ABB IRB 7600 - 500/2.55 User manual

ABB Robotics
Product manual
IRB 7600

Trace back information:
Workspace R13-1 version a6
Checked in 2013-03-31
Skribenta version 1184

Product manual
IRB 7600 - 500/2.55
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
IRB 7600 - 325/3.1
IRB 7600 - 150/3.5
M2000, M2000A, M2004
Document ID: 3HAC022033-001
Revision: M
© Copyright 2007-2013 ABB. All rights reserved.

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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2007-2013 ABB. All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
15Product documentation, M2000/M2000A ........................................................................................
16Product documentation, M2004 .......................................................................................................
18How to read the product manual ......................................................................................................
191 Safety
191.1 Introduction to safety information ......................................................................... 201.2 General safety information .................................................................................. 201.2.1 Introduction to general safety information .................................................... 211.2.2 Safety in the manipulator system ............................................................... 221.2.3 Safety risks ............................................................................................ 221.2.3.1 Safety risks during installation and service work on manipulators ......... 251.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 261.2.3.3 Safety risks related to tools/work pieces .......................................... 271.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 281.2.3.5 Safety risks during operational disturbances ..................................... 291.2.3.6 Risks associated with live electric parts ........................................... 311.2.4 Safety actions ......................................................................................... 311.2.4.1 Safety fence dimensions ............................................................... 321.2.4.2 Fire extinguishing ........................................................................ 331.2.4.3 Emergency release of the manipulator’s arm .................................... 341.2.4.4 Brake testing .............................................................................. 351.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 361.2.4.6 Safe use of the FlexPendant .......................................................... 371.2.4.7 Work inside the manipulator's working range ................................... 381.2.4.8 Signal lamp (optional) ................................................................... 391.2.5 Safety stops ........................................................................................... 391.2.5.1 What is an emergency stop? .......................................................... 411.3 Safety related instructions .................................................................................. 411.3.1 Safety signals in the manual ...................................................................... 431.3.2 Safety symbols on manipulator labels ......................................................... 481.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 491.3.4 DANGER - First test run may cause injury or damage! ................................... 501.3.5 WARNING - The brake release buttons may be jammed after service work ........ 511.3.6 DANGER - Make sure that the main power has been switched off! .................... 521.3.7 WARNING - The unit is sensitive to ESD! ..................................................... 531.3.8 WARNING - Safety risks during handling of batteries ..................................... 541.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
572 Installation and commissioning
572.1 Introduction ...................................................................................................... 582.2 Robot transportation precautions ......................................................................... 632.3 Securing the robot ............................................................................................ 652.4 Unpacking ....................................................................................................... 652.4.1 Pre-installation procedure ......................................................................... 682.4.2 Working range, IRB 7600 - 150/3.5 .............................................................. 692.4.3 Working range, IRB 7600 - 340/2.8 .............................................................. 702.4.4 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ................................ 712.4.5 Working range, IRB 7600 - 500/2.3 .............................................................. 722.4.6 Risk of tipping/stability ............................................................................. 732.5 On-site installation ............................................................................................ 732.5.1 Lifting robot with fork lift ........................................................................... 812.5.2 Lifting robot with lifting slings .................................................................... 832.5.3 Lifting robot with roundslings .................................................................... 852.5.4 Manually releasing the brakes ...................................................................
3HAC022033-001 Revision: M 5
© Copyright 2007-2013 ABB. All rights reserved.
Table of contents

882.5.5 Manually releasing the brakes, external brake release unit .............................. 922.5.6 Lifting the base plate ............................................................................... 932.5.7 Securing the base plate ............................................................................ 972.5.8 Orienting and securing the robot ................................................................ 1002.5.9 Fitting equipment on robot ....................................................................... 1052.5.10 Installation of base spacers (option) ........................................................... 1072.5.11 Extended working range, axis 1 (option 561-1) ............................................. 1082.5.12 Installation of cooling fan for motors, axes 1-3 (option) ................................... 1172.5.13 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 1182.5.14 Loads .................................................................................................... 1192.5.15 Installation of signal lamp (option) .............................................................. 1202.6 Restricting the working range .............................................................................. 1202.6.1 Introduction ............................................................................................ 1212.6.2 Mechanically restricting the working range of axis 1 ...................................... 1232.6.3 Mechanically restricting the working range of axis 2 ...................................... 1252.6.4 Mechanically restricting the working range of axis 3 ...................................... 1282.6.5 Installation of position switches (option) ...................................................... 1402.7 Electrical connections ........................................................................................ 1402.7.1 Robot cabling and connection points ..........................................................
1453 Maintenance
1453.1 Introduction ...................................................................................................... 1463.2 Maintenance schedule and expected life ............................................................... 1463.2.1 Specification of maintenance intervals ........................................................ 1473.2.2 Maintenance schedule ............................................................................. 1513.2.3 Expected component life ......................................................................... 1523.3 Inspection activities .......................................................................................... 1523.3.1 Inspection, oil level gearbox axis 1 ............................................................. 1553.3.2 Inspection, oil level gearbox axis 2 ............................................................. 1583.3.3 Inspection, oil level gearbox axis 3 ............................................................. 1603.3.4 Inspection, oil level gearbox axis 4 ............................................................. 1633.3.5 Inspection, oil level, gearbox axis 5 ............................................................ 1663.3.6 Inspection, oil level gearbox axis 6 ............................................................. 1693.3.7 Inspection, balancing device ..................................................................... 1753.3.8 Inspection, cable harness ......................................................................... 1783.3.9 Inspecting, mechanical stop pin, axis 1 ....................................................... 1803.3.10 Inspection, mechanical stop, axes 1, 2 and 3 ............................................... 1823.3.11 Inspection, damper axes 2-5 ...................................................................... 1843.3.12 Inspection, position switch axes 1, 2 and 3 ................................................... 1883.3.13 Inspection, information labels .................................................................... 1913.3.14 Inspection, UL-lamp ................................................................................. 1933.4 Changing/replacement activities .......................................................................... 1933.4.1 Type of lubrication in gearboxes ................................................................ 1953.4.2 Oil change, gearbox axis 1 ........................................................................ 1993.4.3 Changing oil, axis-2 gearbox .................................................................... 2023.4.4 Changing oil, axis-3 gearbox .................................................................... 2053.4.5 Oil change, gearbox, axis 4 ....................................................................... 2083.4.6 Oil change, gearbox, axis 5 ....................................................................... 2113.4.7 Oil change, gearbox axis 6 ........................................................................ 2143.4.8 Replacing the SMB battery ........................................................................ 2193.5 Lubrication activities ......................................................................................... 2193.5.1 Cleaning activities .................................................................................. 2193.5.1.1 Flushing a contaminated gearbox ................................................... 2213.5.1.2 Cleaning, robot ........................................................................... 2233.5.2 Lubrication of spherical roller bearing, balancing device ................................. 2253.6 Service Information System, M2000 ...................................................................... 2253.6.1 Using the SIS system ............................................................................... 2263.6.2 Description of Service Information System (SIS) ........................................... 2293.6.3 SIS system parameters ............................................................................
6 3HAC022033-001 Revision: M
© Copyright 2007-2013 ABB. All rights reserved.
Table of contents

2313.6.4 Setting the SIS parameters ....................................................................... 2333.6.5 Reading the SIS output logs ...................................................................... 2343.6.6 Exporting the SIS data .............................................................................
2354 Repair
2354.1 Introduction ...................................................................................................... 2364.2 General procedures ........................................................................................... 2364.2.1 Performing a leak-down test ..................................................................... 2374.2.2 Mounting instructions for bearings ............................................................. 2394.2.3 Mounting instructions for seals .................................................................. 2414.3 Complete robot ................................................................................................. 2414.3.1 Replacement of cable harness, axes 1-4 ..................................................... 2504.3.2 Replacement of cable harness, axes 5-6 ...................................................... 2534.3.3 Replacement of complete arm system ......................................................... 2584.4 Upper and lower arm ......................................................................................... 2584.4.1 Replacing turning disk .............................................................................. 2624.4.2 Replacement of complete wrist unit ............................................................ 2664.4.3 Replacement of complete upper arm ........................................................... 2714.4.4 Replacement of complete lower arm ........................................................... 2794.4.5 Replacement of lower arm shaft ................................................................. 2894.5 Frame and base ................................................................................................ 2894.5.1 Replacing the SMB unit ............................................................................ 2924.5.2 Replacement of brake release unit ............................................................. 2984.5.3 Replacing the balancing device .................................................................. 3064.5.4 Replacement of spherical roller bearing, balancing device .............................. 3114.5.5 Unloading the balancing device using hydraulic press tool .............................. 3154.5.6 Restoring the balancing device using a hydraulic press tool ............................ 3184.6 Motors ............................................................................................................ 3184.6.1 Replacement of motor, axis 1 .................................................................... 3224.6.2 Replacement of motor axis 2 ..................................................................... 3274.6.3 Replacement of motor, axis 3 .................................................................... 3334.6.4 Replacement of motor, axis 4 .................................................................... 3384.6.5 Replacement of motor, axis 5 .................................................................... 3424.6.6 Replacement of motor, axis 6 .................................................................... 3484.7 Gearboxes ....................................................................................................... 3484.7.1 Replacing the axis 1 gearbox ..................................................................... 3584.7.2 Replacement of gearbox, axis 2 ................................................................. 3664.7.3 Replacement of gearbox, axis 3 ................................................................. 3724.7.4 Replacement of gearbox, axis 4 ................................................................. 3774.7.5 Replacement of gearbox, axis 5 ................................................................. 3834.7.6 Replacement of gearbox, axis 6 .................................................................
3875 Calibration information
3875.1 Introduction ..................................................................................................... 3885.2 Calibration methods ........................................................................................... 3905.3 Calibration scale and correct axis position ............................................................. 3915.4 Calibration movement directions for all axes .......................................................... 3925.5 Updating revolution counters ............................................................................... 3965.6 Checking the calibration position ..........................................................................
3996 Decommissioning
3996.1 Environmental information .................................................................................. 4006.2 Decommissioning of balancing device ...................................................................
4037 Reference information
4037.1 Introduction ...................................................................................................... 4047.2 Applicable safety standards ................................................................................ 4067.3 Unit conversion .................................................................................................
3HAC022033-001 Revision: M 7
© Copyright 2007-2013 ABB. All rights reserved.
Table of contents

4077.4 Screw joints .................................................................................................... 4107.5 Weight specifications ......................................................................................... 4117.6 Standard tools .................................................................................................. 4127.7 Special tools .................................................................................................... 4157.8 Lifting accessories and lifting instructions ..............................................................
4178 Spare part / part list
4178.1 Introduction ...................................................................................................... 4188.2 Spare parts ...................................................................................................... 4188.2.1 Introduction ............................................................................................ 4198.2.2 Spare part list ......................................................................................... 4228.3 Part list ............................................................................................................ 4228.3.1 Introduction ............................................................................................ 4238.3.2 Rebuilding parts ...................................................................................... 4258.3.3 Part list, overview .................................................................................... 4278.3.4 Mechanical stop axis 1, 3HAC12812-2 ......................................................... 4288.3.5 Base incl frame axis 1, 3HAC12304-1 ..........................................................
429
8.3.6 Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55,
-500/2.55) .............................................................................................. 4338.3.7 Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3) .................................................
434
8.3.8 Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55,
- 500/2.55) .............................................................................................. 4358.3.9 Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3) ..................................... 4368.3.10 Wrist, 3HAC16628-4 / 3HAC16628-3 ........................................................... 4418.3.11 Material set robot, 3HAC13079-1 ................................................................ 4428.3.12 Material set axis 1-2, 3HAC13077-1 ............................................................ 4468.3.13 Material set balancing device, 3HAC13082-1 ................................................ 4478.3.14 Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5) ....................... 4488.3.15 Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) .......................
4499 Exploded views
4499.1 Introduction ..................................................................................................... 4509.2 Base incl. Frame .............................................................................................. 4519.3 Frame-Lower arm 1 ........................................................................................... 4529.4 Frame-Lower arm 2 ........................................................................................... 4549.5 Upper arm ....................................................................................................... 4559.6 Wrist complete .................................................................................................
45710 Circuit diagram
45710.1 About circuit diagrams ....................................................................................... 45910.2 Validity of circuit diagram 3HAC025744-1 .............................................................. 46010.3 Validity of circuit diagram 3HAC13347-1 ................................................................
461Index
8 3HAC022033-001 Revision: M
© Copyright 2007-2013 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
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
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 the robot. Contains general
safety aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Safety
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform maintenance
of the robot. Based on a maintenance schedule that may be used
to plan periodical maintenance.
Maintenance
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts, tools, etc.
Repair
Procedures that do not require specific calibration equipment.
General information about calibration.
Calibration information
Continues on next page
3HAC022033-001 Revision: M 9
© Copyright 2007-2013 ABB. All rights reserved.
Overview of this manual

ContentsChapter
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 shown in exploded views.Spare 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
Procedures in this product manual contain references to the following manuals:
NoteDocument IDDocument name
3HAC044350-001Product manual - IRB 7600 Foundry Prime
3HAC023934-001Product specification - IRB 7600
3HAC13491-1Product specification - IRB 7600 M2000/M2000A
3HAC13347-1Circuit diagram - IRB 7600
3HAC025744-001
3HAC021313-001Product manual - IRC5
3HAC021333-001Product manual - S4Cplus M2000
3HAC022419-001Product manual - S4Cplus M2000A
3HAC16590-1Operating manual - IRC5 with FlexPendant
3HAC7793-1User’s guide - S4Cplus (BaseWare OS 4.0)
3HAC16578-1Operating manual - Calibration Pendulum
M20043HAC025709-001Operating manual - Service Information System
M2000/M2000A3HAC022907-001Operating manual - Levelmeter Calibration
3HAC042927-001Technical reference manual - Lubrication in gear-
boxes
3HAC17076-1Technical reference manual - System parameters
M20043HAC021395-001Application manual - Additional axes and stand
alone controller
M20003HAC9299-1Application manual - External axes
Additional document references
Document IDDocument name
3HAC030421-001Application manual - CalibWare Field 5.0
Continues on next page
10 3HAC022033-001 Revision: M
© Copyright 2007-2013 ABB. All rights reserved.
Overview of this manual
Continued

Revisions
DescriptionRevision
First edition.-
Replaces previous manuals:
• Installation and Commissioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Various corrections due to technical revisions, changes in the toolkits
etc.
Chapter Calibration replaced with chapter Calibration information.A
Following corrections are made:
• In chapter 3: Maintenance in section Exporting the SIS data, the unit
seconds for different SIS parameters is replaced by the unit hours.
The change is only valid for RobotWare release 5.0.
Following updates are made:
• In chapter 4: Repair, the sections Removal of complete lower arm and
Refitting of complete lower arm are completed with more detailed in-
formation about how to use the glycerin pump.
• Section Document references is completed with article numbers for
calibration manuals.
• Section Part list is completed with the spare part number for a variant
of the cable harness/brake release unit.
New lubricating oil in the gearboxes. Changes made in the chapter Mainten-
ance on page 145 and Spare part / part list on page 417.
B
• New variant of the robot (IRB 7600 - 500/2.55) implemented throughout
the manual.
• Wrist unit updated, new spare part number is specified in Replacement
of complete wrist unit on page 262 and Spare part list on page 419.
• Insulated wrist unit implemented, new spare part number is specified
in Replacement of complete wrist unit on page 262 and Spare part list
on page 419. Amount of oil differs from non-insulated wrist unit, changes
made in sections Type of oil in gearboxes and Oil change, gearbox
axis 6 on page 211.
• New section that describes how to replace the bearing at the front eye
of the balancing device, Replacement of spherical roller bearing, balan-
cing device on page 306.
• Incorrect article numbers for position switches are corrected, section
Installation of position switches (option) on page 128.
• New section: Installation of cooling fan for motors, axes 1-3 (option) on
page 108.
• New section: Installation of base spacers (option) on page 105
• New section that specifies all the recommended spare parts: Spare
part list on page 419.
• Repair sections for removal/refitting are restructured into replacement
sections.
• Various corrections made, due to technical revisions etc.
C
Foundry Prime option included.D
Continues on next page
3HAC022033-001 Revision: M 11
© Copyright 2007-2013 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
• New variant of the robot (IRB 7600 - 325/3.1) implemented throughout
the manual.
• In chapter 3 Maintenance section Oil in gearboxes type of oil and art.
no. in gearbox axes 1 has been added.
• New product name has been implemented throughout the manual:
"Mobilgear 600 XP 320". Replaces "Mobil Gearlube X320".
• Interval for change of Shell Tivela S 150 has been changed in section
Maintenance schedule.
• Section Service Information System has been removed from the
manual. There is a specific manual for SIS. See References.
• Section Chip and dust protection has been removed from the manual.
This option is no longer available.
• Standard tightening torque for M24 Allen head screws has been added
in section Screw joints.
• Prerequisites in section Overview
E
This revision includes the following additions and/or changes:
• Section "WARNING! - Mixed oils may cause severe damage to gear-
boxes" in chapter Safety, has been integrated in section "Type of oil in
gearboxes" in the Maintenance chapter.
• The oil Shell Tivela S150 in gearboxes 1, 2, 3 and 6 has been replaced
by Kyodo Yushi TMO 150. Changes made in chapters Maintenance and
Spare Parts.
•The section "Type of oil in gearboxes" in chapter Maintenance has been
updated according to changes made in oil types and intervals for oil
change.
• Sections "Robot transportation precaution" and "Securing the robot"
are added to the Installation chapter.
• Modified maintenace intervals for oil change in gearboxes.
• Chapter Maintenance, section "Mainenance Schedule": interval for re-
placement of battery pack changed.
• Section "Type of oil" changed.
F
This revision include the following addition:
•New WARNING! added in Safety chapter section Work inside the robot´s
working range.
• New WARNING! added in Safety chapter section WARNING! - Safety
risks during work with gearbox oil.
• The text in the introduction to chapters Installation,Maintenance and
Repair has been uppdated concerning the robot being connected to
earth when power connected.
• Section Expected component life in chapter Maintenance: The lifetime
of certain parts has been updated.
• Section Type of oil in chapter Maintenance has been updated.
• Section Foundry Plus,Cable guard added to Installation chapter.
G
This revision includes the following additions and/or changes:
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 457.
•List of standards updated, see Applicable safety standards on page 404.
• Interval changed for inspection and lubrication of balancing device
(Foundry Prime). See chapter Maintenance section Maintenance
schedule on page 147.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 41.
• New safety labels on the manipulators, see Safety symbols on manipu-
lator labels on page 43.
• Revised terminology: robot replaced with manipulator.
H
Continues on next page
12 3HAC022033-001 Revision: M
© Copyright 2007-2013 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
This revision includes the following updates:
• Maximum deviation changed, see Securing the base plate on page 93.
• Corrected part numbers, see Wrist, 3HAC16628-4 / 3HAC16628-3 on
page 436.
• Corrected exploded view, see Wrist complete on page 455.
• Added inspection of oil level in gearboxes and inspection of surface
treatment in maintenance schedule for Foundry Prime. See section
Activities and intervals, Foundry Prime.
•Text in maintenance schedules concering lubrication of balancing device
bearing changed into concerning all bearings of the balancing device,
see Maintenance schedule on page 147.
• Replacement of cable harness in Foundry Prime robots added to
maintenance schedule, see Activities and intervals, Foundry Prime.
J
This revision includes the following updates:
•Removed incorrect article number for fork lift, see Lifting robot with fork
lift on page 73.
• 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 121 and the new section Extended working range, axis
1 (option 561-1) on page 107. Also added signal about option 561-1 in
section Inspecting, mechanical stop pin, axis 1 on page 178.
K
This revision includes the following updates:
• A new block, about general illustrations, added in section How to read
the product manual on page 18.
• 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 348.
• Robot designations are adjusted in sub-headings in section Robot
transportation precautions on page 58.
• 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 271, the new section Replacement
of lower arm shaft on page 279 and the section Frame-Lower arm 2 on
page 452.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 407.
•Added WARNING - Safety risks during handling of batteries on page 53.
•The maximum allowed deviation in levelity of the base plate is changed,
see Securing the base plate on page 93.
• 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 93.
• Added attachment plate for axis-2 switch to equipment list, see Install-
ation of position switches (option) on page 128.
• Friction washer added to the instruction for replacing axis-2 gearbox
and to the exploded view, see Replacement of gearbox, axis 2 on
page 358 and Frame-Lower arm 1 on page 451.
• Moved all information about Foundry Prime to a separate Product
manual, see References on page 10 for document number.
• Corrected article numbers for the o-rings and removed the removal tool
from the equipment list and from the procedure, see Replacement of
gearbox, axis 6 on page 383.
• Corrected article number for axis-2-3 sealing, see Replacement of
complete lower arm on page 271 and Replacement of complete upper
arm on page 266.
L
Continues on next page
3HAC022033-001 Revision: M 13
© Copyright 2007-2013 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
This revision includes the following updates:
• A new SMB unit and battery is introduced, with longer battery lifetime.
M
14 3HAC022033-001 Revision: M
© Copyright 2007-2013 ABB. All rights reserved.
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.
3HAC022033-001 Revision: M 15
© Copyright 2007-2013 ABB. All rights reserved.
Product documentation, M2000/M2000A

Product documentation, M2004
Categories for manipulator documentation
The manipulator documentation 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.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for M2004 manipulator systems.
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).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
Continues on next page
16 3HAC022033-001 Revision: M
© Copyright 2007-2013 ABB. All rights reserved.
Product documentation, M2004

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, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - Introduction to RAPID
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Trouble shooting IRC5, for the controller and manipulator.
3HAC022033-001 Revision: M 17
© Copyright 2007-2013 ABB. All rights reserved.
Product documentation, M2004
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 19.
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 pictures that show a different robot model that the
one described in the current manual.
18 3HAC022033-001 Revision: M
© Copyright 2007-2013 ABB. All rights reserved.
How to read the product manual

1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into two categories:
• General safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
in General safety information on page 20.
• Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 41.
3HAC022033-001 Revision: M 19
© Copyright 2007-2013 ABB. All rights reserved.
1 Safety
1.1 Introduction to safety information

1.2 General safety information
1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
repair and maintenance work.
Sections
The general safety information is divided into the following sections.
ContainingContents
• safety, service
• limitation of liability
• related information
General information
• safety risks during installation or service
• risks associated with live electrical parts
Safety risks lists dangers relevant when
working with the product. The dangers are
split into different categories.
• fire extinguishing
• safe use of the FlexPendant
Safety actions describes actions which
may be taken to remedy or avoid dangers.
• stopping functions
• description of emergency stop
• description of safety stop
• description of safeguarding
Safety stops describes different types of
stops.
20 3HAC022033-001 Revision: M
© Copyright 2007-2013 ABB. All rights reserved.
1 Safety
1.2.1 Introduction to general safety information