ABB IRB 6650S User manual

ROBOTICS
Product manual
IRB 6650S

Trace back information:
Workspace 22A version a16
Checked in 2022-03-11
Skribenta version 5.4.005

Product manual
IRB 6650S - 200/3.0
IRB 6650S - 125/3.5
IRB 6650S - 90/3.9
M2000, M2000A, IRC5
Document ID: 3HAC020993-001
Revision: AG
© Copyright 2004-2022 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2004-2022 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
17Product documentation, M2000/M2000A .........................................................................................
18Product documentation, IRC5 ..........................................................................................................
20How to read the product manual ......................................................................................................
211 Safety
211.1 Safety information .............................................................................................
211.1.1 Limitation of liability .................................................................................
221.1.2 Requirements on personnel ......................................................................
231.2 Safety signals and symbols .................................................................................
231.2.1 Safety signals in the manual ......................................................................
251.2.2 Safety symbols on manipulator labels .........................................................
311.3 Robot stopping functions ....................................................................................
321.4 Safety during installation and commissioning .........................................................
351.5 Safety during operation ......................................................................................
361.6 Safety during maintenance and repair ...................................................................
361.6.1 Safety during maintenance and repair .........................................................
391.6.2 Emergency release of the robot axes ..........................................................
401.6.3 Brake testing ..........................................................................................
411.7 Safety during troubleshooting ..............................................................................
421.8 Safety during decommissioning ...........................................................................
432 Installation and commissioning
432.1 Introduction to installation and commissioning .......................................................
442.2 Unpacking .......................................................................................................
442.2.1 Pre-installation procedure .........................................................................
482.2.2 Working range and type of motion ..............................................................
522.2.3 Risk of tipping/stability .............................................................................
532.2.4 The unit is sensitive to ESD .......................................................................
542.3 On-site installation ............................................................................................
542.3.1 Lifting robot with fork lift ...........................................................................
592.3.2 Lifting robot with roundslings ....................................................................
612.3.3 Lifting robot with lifting accessory ..............................................................
632.3.4 Manually releasing the brakes ...................................................................
652.3.5 Lifting the base plate ................................................................................
662.3.6 Securing the base plate ............................................................................
712.3.7 Orienting and securing the robot ................................................................
742.3.8 Fitting equipment on robot .......................................................................
802.3.9 Signal lamp (option) .................................................................................
812.3.10 Installation of base spacers (option) ...........................................................
832.3.11 Installation of cooling fan for motors (option) ................................................
892.3.12 Installation of Foundry Plus Cable guard (option no. 908-1) .............................
902.3.13 Loads fitted to the robot, stopping time and braking distances .........................
912.4 Restricting the working range ..............................................................................
912.4.1 Axes with restricted working range .............................................................
922.4.2 Mechanically restricting the working range of axis 1 ......................................
942.4.3 Extended working range, axis 1 (option) .....................................................
962.4.4 Mechanically restricting the working range of axis 2 ......................................
982.4.5 Mechanically restricting the working range of axis 3 ......................................
1012.5 Electrical connections ........................................................................................
1012.5.1 Robot cabling and connection points ..........................................................
1052.6 Start of robot in cold environments ......................................................................
1062.7 Test run after installation, maintenance, or repair ....................................................
1073 Maintenance
1073.1 Introduction ......................................................................................................
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1083.2 Maintenance schedule and expected component life ...............................................
1083.2.1 Specification of maintenance intervals ........................................................
1093.2.2 Maintenance schedule .............................................................................
1123.2.3 Expected component life .........................................................................
1133.3 Inspection activities ...........................................................................................
1133.3.1 Inspecting the motor seal .........................................................................
1153.3.2 Inspecting the oil level in axis-1 gearbox .....................................................
1173.3.3 Inspecting the oil level in axis-2 gearbox .....................................................
1193.3.4 Inspecting the oil level in axis-3 gearbox .....................................................
1223.3.5 Inspecting the oil level in axis-4 gearbox .....................................................
1243.3.6 Inspecting the oil level in axis-5 gearbox .....................................................
1263.3.7 Inspecting the oil level in axis-6 gearbox .....................................................
1313.3.8 Inspecting the balancing device .................................................................
1363.3.9 Inspecting the cable harness .....................................................................
1403.3.10 Inspecting the information labels ................................................................
1423.3.11 Inspecting the axis-1 mechanical stop pin ...................................................
1443.3.12 Inspecting the additional mechanical stops .................................................
1473.3.13 Inspecting the damper on axes 2-5 .............................................................
1493.3.14 Inspecting, signal lamp ............................................................................
1513.4 Replacement/changing activities ..........................................................................
1513.4.1 Type of lubrication in gearboxes ................................................................
1533.4.2 Changing oil, axis-1 gearbox .....................................................................
1563.4.3 Changing oil, axis-2 gearbox .....................................................................
1593.4.4 Changing oil, axis-3 gearbox .....................................................................
1623.4.5 Changing oil, axis-4 gearbox .....................................................................
1653.4.6 Changing oil, axis-5 gearbox .....................................................................
1683.4.7 Changing oil, axis-6 gearbox .....................................................................
1713.4.8 Replacing the SMB battery ........................................................................
1753.5 Lubrication activities ..........................................................................................
1753.5.1 Lubrication of spherical roller bearing, balancing device .................................
1783.6 Cleaning activities .............................................................................................
1783.6.1 Cleaning the IRB 6650S ............................................................................
1813.7 Service Information System, M2000 ......................................................................
1813.7.1 Using the SIS system ...............................................................................
1823.7.2 Description of Service Information System (SIS) ...........................................
1853.7.3 SIS system parameters ............................................................................
1863.7.4 Setting the SIS parameters .......................................................................
1873.7.5 Reading the SIS output logs ......................................................................
1883.7.6 Exporting the SIS data .............................................................................
1894 Repair
1894.1 Introduction ......................................................................................................
1904.2 General procedures ...........................................................................................
1904.2.1 Performing a leak-down test ......................................................................
1914.2.2 Mounting instructions for bearings .............................................................
1934.2.3 Mounting instructions for sealings ..............................................................
1964.2.4 Cut the paint or surface on the robot before replacing parts ............................
1974.2.5 The brake release buttons may be jammed after service work .........................
1984.3 Complete robot .................................................................................................
1984.3.1 Replacing cable harness, axes 1-6 .............................................................
2144.3.2 Replacement of cable harness, axes 1-4 .....................................................
2244.3.3 Replacement of cable harness, axes 5-6 ......................................................
2294.3.4 Replacement of cabling, axis 5 motor ..........................................................
2314.3.5 Replacement of complete arm system .........................................................
2374.4 Upper and lower arm .........................................................................................
2374.4.1 Replacing the turning disk ........................................................................
2414.4.2 Replacement of complete wrist unit ............................................................
2474.4.3 Replacement of upper arm ........................................................................
2564.4.4 Replacement of complete lower arm ...........................................................
6 Product manual - IRB 6650S
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Table of contents

2664.4.5 Replacement of lower arm shaft .................................................................
2744.4.6 Securing the lower arm ............................................................................
2784.5 Frame and base ................................................................................................
2784.5.1 Replacing the SMB unit ............................................................................
2814.5.2 Replacing the brake release board .............................................................
2854.5.3 Replacement of spherical roller bearing, balancing device ..............................
2884.5.4 Replacement of balancing device ...............................................................
2884.5.4.1 Replacing the balancing device ......................................................
2994.6 Motors ............................................................................................................
2994.6.1 Replacement of motor, axis 1 ....................................................................
3044.6.2 Replacement of motor axis 2 .....................................................................
3104.6.3 Replacement of motor, axis 3 ....................................................................
3174.6.4 Replacement of motor, axis 4 ....................................................................
3224.6.5 Replacement of motor, axis 5 ...................................................................
3284.6.6 Replacement of motor, axis 6 ....................................................................
3354.7 Gearboxes .......................................................................................................
3354.7.1 Replacing the axis 1 gearbox .....................................................................
3464.7.2 Replacement of gearbox axis 2 ..................................................................
3534.7.3 Replacement of gearbox, axis 3 .................................................................
3604.7.4 Replacement of gearbox, axis 6 .................................................................
3675 Calibration
3675.1 Introduction to calibration ...................................................................................
3675.1.1 Introduction and calibration terminology ......................................................
3685.1.2 Calibration methods .................................................................................
3715.1.3 When to calibrate ...................................................................................
3725.2 Synchronization marks and axis movement directions .............................................
3725.2.1 Synchronization marks and synchronization position for axes .........................
3735.2.2 Calibration movement directions for all axes ................................................
3745.3 Updating revolution counters ...............................................................................
3745.3.1 Updating revolution counters on IRC5 robots ...............................................
3795.4 Calibrating with Axis Calibration method ...............................................................
3795.4.1 Description of Axis Calibration ..................................................................
3825.4.2 Calibration tools for Axis Calibration ...........................................................
3845.4.3 Installation locations for the calibration tools ...............................................
3855.4.4 Axis Calibration - Running the calibration procedure ......................................
3895.4.5 Reference calibration ...............................................................................
3915.5 Calibrating with Calibration Pendulum method .......................................................
3925.6 Calibrating with Wrist Optimization method ...........................................................
3945.7 Verifying the calibration ......................................................................................
3955.8 Checking the synchronization position ..................................................................
3976 Decommissioning
3976.1 Environmental information ..................................................................................
3996.2 Scrapping of robot .............................................................................................
4006.3 Decommissioning of balancing device ...................................................................
4037 Robot description
4037.1 Type A vs type B motors ....................................................................................
4058 Spare part lists
4058.1 Spare part lists and illustrations ...........................................................................
4079 Reference information
4079.1 Introduction ......................................................................................................
4089.2 Applicable standards .........................................................................................
4109.3 Unit conversion .................................................................................................
4119.4 Screw joints ....................................................................................................
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4149.5 Weight specifications .........................................................................................
4159.6 Standard tools ..................................................................................................
4169.7 Special tools ....................................................................................................
4209.8 Lifting accessories and lifting instructions ..............................................................
42110 Circuit diagram
42110.1 Circuit diagrams ................................................................................................
42310.2 Circuit diagram 3HAC 025744-001 ........................................................................
42310.2.1 Validity of circuit diagram 3HAC025744-1 ....................................................
42410.3 Circuit diagram 3HAC 13347-1 .............................................................................
42410.3.1 Validity of circuit diagram 3HAC13347-1 ......................................................
425Index
8 Product manual - IRB 6650S
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© Copyright 2004-2022 ABB. All rights reserved.
Table of contents

Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the
manual.
The robot described in this manual has the protection type Standard and Foundry
Plus.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the IRB 6650S. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information about how to avoid
personal injuries and damage to the product.
Safety
Required information about lifting and installation of the robot.Installation and commis-
sioning
Continues on next page
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© Copyright 2004-2022 ABB. All rights reserved.
Overview of this manual

ContentsChapter
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used in the work of planning periodical maintenance.
Maintenance
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Calibration procedures and general information about calibra-
tion.
Calibration
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional
documents, safety standards etc.
Reference information
Complete spare part list and complete list of robot components,
shown in the exploded views.
Spare part / Part list
Detailed illustrations of the robot with reference numbers to the
part list.
Exploded views
Reference to the circuit diagram for the robot.Circuit diagram
References
NoteDocument IDDocument name
Document.ID-1Product specification - IRB 6650S
3HAC14064-1Product specification - IRB 6600/6650/6650S
M2000/M2000A
3HAC049111-001Product manual, spare parts - IRB 6650S
3HAC13347-1Circuit diagram
3HAC025744-001
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC021333-001Product manual - S4Cplus M2000
3HAC022419-001Product manual - S4Cplus M2000A
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC7793-1User’s guide - S4Cplus (BaseWare OS 4.0)
3HAC16578-1Operating manual - Calibration Pendulum
M2000/M2000A3HAC022907-001Operating manual - Levelmeter Calibration
M20043HAC050944-001Operating manual - Service Information System
3HAC042927-001Technical reference manual - Lubrication in gear-
boxes
3HAC050948-001Technical reference manual - System parameters
M20043HAC051016-001Application manual - Additional axes and stand alone
controller
M2000/M2000A3HAC9299-1Application manual - External axes
3HAC030421-001Application manual - CalibWare Field
Continues on next page
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Overview of this manual
Continued

Additional document references
Document IDDocument name
3HAC16090-1CalibWare 2.0 User’s guide (M2000)
Revisions
DescriptionRevision
First edition.-
A• Model M2004 implemented.
• Product manual divided into two parts: Product manual, procedures and
Product manual, reference information.
• New foldouts: See Frame - lower arm 1 and Frame - lower arm 2 in
Product manual, spare parts - IRB 6650S.
• Updated list with special tools, section Special tools on page 416.
• Added spare part list, new section Spare part list in Product manual,
spare parts - IRB 6650S.
Various corrections and editing made in text and figures due to technical revi-
sions etc.
Chapter Calibration replaced with chapter Calibration information.B
Section Document references is completed with article numbers for calibration
manuals.
New lubricating oil in the gearboxes, axes 1, 2, 3 and 6. Changes made in:C
• chapter Maintenance on page 107.
• This is detailed in section Spare part lists on page 405.
D• Article number for mechanical stop set added to section Mechanically
restricting the working range of axis 2 on page 96.
• New section added to the manual: Installation of cooling fan for motors
(option) on page 83.
• A complete (undivided) cabling from axis 1 to axis 6 is added to the
spare parts in Spare part lists on page 405. New procedure Replacing
cable harness, axes 1-6 on page 198. Also a new circuit diagram is added
to the manual, due to the new cabling.
•IRB 6650S included in section Rebuilding parts in Product manual, spare
parts - IRB 6650S.
E• New variant IRB 6650S - 90/3.9 is implemented throughout the manual.
Foundry Prime Option included.F
Changes made in:G
• Prerequisites in section Overview
• Oil change in section Maintenance
This revision includes the following additions and/or changes:H
• The product name RobotStudio Online is changed to RobotStudio.
• Section "WARNING! - Mixed oils may cause severe damage to gear-
boxes" in chapter Safety, has been integrated in section "Type of oil in
gearboxes" in the Maintenance chapter.
• The oil Shell Tivela S150 in gearboxes 1, 2, 3 and 6 has been replaced
by Kyodo Yushi TMO 150. Changes in chapters Maintenance and Spare
parts.
• Modified maintenance intervals for oil change in gearboxes.
• Wrong illustration has been replaced by the correct one in "Analysis of
water content in oil, gearbox axis 6 (Foundry Prime)", section Inspection,
oil level gearbox axis 6 chapter maintenance.
Continues on next page
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Continued

DescriptionRevision
• The section "Type of oil in gearboxes" in chapter Maintenance has been
updated according to changes made in oil types and intervals for oil
change.
•Values for tightening torque on M24 screws in chapter Reference inform-
ation, added.
• Maintenance/Cleaning of robot
•Maintenance/Maintenance schedule: Interval for replacement of battery
pack changed
•Maintenance/Maintenance schedule: Intervals for inspection activities
and oilchanges has been revised.
•Maintenance/Maintenance schedule: Overhaul of robot is new.
•Maintenance/Maintenance schedule: The information about Service In-
formation System (SIS) has been updated.
•Maintenance/Expected component life: The lifetime of certain parts has
been revised.
• Section What is an emergency stop? added to chapter Safety.
This revision include the following addition:J
•New WARNING! added in Safety chapter section Work inside the robot´s
range.
• New WARNING! added in Safety chapter section WARNING! - Safety
risks during work with gearbox oil.
• The text in the introductions to chapters Installation,Maintenance and
Repair has been updated concerning the robot being connected to earth
when power connected.
• Section Expected component life in chapter Maintenance: The lifetime
of certain parts has been updated.
• Section Foundry Plus,Cable guard added to Installation chapter.
This revision includes the following additions and/or changes:K
•Instruction for how to inspect oil level for wrist type 2 added, see Inspect-
ing the oil level in axis-6 gearbox on page 126.
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 421.
• List of standards updated, see Applicable standards on page 408.
• Interval changed for inspection and lubrication of balancing device
(Foundry Prime). See chapter Maintenance section Maintenance
schedule on page 109.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 23.
• New safety labels on the manipulators, see Safety symbols on manipu-
lator labels on page 25.
• Revised terminology: robot replaced with manipulator.
This revision includes the following updates:L
• Maximum deviation changed, see Securing the base plate on page 66.
• New washer, see Replacement of upper arm on page 247.
• Corrected spare part numbers.
This revision includes following additions and/or changes:M
• Removed information about lubricating attachment screws, section In-
specting the additional mechanical stops on page 144.
• New safety labels on the manipulators, see Safety symbols on manipu-
lator labels on page 25.
• Removed incorrect article number for fork lift, see Lifting robot with fork
lift on page 54.
• Minor adjustments made in the text concerning counters in section
Service Information System, M2000 on page 181.
Continues on next page
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Continued

DescriptionRevision
•Footnote about ambient temperature in maintenance schedule is deleted,
see Maintenance schedule on page 109.
• Information about restricting and extending the working range of axis 1
is now separated, see Mechanically restricting the working range of axis
1 on page 92 and the new section Extended working range, axis 1 (op-
tion) on page 94. Also added signal about option 561-1 in section Inspect-
ing the axis-1 mechanical stop pin on page 142.
• Removed information about other robots than IRB 6650S from tables
for oil type and amount in gearboxes, see Type of lubrication in gear-
boxes on page 151.
This revision includes the following updates:N
• A new block, about general illustrations, added in section How to read
the product manual on page 20.
• Removed all information about Foundry Prime from the manual.
• Adjusted the forces on foundation, see Loads on foundation, robot on
page 45.
•Added figures for installed position switches on axes 2 and 3 and attach-
ment plate on axis 2.
• Made minor corrections and improvements in the complete instruction
for how to replace the axis 1 gearbox, see Replacing the axis 1 gearbox
on page 335.
• Added new mechanical structure of the lower arm attachment point for
robots with protection Foundry Plus and Foundry Prime, see Replace-
ment of complete lower arm on page 256 and Replacement of lower arm
shaft on page 266.
•Some general tightening torques have been changed/added, see updated
values in Screw joints on page 411.
• Added information about batteries.
• The maximum allowed deviation in levelity of the base plate is changed,
see Securing the base plate on page 66.
• Corrected the article number for mechanical stops of axis 2, see Mech-
anically restricting the working range of axis 2 on page 96 and Inspecting
the additional mechanical stops on page 144.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 66.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of oil in
gearboxes on page 151.
• Corrected the method of inspecting oil level in the axis-6 gearbox, see
Inspecting the oil level in axis-6 gearbox on page 126.
• Removed information about serrated lock washers from procedure Re-
placement of complete arm system on page 231.
• Corrected type of screws in Base incl frame ax 1, see Product manual,
spare parts - IRB 6650S and Replacement of complete arm system on
page 231.
This revision includes the following updates:P
• A new SMB unit and battery is introduced, with longer battery lifetime.
This revision includes the following updates:Q
•Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 399.
•Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare parts - IRB
6650S.
Continues on next page
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Continued

DescriptionRevision
This revision includes the following updates:R
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 66.
• Minor corrections.
This revision includes the following updates:S
• New standard calibration method introduced (Axis Calibration). See
Calibration on page 367.
• Tightening torque for securing screw in piston shaft front eye changed,
see Replacing the balancing device on page 288.
• Turning disk fixture is removed from special tools for Levelmeter calib-
ration.
This revision includes the following updates:T
• Edited information regarding deciding calibration routine in each repair
section.
• Added information about inspection of calibration tool prior to usage,
see Examining the calibration tool on page 382.
• Added a warning that calibration pin must be inserted in the calibration
bushing until it snaps, see Description of Axis Calibration on page 379.
• Added warning regarding risk of pinching, in Description of Axis Calib-
ration on page 379.
• Added information about Axis Calibration when SafeMove is installed,
see Axis Calibration with SafeMove option on page 387.
• Added information about the calibration procedure, see Overview of the
calibration procedure on the FlexPendant on page 385,Restarting an in-
terrupted calibration procedure on page 387.
Published in release R16.2. The following updates are done in this revision:U
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 66.
• Drawing of tool flange for LeanID added.
• Added spare part number for protection cover and plug set (Axis Calib-
ration).
Published in release R17.1. The following updates are made in this revision:V
• Removed article number for press fixture (for pressing the pinion of the
axis-5 motor). The fixture is not sold by ABB.
Published in release R17.2. The following updates are made in this revision:W
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Added screw, Loctite, tightening torque and washer for wrist cover.
(Tightening torque: 14 Nm±10%, Screw 3HAB3409-25 (with Loctite),
Washer 3HAC062379-001.)
• Updated list of applicable standards.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Section Start of robot in cold environments on page 105 added.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Definition of reference calibration clarified.
Published in release R18.1. The following updates are made in this revision:X
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 382.
Continues on next page
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Continued

DescriptionRevision
• Updated information about locking liquid in Replacement of cable har-
ness, axes 1-4.
• Added sections in General procedures on page 190.
• Safety restructured.
• Updated spare part number brake release board (was DSQC563).
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calibra-
tion values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
• Type B motors are introduced throughout the manual.
- New periodic maintenance activity regarding inspection of the
type B motor oil seal.
- New gasket at axis-6 motor cable inlet.
• Changed direction of installed cooling fan on axis-2 motor and removed
a faulty image showing the design of the cooling fan. Also added detailed
images to installation procedure for the fan.
Published in release R18.2. The following updates are made in this revision:Y
• New dimensions added on illustration, see Illustration, fitting of extra
equipment on frame on page 77.
Published in release R18.2. The following updates are made in this revision:Z
• Updated references.
Published in release 19B. The following updates are made in this revision:AA
•New touch up color Graphite White available. See Cut the paint or surface
on the robot before replacing parts on page 196.
• Levelmeter 2000 kit (6369901-347) no longer available.
Published in release 19D. The following updates are made in this revision:AB
•Added references to DressPack manual in Robot cabling and connection
points on page 101.
Published in release 20B. The following updates are made in this revision:AC
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 193.
• Clarified text about position of robot and added table with dependencies
between axes during Axis Calibration.
• Added information about Wrist Optimization in calibration chapter.
• Replaced article number and name of grease, previously 3HAB3537-1.
• Updated spare part number for axis 1-6 cable harness.
Published in release 20C. The following updates are made in this revision:AD
• New press equipment introduced for following repair procedures. New
article numbers added. User instructions for the equipment are enclosed
with the tool and removed from this manual.
- unloading balancing device
- replacing lower arm shaft
- replacing balancing device shaft
Published in release 21A. The following updates are made in this revision:AE
• Added information about velcro strap and linear guide for new axis-1-6
cable harness.
Published in release 21B. The following updates are made in this revision:AF
• Oil name Optimol PD0 is changed to Tribol GR 100-0-PD in Lubrication
of spherical roller bearing, balancing device and Replacement of balan-
cing device.
• Text regarding fastener quality is updated, see Fastener quality on
page 79.
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
Published in release 22A. The following updates are done in this revision:AG
• Updated information about Gleitmo treated screws, see Screw joints on
page 411.
• Removed information about position switches as they are no longer
available.
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Overview of this manual
Continued

Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including
controller, robot and any hardware option, consists of the manuals listed below:
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools ).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Software manuals
The software documentation consists of a wide range of manuals, ranging from
manuals for basic understanding of the operating system to manuals for entering
parameters during operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation.
Each document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.
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Product documentation, M2000/M2000A

Product documentation, IRC5
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation, IRC5

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation, IRC5
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 21.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual