
M2000A
M2004
Document ID: 3HAC 020938-001

Revision: C
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Reference information 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Spare part / part list 25

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.2 Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.2 Rebuilding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.3 Part list, overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.4 Base incl frame ax 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3.5 Axis 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.6 Axis 3-4, Foundry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3.7 Wrist, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3.8 Wrist Foundry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.9 Wrist, insulated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3.10 Material set, manipulator, 3HAC 13263-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.11 Material set, axis 1-2, 3HAC 13264-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3.12 Material set, balancing device, 3HAC 13265-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3.13 Arm extension set, 250 mm, 3HAC 12311-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Exploded views 55
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2 Base incl. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.6 Wrist complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Circuit Diagram 61
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3HAC 020938-001 Revision: C 3

Table of Contents
4 3HAC 020938-001 Revision: C

Overview
Overview
About this manual

This manual contains reference information for all procedures described in the Product
manual, procedures .
Usage
This manual should be used during
• installation
• maintenance work
• repair work.
Who should read this manual?

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

Overview
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Reference information Useful information when performing installation, maintenance or
repair work (lists of necessary tools, reference documents, safety
standards).
Spare part / Part list Complete list of manipulator parts, shown in the exploded views
or foldouts.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Circuit diagram of the robot.
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commssioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Various corrections due to technical revisions, changes in the toolkits
etc.
A • Model M2004 implemented.
• Spare part list added to manual.
B • Section Document references is comleted with article for calibration
manuals.
C • New lubricating oil in the gearboxes. Changes made in the section Part
list on page 29.

Product documentation, M2000/M2000A
Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual

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

Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

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


1 Reference information
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.

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

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

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

1.4. Screw joints
1.4. Screw joints
General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

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

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

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil- Class 10.9, oil- Class 12.9, oil-
lubricated lubricated lubricated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34

1.4. Screw joints
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M10 55 66
M12 96 115
M16 235 280
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque Tightening torque Tightening torque

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

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

1.6. Standard toolkit
1.6. Standard toolkit
General
All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents, standard toolkit, 3HAC 15571-1
Qty Art. no. Tool Rem.

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

1.7. Special tools
1.7. Special tools
General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in section Standard toolkit on page 18, and
of special tools, listed directly in the instructions and also gathered in this section.
Basic tools
The table below specifies the tools in the basic toolkit (3HAC 15571-3) that are used for the
current robot model. This toolkit is necessary primarly when removing and refitting the
motors.
The tools are also listed directly in the instructions.
Description Qty Art. no.

Bolts (M16 x 60) for Mech stop ax 3 2 3HAB 3409-86
Guide pins M8 x 100 2 3HAC 15520-1
Lifting tool, wrist unit 1 3HAC 13605-1
Lifting tool, motor ax 1, 4, 5 1 3HAC 14459-1
Lifting tool, motor ax 2, 3, 4 1 3HAC 15534-1
Mech stop ax 3 2 3HAC 12708-1
Removal tool, motor M10x 2 3HAC 14972-1
Fits motors, axes 4, 5 and 6.
Removal tool, motor M12x 2 3HAC 14631-1
Fits motors axes 1, 2 and 3.
Rotation tool 1 3HAC 17105-1
Standard toolkit (content described in 1 3HAC 15571-1
section Standard toolkit on page 18)
Washers for mech stop axis 3 2 3HAA 1001-186
Special tools
The table below specifies the special tools required during several of the service procedures.
The tools may be ordered separately and are also specified directly in concerned instructions
in the Product manual, procedures.

Fixture lower arm 1 3HAC 020584-001
Gearbox crank 1 3HAC 16488-1
Guide pins M12 x 130 2 3HAC 022637-001

1.7. Special tools

Guide pins, sealing ax 2/3, 100mm 1 3HAC 14628-2
Guide pins, sealing ax 2/3, 80mm 1 3HAC 14628-1
Hydraulic cylinder 1 3HAC 11731-1
Hydraulic pump, 80 MPa 1 3HAC 13086-1
Hydraulic pump, 150 MPa (Glycerin) 1 3HAC 021563-012
Lifting device, base 1 3HAC 15560-1
Lifting device, manipulator 1 3HAC 15607-1
Lifting device, upper arm 1 3HAC 15994-1
Lifting eye VLBG M12 1 3HAC 16131-1
Lifting eye M12 2 3HAC 14457-3
Lifting eye M16 2 3HAC 14457-4
Lifting tool (chain) 1 3HAC 15556-1
Lifting tool, gearbox axis 2 1 3HAC 13698-1
Measuring tool 1 6896 134-GN
Motor press pinion 1 3HAC 021883-001
Oil injector / max 500 MPa 1 3HAC 021590-001
Press tool, axis 2 bearing 1 3HAC 13527-1
Puller device, axis 2 shaft 1 3HAC 021563-001
Press device, axis 2 shaft 1 3HAC 021600-001
Press tool, balancing device 1 3HAC 020902-001
Press tool, balancing device shaft 1 3HAC 17129-1
Puller tool, balancing device shaft 1 3HAC 12475-1
Shackle, balancing device 1 3HAC 020997-1
Support, base 1 3HAC 15535-1
Tool set balancing device 1 3HAC 021984-001
Tools that may be rented

The table below specifies the tools that may be rented from ABB in order to perform certain
service procedures as described in the Product manual.
The special tools are also listed directly in the instructions.
Description Art. no. Note

Lifting tool, lower arm 3HAC 14691-1 Includes
• guidings, 3HAC 14446-1

1.7. Special tools
Calibration equipment, Wyler

The table below specifies the calibration equipment required when calibrating the robot with
the Wyler method, using the Levelmeter 2000.

Angel bracket 68080011-LP
Calibration bracket 3HAC 13908-9
Calibration tool ax1 3HAC 13908-4
Levelmeter 2000 kit 6369901-347 Includes one sensor.
Measuring pin 3HAC 13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC 0392-1
Sync. adapter 3HAC 13908-1
Turn disk fixture 3HAC 68080011-GU
Calibration equipment, Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with
the Pendulum method.

CalPen (Calibration 3HAC 15716-1 Complete kit that also includes user
Pendulum) instructions.
Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.

Oil exchange equipment 3HAC 021745-001 Includes
• vacuum pump with
regulator, hose and coupling
• couplings and adapters
• pump (manual) with hose
and coupling
• graduated measuring glass
• oil gun
• user instructions.

1.8. Document references
General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot

The product specification includes generic technical data. The specification listed below is
the English version.
Document name Document ID

Product specification 3HAC 14064-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name Document ID

Product manual, S4Cplus M2000 3HAC 021333-001
Product manual, S4Cplus M2000A 3HAC 021128-001
Product manual, IRC5 M2004 3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name Document ID Note

User’s guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation
of S4Cplus based robot systems.
Operator’s manual (IRC5) 3HAC 16590-1
Calibration manuals

Calibration Pendulum 3HAC 16578-1 Enclosed with the Calibration
Instruction Pendulum Toolkit.
Instructions for Levelmeter 3HAC 022907-001 Enclosed with the Levelmeter 2000.
calibration (alternative method)
CalibWare 2.0 Users Guide 3HAC 16090-1 Manual for Absolute Accuracy
calibration.

Additional documentation

External axes 3HAC 9299-1

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

2 Spare part / part list
2.1. Introduction

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

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

2.2.2. Spare part list
Repair instructions
Each spare part is replaced as described in corresponding repair instruction in the Product
manual, procedures.
In addition to the spare part list in this section, there is also a part list with other replacement
articles for the robot in section Part list on page 29.
Robot overview
The figure below shows the location of all spare parts on the robot.
xx0400001022
Parts
Description Spare part no. Item in figure

Motor axis 1 3HAC 15879-2 A
Gearbox axis 1 3HAC 10828-8 B
Motor axis 2 (175/2.55) 3HAC 15882-2 C

Description Spare part no. Item in figure

Motor axis 2 3HAC 15885-2 C
(125/3.2, 175/2.8, 200/2.75, 225/2.55
Gearbox axis 2 3HAC 020043-001 D
Motor axis 3 (175/2.55) 3HAC 15882-2 E
Motor axis 3 3HAC 15885-2 E
(125/3.2, 175/2.8, 225/2.55, 200/2.75)
Gearbox axis 3 3HAC 021127-001 F
Motor axis 4 (175/2.55) 3HAC 15887-2 G
Motor axis 4 3HAC 15889-2 G
(125/3.2, 175/2.8, 225/2.55, 200/2.75)
SMB unit 3HAC 16014-1 H
Battery pack 3HAC 16831-1 I
Cable harness axis 1-4 (IRB 6600) 3HAC 14940-1 -
Cable harness axis 1-4 3HAC 16331-1 -
(IRB 6650)
Wrist (175/2.55) 3HAC 16627-1 J
Wrist (175/2.55, insulated turning disk) 3HAC 17372-1 J
Wrist 3HAC 16626-2 J
(125/3.2, 175/2.8, 225/2.55, 200/2.75)
Wrist (insulated turning disk) 3HAC 16626-3 J
(125/3.2, 175/2.8, 225/2.55, 200/2.75)
Cable harness axis 5 3HAC 14139-1 -
Motor axis 5 (175/2.55) 3HAC 17484-7 -
Motor axis 5 3HAC 17484-10 -
(125/3.2, 200/2.75, 175/2.8, 225/2.55)
VK-Cover VK 120x12 3HAA 2166-23 -
Turning disk, dia. 200 (175/2,55) 3HAC 9744-5 K
Turning disk, dia. 200 3HAC 13752-1 K
(125/3.2, 200/2.75, 175/2.8, 225/2.55)
Gearbox axis 6 (175/2.55) 3HAC 10828-10 -
Gearbox axis 6 3HAC 10828-13 -
(125/3.2, 200/2.75, 175/2.8, 225/2.55)
Motor axis 6 (175/2.55) 3HAC 15990-4 -
Motor axis 6 3HAC 15991-4 -
(125/3.2, 200/2.75, 175/2.8, 225/2.55)
Cable harness axes 5-6 3HAC 14140-1 -
Balancing device (IRB 6600) 3HAC 020691-001 L
Balancing device (IRB 6650) 3HAC 020692-001 L
Complete maintenance kit, balancing 3HAC 021592-001 -
device
Maintenance kit with bearings, balancing 3HAC 021593-001 -
device

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

2.3.2. Rebuilding parts
Overview
The IRB 6600/6650 has some rebuilding parts that differ from eachother, depending on the
version of the robot. This section is a general overview of which parts belong to which
versions.
The following section, Part list on page 29also gives further details of the parts specified
below.
Rebuilding parts
2.55/ 2.55/ 2.75/ 2.8/ 3.2/

Art. no. Part Type
175 225 200 175 125
3HAC 10746-1 Axis 3-4 X X X X Standard
3HAC 10746-3 Axis 3-4 X Standard
3HAC 10746-6 Axis 3-4 X X X X Foundry
3HAC 10746-7 Axis 3-4 X Foundry
3HAC 020049-001 Tube shaft 2.55 X X X X X Standard
3HAC 020053-001 Tube shaft 2.55 X X X X X Foundry
3HAC 10141-1 Lower arm X X X
3HAC 13940-1 Lower arm X X
3HAC 14940-1 Harness ax. 1-4 X X X
3HAC 16331-1 Harness ax.1-4 X X
3HAC 9760-3 Arm extender X Standard
250mm
250mm and Foundry
450mm
450mm and Foundry
3HAB 7700-69 Screw M12x50 12X 12X
3HAA 1001-134 Washer 12X 12X
13x19x1,5
9ABA 107-56 Parallel pin X X
10x20
9ADA 618-56 Screw M6x16 4X 6X
3HAC 9760-9 Cover 250mm X
3HAC 9760-10 Cover 450mm X
3HAC 15879-2 Motor axis 1 X X X X X
3HAC 15885-2 Motor axis 2 X X X X
3HAC 15882-2 Motor axis 2 X

2.55/ 2.55/ 2.75/ 2.8/ 3.2/

Art. no. Part Type
175 225 200 175 125
3HAC 16627-3 Wrist 175 kg X
3HAC 16626-2 Wrist 225 kg X X X X

2.3.3. Part list, overview
Part list
Item Qty Art. number Description Note / Dimension

5 1 3HAC 17358-1 Mechanical stop ax 1,
assembly
101 1 3HAC 12685-1 Base incl frame ax 1 See section Base incl
frame ax 1 on page 34
102 1 3HAC 10746-1 Axis 3-4 See section Axis 3-4 on
page 35
102 1 3HAC 10746-3 Axis 3-4 (6600 - 175/2.55) See section Axis 3-4 on
page 35.
102 1 3HAC 10746-4 Axis 3-4, Foundry See section Axis 3-4,
Foundry on page 39
102 1 3HAC 10746-5 Axis 3-4, Foundry (6600 - See section Axis 3-4,
175/2.55) Foundry on page 39.
103 1 3HAC 8114-1 Wrist (6600 - 175/2.55) See section Wrist,
standard on page 40.
103 1 3HAC 8114-3 Wrist See section Wrist,
standard on page 40
103 1 3HAC 8114-5 Wrist, Foundry See section Wrist
Foundry on page 45
103 1 3HAC 8114-6 Wrist, Foundry (6600 - 175/ See section Wrist
2.55) Foundry on page 45.
103 1 3HAC 8114-7 Wrist, insulated (6600 - 175/ See section Wrist,
2.55) insulated on page 46.
103 1 3HAC 8114-8 Wrist, insulated See section Wrist,
insulated on page 46.
104 1 3HAC 17117-2 Balancing Device A (6600-
225/2.55, 6600-175/2.8,
6600-175/2.55)
104 1 3HAC 17117-3 Balancing Device B (6650-
125/3.2, 6650-200/2.75)
105 1 3HAC 10141-1 Lower arm (6600 - 175/2.55,
6600-225/2.55, 6600-175/
2.8)
105 1 3HAC 13940-1 Lower arm (6650-125/3.2,
6650-200/2.75)
106 1 3HAC 14940-1 Cable harness, man. ax1-4
(6600-225/2.55, 6600-175/
2.8, 6600-175/2.55)
106 1 3HAC 16331-1 Cable harness, man ax 1-4
(6650-125/3.2, 6650-200/
2.75)
108 1 3HAC 13263-1 Material set manipulator See section Material set,
manipulator, 3HAC
13263-1 on page 48


109 1 3HAC 13264-1 Material set ax 1-2 See section Material set,
axis 1-2, 3HAC 13264-1
on page 49
110 1 3HAC 13265-1 Mtrl.set balancing device See section Material set,
balancing device, 3HAC
13265-1 on page 52
111 1 3HAC 12311-4 Arm extension set 250mm See section Arm
(175/2.8) extension set, 250 mm,
3HAC 12311-4 on page
53
111 1 3HAC 12311-5 Arm extension set 450mm See section Arm
(125/3.2) extension set, 450 mm,
3HAC 12311-5.
112 2 or 1 3HAC 12129-1 Cover plate t=1,5 mm
113 8 or 4 9ADA 618-56 Torx pan head screw M6 x 16
114 1 3HAC 13416-1 Protection cover Shell size 16
115 1 3HAC 18281-1 Cover

2.3.4. Base incl frame ax 1
2.3.4. Base incl frame ax 1
Part list

101.1 1 3HAC 17224-4 Base, machining See block Base,
machining, 3HAC 17224-
4.
101.2 1 3HAC 12684-1 Frame incl ax 1 gearbox See block Frame incl ax
1 gearbox, 3HAC
020858-001.
101.3 3 3HAC 11732-2 Washer T=3
101.4 18 3HAB 7700-5 Hex socket head cap screw
101.5 1 3HAC 11529-1 Rubber lined clip D=28
101.6 1 3HAC 14453-1 Hose with flange
101.7 1 3HAC 14453-2 Plug
101.8 1 3HAC 4428-2 Hose Clip D=23-27
101.9 1 9ADA 618-56 Torx pan head screw M6 x 16
Base, machining
Item Qty Art. number Description Dimension

101.1.1 1 3HAC 17224-2 Base, casting
101.1.2 5 3HAC 4836-7 Protection plug 16 x 12.3 x 9 x 7
101.1.3 1 3HAC 1383-2 Protection Cover compl.
101.1.4 1 3HAC 14024-1 Protection screw
Frame incl ax 1 gearbox

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

2.3.5. Axis 3-4
2.3.5. Axis 3-4
Overview
Item Qty Art. number Description Note

102.1 1 3HAC 13350-1 Material set ax 4 See block Material set ax 4, 3HAC
13350-1.
102.2 1 3HAC 020049-001 Tube shaft 2,55 See block Tube shaft 2.55, 3HAC
020049-001.
102.3 1 3HAC 13351-1 Axis 3 See block Axis 3, 3HAC 13351-2/1.
102.4 1 3HAC 14753-1 Rot ac motor incl See block Rot ac motor incl
gearbox (6600- gearbox, 3HAC 14752-1.
175/2.55)
gearbox gearbox, 3HAC 14752-1.
Material set ax 4, 3HAC 13350-1
Item Qty Art. number Description Dimension / Note

102.1.1 1 3HAC 12261-1 Gear Z4 /4
102.1.3 8 9ADA 183-37 Hex socket head cap screw M8 x 25
102.1.4 8 9ADA 312-7 Plain washer 8.4 x 16 x 1.6
102.1.5 1 3HAC 12259-1 Wheel unit ax4 225kg See sub-block Wheel unit
ax 4, 225 kg, 3HAC
12259-1.
102.1.6 3 3HAA 1001-99 Wedge
102.1.7 3 3HAC 12560-1 Stud bolt M8 x 65
102.1.8 12 9ADA 334-7 Spring washer, conical 8.4 x 18 x 2
102.1.9 3 9ADA 267-7 Hexagon nut M8
102.1.11 3 9ADA 334-8 Spring washer, conical 10.5 x 23 x 2.5
102.1.12 1 3HAC 13564-1 Damper axis 4 See sub-block Damper,
axis 4, 3HAC 13564-1.
102.1.13 1 3HAA 1001-17 Stop, Axis 4, Casting
102.1.14 1 3HAC 11925-1 Mechanical stop head
102.1.16 1 3HAA 1001-98 Gasket T=1
102.1.17 1 3HAC 12149-4 Cover ax4 with sealing See sub-block Cover axis
4 with sealing, 3HAC
12149-4.
102.1.18 14 9ADA 618-56 Torx pan head screw M6 x 16
102.1.20 1 3HAC 17218-1 Set of shims
102.1.21 1 3HAC 17219-2 Thrust washer
102.1.22 1 9ABA 135-45 Retaining ring, shaft 170
102.1.23 2 2213 253-5 Ball bearing 170 x 215 x 22
102.1.24 1 2216 261-18 Sealing 170 x 200 x 15

2.3.5. Axis 3-4

102.1.25 1 2216 0086-4 Sealing (Nilos) 180 x 215 x 4
102.1.26 1 3HAB 4317-1 Sealing
102.1.27 1 3HAC 3774-7 Spacer ring
102.1.28 1 21522012-535 O-ring 169.3 x 5.7
102.1.29 1 9ABA 107-56 Parallel pin 10 x 20
102.1.30 8,100 1171 2016-604 Lubricating oil
ml
102.1.31 30 g 3HAB 3537-1 Bearing grease
102.1.32 1 ml 3HAB 7116-1 Locking liquid
102.1.34 1 3HAC 16721-1 Magnetic plug R 1/2"
Wheel unit ax 4, 225 kg, 3HAC 12259-1
Item Qty Art. number Description Dimenstion / Note

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

102.1.5.2.0 1 3HAC 12259-3 Pinion Z3 /4
102.1.5.2.0 1 3HAC 12259-4 Gear Z2 /4
Damper, axis 4, 3HAC 13564-1

102.1.12.2 2 3HAC 13564-2 Plate for damper
Cover axis 4 with sealing, 3HAC 12149-4

102.1.17.1 1 3HAC 12149-3 Cover ax4 with gasket
102.1.17.2 1 3HAA 1001-628 Sealing
Tube shaft 2.55, 3HAC 020049-001

102.2.1 1 3HAC 10139-2 Tube shaft 2,55, casting

2.3.5. Axis 3-4

102.2.2 1 3HAC 1383-2 Protection Cover compl. See sub-block Protection
cover compl., 3HAC 1383-2
Protection cover compl., 3HAC 1383-2

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

102.3.1 1 3HAC 10133-1 Axis 4 housing
102.3.2 1 3HAC 021127-001 RV 410F-270,176 See sub-block RV 410F-
assembly 270, 176 assembly, 3HAC
021127-001
102.3.3 24 3HAB 3409-71 Hex socket head M12 x 60
cap screw
102.3.4 24 3HAA 1001-134 Washer 13 x 19 x 1.5
102.3.5 1 3HAC 14750-1 Rot ac motor incl See sub-block Rot ac
pinion motor incl pinion, 3HAC
14750-1
102.3.6 4 3HAB 3409-50 Hex socket head M10 x 40
cap screw
102.3.7 4 3HAB 4233-1 Washer
102.3.9 2,500 ml 3HAC 16843-1 Lubricating oil, RMO Do not mix different types
150 of oil!
102.3.9 2,500 ml 3HAC 021469-001 Lubricating oil, Shell Do not mix different types
Tivela S 150 of oil!
102.3.10 1 9ABA 142-92 Spring pin, slotted 10 x 30
RV 410F-270, 176 assembly, 3HAC 021127-001

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

102.3.5.1 1 3HAC 17484-9 Rotational ac motor M9
102.3.5.2 1 3HAC 10122-15 Input gear

2.3.5. Axis 3-4

102.3.5.3 1 2152 2012-430 O-ring 89.5 x 3
102.3.5.4 1 9ADA 183-444 Hex socket head cap screw M8 x 130
Rot ac motor incl gearbox

102.4.1 1 3HAC 17484-10 Rotational ac motor M10
102.4.1 1 3HAC 17484-7 Rotational ac motor M7 (6600-
175/2.55)
102.4.2 1 3HAC 12260-1 Pinion Z1 /4
102.4.3 1 2152 2012-430 O-ring 89,5x3

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

102.1 1 3HAC 13350-1 Material set ax 4 See block Material set ax 4,
3HAC 13350-1 on page 35
102.2 1 3HAC 020053-001 Tube shaft 2,55 foundry
102.3 1 3HAC 13351-1 Axis 3 See block Axis 3, 3HAC
13351-1 on page 37
102.4 1 3HAC 14753-1 Rot ac motor incl gearbox See block Rot ac motor incl
(6600-175/2.55) gearbox on page 38
gearbox on page 38

2.3.7. Wrist, standard
Overview

103.1 1 3HAC 8114-4 Material set See block Material set, 3HAC
8114-4.
gearbox gearbox, 3HAC 7941-30.
gearbox (6600- gearbox on page 42.
175/2.55)
103.3 10 3HAB 3409-89 Hex socket head M16 x 80
cap screw
103.4 1 3HAC 13890-1 Axis 6 complete See block Axis 6 complete, 3HAC
13890-1/2.
103.4 1 3HAC 9744-1 Axis 6 complete See block Axis 6 complete, 3HAC
(6600-175/2.55) 9744-1, 3HAC 16032-1 on page
43.
103.5 1 3HAC 12732-1 Label (6600-175/
2.55)
103.5 1 3HAC 12732-3 Label
Material set, 3HAC 8114-4

103.1.1 1 3HAC 7956-1 Wrist housing, 225kg
103.1.2 1 3HAC 7941-28 Set of shim, motor
103.1.3 1 3HAC 7941-19 Set of shim, bevel gear
103.1.6 1 3HAA 2166-11 VK-Cover D=80 B=10
103.1.7 1 3HAC 4334-3 Cylindrical roll. bearing 50 x 90 x 20
103.1.8 4 3HAC 12560-1 Stud bolt M8 x 65
103.1.10 16 9ADA 334-7 Spring washer, conical 8.4 x 18 x 2
103.1.11 4 9ADA 267-7 Hexagon nut M8
103.1.12 4 3HAA 1001-99 Wedge
103.1.13 1 3HAB 7299-1 Sealing Di=115 Dy=140 B=12
103.1.14 1 3HAA 2166-23 VK-Cover D=120, B=12
103.1.15 1 3HAC 7941-32 Support shaft incl bearing See sub-block Support
shaft incl bearing, 3HAC
7941-32.
103.1.17 2 3HAB 4337-2 Damper axis 5
103.1.18 1 3HAC 9953-1 Syncplate with nonie T=1.5


103.1.24 1 3HAC 14139-1 Manip. Harness ax 5
103.1.25 6,700 1171 2016-604 Lubricating oil
ml
103.1.26 1 3HAC 7941-6 Interm.wheel unit/5 225kg See sub-block Interm.
wheel unit/5 225 kg,
3HAC 7941-6.
103.1.27 1 3HAA 1001-266 Screw M16 x 60
103.1.28 1 3HAC 7941-21 Gear wheel unit z6/5 225 See sub-block Gear
wheel unit z6/5 225,
3HAC 7941-21
103.1.29 1 3HAC 8081-8 Cover with gasket, 225kg
103.1.30 1 3HAC 8081-3 Cable cover
103.1.31 1 3HAC 14140-1 Manip. Harn. ax 5/6
103.1.32 2 2166 2055-3 Cable straps, outdoors 4.8 x 208
103.1.33 5 3HAA 1001-106 Washer D/d =15/6.4 t=3
Support shaft incl bearing, 3HAC 7941-32

103.1.15.1 1 3HAC 14731-1 Shaft
103.1.15.2 1 3HAB 3643-11 Groove ball bearing 130 x 165 x 18
103.1.15.3 3 9ADA 618-56 Torx pan head screw M6 x 16
Interm. wheel unit/5 225 kg, 3HAC 7941-6

103.1.26.1 1 3HAC 7946-1 Hub ax5, machining
103.1.26.2 2 3HAA 1001-130 Taper Roller Bearing
103.1.26.3 1 3HAC 7941-12 Gear Unit z4-z5/5 225kg See sub-block below!
103.1.26.4 1 3HAC 13142-1 Washer 17 x 30 x 6
103.1.26.5 1 3HAC 7941-11 Locking Nut
Gear unit Z4-Z5/5 225 kg, 3HAC 7941-12

103.1.26.3.1 1 3HAC 7941-7 Pinion z5/5 225kg
103.1.26.3.2 1 3HAC 7941-5 Gear z4/5 225kg

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

103.1.28.1 1 3HAC 7941-8 Gear z6/5 225kg
103.1.28.2 1 3HAB 4271-1 Groove ball bearing 110 x 150 x 20
103.1.28.3 1 3HAB 6686-1 Support ring
Rot ac motor incl gearbox

175/2.55)
103.2.2 1 3HAC 7941-1 Bevelgear set unit z1-3/5
103.2.3 1 2152 2012-430 O-ring 89.5 x 3
Axis 6 complete, 3HAC 13890-1/2

103.4.1 1 3HAC 13752-1 Turning disk
103.4.2 1 3HAC 10828-13 RV 70F-125,8 assembly See sub-block RV 40E-
81 assembly, 3HAC
10828-13.
103.4.3 1 3HAC 11522-2 Tilt housing RV70
103.4.3 1 3HAC 16009-1 Tilt housing RV70, foundry
103.4.4 1 3HAC 14754-1 Rot ac motor incl pinion See sub-block Rot ac
motor incl. pinion, 3HAC
14754-1.
103.4.6 4 9ADA 183-37 Hex socket head cap M8 x 25
screw
103.4.7 18 3HAA 1001-172 Washer 8.4 x 13 x 1.5
103.4.8 2 2522 122-1 Magnetic plug R1/4"
103.4.9 450 ml 3HAC 16843-1 Lubricating oil, RMO 150 Do not mix different
types of oil!
103.4.9 450 ml 3HAC 021469- Lubricating oil, Shell Do not mix different
001 Tivela S 150 types of oil!
103.4.11 1 3HAB 3772-64 O-ring 150.0 x 2.0
103.4.12 12 3HAB 3772-61 O-ring 13.1 x 1.6
103.4.13 1 3HAC 16862-1 Syncplate 175 kg
103.4.14 12 3HAB 7700-65 Hex socket head cap M12 x 30
screw
screw


103.4.20 1 3HAC 14263-1 Protection Cover
103.4.21 1 9ADA 624-69 Torx counters. head screw M8 x 20
RV 70F-125,8 assembly, 3HAC 10828-13

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

103.4.4.2 1 3HAC 11173-3 Pinion RV 70F.125,8
103.4.4.3 1 2152 2012-430 O-ring 89.5 x 3
103.4.4.4 1 9ADA 183-415 Hex socket head cap screw M5 x 55
103.4.4.6 1 3HAC 12877-1 Gasket
Axis 6 complete, 3HAC 9744-1, 3HAC 16032-1

103.4.1 1 3HAC 9744-5 Turning disk
103.4.2 1 3HAC 10828-10 RV 40E-81 assembly See sub-block RV 40E-
81 assembly, 3HAC
10828-10 on page 44.
103.4.3 1 3HAC 9744-3 Tilt housing RV40
103.4.3 1 3HAC 16009-2 Tilt housing RV40, foundry
motor incl. pinion, 3HAC
14755-1 on page 44.
103.4.6 4 9ADA 183-37 Hex socket head cap M8 x 25
screw
103.4.7 18 3HAA 1001-172 Washer 8.4 x 13 x 1.5
103.4.8 2 2522 122-1 Magnetic plug R1/4"
103.4.9 300 ml 3HAC 16843-1 Lubricating oil, RMO 150 IRB 6600 - 175/2.55
103.4.9 450 ml 3HAC 16843-1 Lubricating oil, RMO 150 IRB 6600 - 225/2.55 -
175/2.8, IRB 6650
Do not mix different
types of oil!
103.4.9 300 ml 3HAC 021469- Lubricating oil, Shell IRB 6600 - 175/2.55
001 Tivela S 150


103.4.9 450 ml 3HAC 021469- Lubricating oil, Shell IRB 6600 - 225/2.55 -
001 Tivela S 150 175/2.8, IRB 6650
Do not mix different
types of oil!
103.4.11 1 3HAB 3772-65 O-ring
103.4.12 12 21520431-20 O-ring
103.4.13 1 3HAC 16862-2 Syncplate 175 kg
103.4.14 12 21212518-577 Hex socket head cap
screw
screw
103.4.16 2 21520441-1 Washer
103.4.20 1 3HAC 14263-1 Protection Cover
103.4.21 1 9ADA 624-69 Torx counters. head screw M8 x 20
RV 40E-81 assembly, 3HAC 10828-10

103.4.2.1 1 3HAC 10828-5 RV 40E, i=81
103.4.2.2 1 3HAB 3772-58 O-ring
Rot ac motor incl. pinion, 3HAC 14755-1

103.4.4.2 1 3HAC 10122-24 Pinion RV 40E-81
103.4.4.3 1 2152 2012-430 O-ring 89.5 x 3
103.4.4.4 1 9ADA 183-20 Hex socket head cap screw
103.4.4.6 1 3HAC 12877-1 Gasket

2.3.8. Wrist Foundry
2.3.8. Wrist Foundry
Overview

103.1 1 3HAC 8114-4 Material set See block Material set,
3HAC 8114-4 on page 40
103.2 1 3HAC 7941-30 Rot ac motor incl gearbox See block Rot ac motor
incl gearbox on page 42
103.2 1 3HAC 7941-29 Rot ac motor incl gearbox See block Rot ac motor
(6600-175/2.55) incl gearbox on page 42.
103.3 10 3HAB 3409-89 Hex socket head cap screw M16 x 80
103.4 1 3HAC 13890-2 Axis 6 complete Foundry See block Axis 6
complete, 3HAC 13890-1/
2 on page 42
103.4 1 3HAC 16032-1 Axis 6 complete Foundry See block Axis 6
(6600-175/2.55) complete, 3HAC 9744-1,
3HAC 16032-1 on page
43.
103.5 1 3HAC 12732-2 Label
103.5 1 3HAC 12732-4 Label

2.3.9. Wrist, insulated
Overview
Item Qty Art. no. Description Note/Dimension

103.1 1 3HAC 8114-4 Material set See block Material set, 3HAC
8114-4 on page 40.
103.2 1 3HAC 7941-29 Rot ac motor incl gearbox See block Material set, 3HAC
(6600-175/2.55) 8114-4 on page 40.
gearbox on page 42.
103.3 8 3HAB 3409-89 Hex socket head cap screw
10
103.4 1 3HAC 17255-1 Ax 6 complete, insulated See block Ax 6 complete,
(6600-175/2.55) insulated, 3HAC 17255-1 on
page 46.
103.4 1 3HAC 17371-1 Ax 6 complete, insulated See block Ax 6 complete,
insulated, 3HAC 17371-1 on
page 47.
103.5 1 3HAC 12732-5 Label
103.5 1 3HAC 12732-6 Label
Ax 6 complete, insulated, 3HAC 17255-1

103.4.1 1 3HAC 17098-1 Axis 6 insulated
motor incl pinon, 3HAC
14755-1 on page 46.
103.4.3 4 9ADA 312-7 Plain washer M8
103.4.4 4 9ADA 183-37 Hex socket head cap screw
103.4.5 300 3HAC 021469- Lubricating oil, Shell Tivela S
ml 001 150
103.4.5 300 3HAC 16843-1 Lubricating oil, RMO 150
ml
103.4.7 1 3HAC 16862-2 Syncplate 175 kg
103.4.8 2 9ADA 618-32 Torx pan head screw
103.4.9 1 3HAC 14263-1 Protection cover
103.4.10 1 9ADA 624-69 Torx counters, head screw
Rot ac motor incl pinon, 3HAC 14755-1
Item Qty Art. no. Description Note

103.4.2.2 1 3HAC 10122-24 Pinion RV40E-81


103.4.2.3 1 21522012-430 O-ring
103.4.2.4 1 9ADA 183-20 Hex socket head screw
103.4.2.6 1 3HAC 12877-1 Gasket
Ax 6 complete, insulated, 3HAC 17371-1

103.4.1 1 3HAC 17196-1 Axis 6 insulated
motor incl pinon, 3HAC
14754-1 on page 47.
103.4.3 4 9ADA 312-7 Plain washer M8
103.4.4 4 9ADA 183-37 Hex socket head cap screw
103.4.5 450 3HAC 021469- Lubricating oil, Shell Tivela S
ml 001 150
103.4.5 450 3HAC 16843-1 Lubricating oil, RMO 150
ml
103.4.7 1 3HAC 16862-1 Syncplate 225 kg
103.4.8 2 9ADA 618-32 Torx pan head screw
103.4.9 1 3HAC 14263-1 Protection cover
103.4.10 1 9ADA 624-69 Torx counters, head screw
Rot ac motor incl pinon, 3HAC 14754-1

103.4.2.2 1 3HAC 11173-3 Pinion RV70F-125,8
103.4.2.3 1 21522012-430 O-ring
103.4.2.4 1 9ADA 183-415 Hex socket head screw
103.4.2.6 1 3HAC 12877-1 Gasket

2.3.10. Material set, manipulator, 3HAC 13263-1
2.3.10. Material set, manipulator, 3HAC 13263-1
Overview
Dimension /
Item Qty Art. number Description
Note
108.201 2 3HAC 17212-1 Sealing axis 2/3
108.203 3 3HAC 12703-1 Washer, axis 3
108.204 33 3HAA 1001-134 Washer
108.207 12 3HAA 1001-134 Washer 13 x 19 x 1.5
108.210 1 3HAC 14300-1 Cable protector
108.211 1 3HAC020507-001 Lower arm cable protection
(IRB6650)
108.211 1 3HAC 16926-1 Lower arm cable protection
(IRB6600)
108.212 1 3HAC 11771-1 Cable guide, end part
108.213 1 3HAC 13960-1 Connection plate, ax3 t = 4 mm
108.214 2 3HAC 12320-1 Damper, axis 3
108.215 2 3HAC 12991-1 Damper, axis 2
108.216 2 9ADA 624-65 Torx counters. head screw M6 x 60
108.217 2 9ADA 334-7 Spring washer, conical 8.4 x 18 x 2
108.220 2 3HAC 9953-1 Syncplate with vernier T=1.5
108.222 1 3HAC 12719-1 Syncplate with vernier ax3 T=1.5
108.223 2 9ADA 183-48 Hex socket head cap screw M10 x 16
108.224 1 3HAC 12844-1 Cable cover
108.228 1 3HAC 3261-1 Cover
108.229 1 3HAC 15431-1 Cable protection
108.230 1 3HAC 14880-1 Cable fixing bracket t=3
108.231 1 21520441-1 Washer
108.232 6 3HAC 16721-1 Magnetic plug R 1/2"
108.233 1 2522122-1 Magnetic plug G 1/4"
108.235 1 3HAC 020958-001 Cable protection lower arm

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

109.301 1 3HAC 021127-001 Reduction gear See block Reduction
gear.
109.302 1 3HAC 16829-1 Cover, axis 2
109.303 1 3HAC 14699-1 Friction washer 294x333x1,0
109.304 24 3HAB 3409-71 Hex socket head cap M12 x 60
screw
109.305 24 3HAA 1001-134 Washer 13 x 19 x 1.5
109.306 1 3HAC 14749-1 Rot ac motor incl pinion See block Rot ac motor
incl pinion, 3HAC
14749-1.
incl pinion, 3HAC
14750-1/ 14751-1 on
page 51.
(6600-175/2.55) incl pinion, 3HAC
14750-1/ 14751-1 on
page 51.
109.308 8 3HAB 3409-50 Hex socket head cap M10 x 40
screw
109.309 8 3HAB 4233-1 Washer
109.310 1 3HAC 12252-1 Bottom plate T=3
109.311 1 3HAC 14131-1 Connection plate, base t=3 mm
109.312 1 3HAC 11774-3 Adapter, complete See block Adapter,
complete, 3HAC 11774-
3.
109.313 1 3HAC 11769-1 Cable guide, ax.1
109.314 1 3HAC 16295-3 Cover
109.315 29 9ADA 183-39 Hex socket head cap M8 x 35
screw
109.316 29 9ADA 312-7 Plain washer 8.4 x 16 x 1.6
109.317 1 3HAB 3772-68 O-ring 276x3,53
109.318 1 3HAB 3772-69 O-ring 378x4
109.319 1 3HAB 3772-70 O-ring 340x3,5
109.320 1 3HAC 12671-5 Profile with sync scale
109.321 1 3HAC 12671-6 Block for calibration
109.322 1 3HAC 14024-1 Protection screw See block Protection
screw, 3HAC 14024-1.
109.326 1 3HAC 16014-1 Serial measurement unit
109.327 1 3HAC 14692-3 Cover SMB and BRU See block Cover SMB
and BRU.


109.328 1 3HAC 16831-1 Battery pack
109.329 1 3HAC 13151-1 Cable battery/SMB L=350 ± 20
109.330 2 3HAC 11526-1 Stud screw M6 x 150
109.332 1 3HAC 14791-3 Cover battery box See block Cover,
battery box, 3HAC
14791-3.
109.335 1 3HAA 2166-23 VK-Cover D=120, B=12
109.336 1 3HAC 020745-001 Attachment plate IRB 6600
109.337 2 3HAC 12625-1 Strap, Velcro 25 x 450
109.338 1 3HAC 14792-1 Bracket T=3
109.339 1 3HAC 15619-1 Cable, FB7-SMB 1.7
109.341 7,300 3HAC16843-1 Lubricating oil, RMO 150 Do not mix the types of
ml oil!
109.341 7,300 3HAC 021469-001 Lubricating oil, Shell Do not mix the types of
ml Tivela S 150 oil!
109.342 4,600 3HAC 16843-1 Lubricating oil, RMO 150 Do not mix the types of
ml oil!
109.342 4,600 3HAC 021469-001 Lubricating oil, Shell Do not mix the types of
ml Tivela S 150 oil!
109.344 1 ml 3HAB 7116-1 Locking liquid
109.345 2 9ADA 267-6 Hexagon nut M6
109.346 1 3HAC 16035-1 BU w. buttons DSQC 563
109.347 1 3HAC 6499-1 Push button guard
109.348 4 9ADA 629-56 Torx pan head roll. screw M6 x 16
109.350 1 3HAC 4813-1 Cover, push button guard
Reduction gear

109.301.1 1 3HAC 10828-11 Reduction gear
109.301.2 1 3HAB 3772-68 O-ring
Rot ac motor incl pinion, 3HAC 14749-1

109.306.2 1 3HAC 11350-1 Pinion RV 500C & RV 320C
109.306.3 1 2152 2012-430 O-ring 89.5 x 3

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

175/2.55)
109.307.2 1 3HAC 10122-15 Input gear
109.307.3 1 21522012-430 O-ring 89.5 x 3
109.307.4 1 9ADA 183-444 Hexagon socket head screw
Adapter, complete, 3HAC 11774-3

109.312.1 1 3HAC 11774-1 Adapter, machined
109.312.2 2 2152 2012-428 O-ring 79.5 x 3
109.312.3 1 ml 1234 0011-125 Acrylate adhesive
Protection screw, 3HAC 14024-1

109.322.1 1 3HAC 13582-1 Protection screw
109.322.2 1 3HAB 3772-32 O-ring 17 x 3
Cover SMB and BRU

109.327.1 1 3HAC 14692-1 Cover
109.327.2 1 3HAC 14692-2 Gasket
109.327.3 1 3HAC 14692-4 Rubber cloth
Cover, battery box, 3HAC 14791-3

109.332.1 1 3HAC 14791-1 Cover T=4
109.332.2 1 3HAC 14791-2 Gasket T=3
109.332.3 1 3HAC 16977-1 Warning label battery

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

110.401 1 3HAC 12441-2 Spherical roller bearing 65 x 120 x 38
110.402 1 3HAC 12481-1 Thrust washer
110.403 1 3HAC 12627-1 Bushing
110.404 1 9ABA 135-31 Retaining ring, shaft 65
110.405 1 3HAC 12480-1 Shaft
110.406 1 3HAC 4836-7 Protection plug 16 x 12.3 x 9 x 7
110.408 2 9ABA 107-56 Parallel pin 10 x 20
110.409 1 3HAC 12548-1 Protection washer T=1
110.410 1 3HAC 12534-1 Shaft, balancing device
110.411 4 3HAA 1001-186 Washer 17 x 25 x 3
110.412 50 ml 3HAA 1001-294 Grease
110.413 2 3HAC 4836-1 Protection plug 20 x 14.6 x 7.5 x 5.5
110.414 1 9ADA 183-490 Hex socket head cap screw M16 x 180
110.415 1 9ADA 312-10 Plain washer 17 x 30 x 3

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

111.501 1 3HAC 9760-3 Arm extender 250mm
111.501 1 3HAC 15859-2 Arm extender 250mm, Foundry
111.504 12 3HAA 1001-134 Washer 13 x 19 x 1.5
111.505 1 9ABA 107-56 Parallel pin 10 x 20
111.506 1 3HAC 9760-9 Cable cover 250mm


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

3 Exploded views
3.2. Base incl. Frame
3.2. Base incl. Frame
xx0200000329

3 Exploded views
3.3. Frame-Lower arm 1
Exploded view
xx0200000334

3 Exploded views
xx0200000335

3 Exploded views
3.5. Upper arm
3.5. Upper arm
xx0200000337

3 Exploded views
3.6. Wrist complete
3.6. Wrist complete
xx0200000336

4 Circuit Diagram
4.1. Introduction
4 Circuit Diagram
4.1. Introduction
Overview
This chapter includes the circuit diagram of the robot.

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

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Product manual (part 2 of 2), reference information

Document ID: 3HAC 020938-001

© Copyright 2004 ABB All right reserved.

2 Spare part / part list 25

3HAC 020938-001 Revision: C 3

4 3HAC 020938-001 Revision: C

About this manual

Who should read this manual?

3HAC 020938-001 Revision: C 5

6 3HAC 020938-001 Revision: C

Product documentation, M2000/M2000A

Controller hardware option manual

3HAC 020938-001 Revision: C 7

Product documentation, M2004

8 3HAC 020938-001 Revision: C

3HAC 020938-001 Revision: C 9

10 3HAC 020938-001 Revision: C

3HAC 020938-001 Revision: C 11

1.2. Applicable Safety Standards

Standards, robot cell

12 3HAC 020938-001 Revision: C

1.3. Unit conversion

3HAC 020938-001 Revision: C 13

1.4. Screw joints

Gleitmo treated screws

Screws lubricated in other ways

Lubricant Art. no.

14 3HAC 020938-001 Revision: C

Tightening torque (Nm)

Tightening torque Tightening torque Tightening torque

Tightening torque (Nm) Tightening torque (Nm)

3HAC 020938-001 Revision: C 15

Tightening torque (Nm) Tightening torque (Nm)

Tightening torque Tightening torque Tightening torque

16 3HAC 020938-001 Revision: C

1.5. Weight specifications

3HAC 020938-001 Revision: C 17

1.6. Standard toolkit

Contents, standard toolkit, 3HAC 15571-1

Qty Art. no. Tool Rem.

18 3HAC 020938-001 Revision: C

1.7. Special tools

Description Qty Art. no.

Description Qty Art. no.

3HAC 020938-001 Revision: C 19

Description Qty Art. no.

Tools that may be rented

Description Art. no. Note

20 3HAC 020938-001 Revision: C

Calibration equipment, Wyler

Description Art. no. Note

Calibration equipment, Pendulum

Description Art. no. Note

Oil exchange equipment

Description Art. no. Note

3HAC 020938-001 Revision: C 21

1.8. Document references

Product specification, robot

Document name Document ID

Product manuals, controller

Document name Document ID

Document name Document ID Note

Document name Document ID Note