1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil
 3HAC022032-001  Revision: E36
© Copyright 2004-2008 ABB. All rights reserved.
1.3.5. WARNING - Safety risks during work with gearbox oil
Description
When handling the gearbox oil, there are several dangers to both personal injuries and product 
damages! Following safety information must be regarded before performing any work with 
the oil in the gearboxes!
Warnings and elimination
Warning Description Elimination / Action
-
Hot oil!
Changing and draining 
gearbox oil may require  
handling hot oil of up to 90 °C!
Make sure that protective gear 
like goggles and  gloves are 
always worn during this activity.
-
Possible pressure build 
up in gearbox!
When opening the oil plug, 
there may be pressure present 
in the gearbox,  causing oil to 
spray from the opening!
Open oil plug carefully and keep 
away from the opening. Do not 
overfill the  gearbox when filling.
-
Do not overfill!
Overfilling of gearbox oil can 
lead to internal over-pressure 
inside the gearbox which in 
turn may:
• damage seals and 
gaskets
• completely press out 
seals and gaskets
• prevent the manipulator 
from moving freely.
Make sure not to overfill the 
gearbox when filling with oil! 
After filling, check the correct oil 
level.
-
Do not mix types of oil!
Mixing types of oil may cause 
severe damage to the 
gearbox!
When filling gearbox oil, do not 
mix different types of oil   unless 
specified in the instruction. 
Always use the type of oil  
specified by the manufacturer! 
-
Heat up the oil!
Warm oil drains quicker than 
cold oil.  
 When changing gearbox oil, first 
run the robot for a time to  heat 
up the oil. 
-
Specified amount 
depends on drained 
volume!
The specified amount of oil  is 
based on the total volume of 
the gearbox. When changing 
the oil, the amount of refilled oil 
may differ from the specified 
amount, depending on how 
much oil has previously been 
drained from the gearbox.
After refilling, check the oil level.