Product manual (part 1 of 2), procedures - Technology

Product manual (part 1 of 2), procedures 

Articulated robot 

IRB 140 

M2000, M2000A, M2004

Product manual (part 1 of 2), procedures 

IRB 140 

M2000 

M2000A 

M2004 

Document ID: 3HAC 023297-001 

Revision: -

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 

Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 

How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 

1 Safety 13 

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 

1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 

1.2.2.2 Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 

1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 

1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 

1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 

1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 

1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 

1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 

1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 

1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 

1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 

1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 

1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 

1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 

1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 

1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 

1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 

1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 

1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 

2 Installation and commissioning 41 

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 

2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 

2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 

2.2.2 Working range, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 

2.2.3 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 

2.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 

2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 

2.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 

2.3.4 Restricting the working space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 

2.3.5 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 

2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 

2.3.7 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 

2.3.8 Bolt pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 

2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 

2.4.1 Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 

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3 Maintenance 63 

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 

3.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 

3.2.1 Maintenance schedule, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 

3.3.1 Inspection, damper axes 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 

3.3.2 Inspection, robot cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 

3.3.3 Inspection, timing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 

3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 

3.4.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 

3.5 Changing/ replacing activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 

3.5.1 Oil change, gearbox, axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 

4 Repair 77 

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 

4.2 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 

4.2.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 

4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 

4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 

4.2.4 Replacement of base, spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 

4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 

4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 

4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 


4.3.4 Replacement of cover, arm housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 

4.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 

4.4.1 Replacement of lower arm cover and gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 


4.4.3 Replacement of indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 

4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 

4.5.1 Replacement of cover, console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 

4.5.2 Replacement of console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 

4.5.3 Replacement of serial measurement unit and battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 

4.5.4 Replacement of control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 

4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 


4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 


4.6.5 Replacement of motor and timing belt, axes 5 or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 

4.6.6 Adjustments and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 

4.6.6.1 Measuring the gear play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 

4.6.6.2 Measuring the gear play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 

4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 

4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 

4.7.2 Service work on gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 

5 Calibration information 163 

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 

5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 

5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 

4 

3HAC 023297-001 Revision: -


5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 

5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 

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6 


Overview 

Overview 

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. 

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 and calibration. 

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. 

Organization of chapters 

The manual is organized in the following chapters: 

Chapter 

Safety, service 

Installation and 

commissioning 

Maintenance 

Repair 

Calibration information 

Decommissioning 

Contents 

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. 

Required information about lifting and installation of the robot. 

Step-by-step procedures that describe how to perform 

maintenance of the robot. Based on a maintenance schedule 

that may be used in the work of planning periodical maintenance. 

Step-by-step procedures that describe how to perform repair 

activities of the robot. Based on available spare parts. 

Procedures that does not require specific calibration equipment. 

General information about calibration. 

Environmental information about the robot and its components. 

3HAC 023297-001 Revision: - 

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Overview 

Revisions 

Revision 

Description 

- 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. 

• Chapter Calibration replaced with chapter Calibration information. 

• Chapter Safety, service replaced with new safety chapter. 

• Information about the controller removed from the manual. 

• Additional spare part numbers for the motors. 

8 


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. 

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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) 

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• 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 - RobotStudioOnline 

• 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) 

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How to read the product manual 

How to read the product manual 

Reading the procedures 

The procedures contain references to figures, tools, material etc. The references are read as 

described below. 

References to figures 

The procedures often include references to components or attachment points located on the 

robot/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 an procedure. 

Step Action 

Note/Illustration 

8. Remove the rear attachment screws, gearbox. Shown in the figure Location of 

gearbox on page xx. 

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, i.e. article number, dimension. 

The denomination in the procedure for the component or attachment point corresponds to the 

denomination in the referenced list. 

The table below shows an example of a reference to a list of required equipment, from a step 

in an procedure. 

Step Action Note/Illustration 

3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required 

equipment on page xx. 

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 chapter Safety on page 13. 

12 


1 Safety 

1.1. Introduction 

1 Safety 


Overview 

The safety information in this manual is divided in 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 section General 

safety information on page 14. 

• specific safety information, pointed out in the procedure at the moment of the danger. 

How to avoid and eliminate the danger is either detailed directly in the procedure, or 

further detailed in separate instructions, found in section Safety related instructions on 

page 34. 

3HAC 023297-001 Revision: - 

13

1 Safety 

1.2.1. Introduction 

1.2 General safety information 

1.2.1. Introduction 

Definitions 

Sections 

This section details general safety information for service personnel i.e. personnel performing 

installation, repair and maintenance work. 

The general safety information is divided into the following sections: 

1. General information contains lists of: 

• Safety, service 

• Limitation of liability 

• Referenced documents 

2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split 

into different categories: 

• Safety risks during service work on robot 

• Safety risks related to gripper/end effector 

• Safety risks related to tools/workpieces 

• Safety risks related to pneumatic/hydraulic systems 

• Safety risks during operational disturbances 

• Safety risks during installation and service 

• Risks associated with live electric parts 

3. Safety actions details actions which may be taken to remedy or avoid dangers. 

• Safety fence dimensions 

• Fire extinguishing 

• Emergency release of the manipulator´s arm 

• Brake testing 

• Risk of disabling function "Reduced speed 250 mm/s" 

• Safe use of the Teach Pendant Unit enabling device 

• Work inside the manipulator´s working range 

• Signal lamp (optional) 

14 


1 Safety 

1.2.2.1. Safety, service 

1.2.2. General information 

1.2.2.1. Safety, service 

Validity and responsibility 

The information does not cover how to design, install and operate a complete system, nor 

does it cover all peripheral equipment, which can influence the safety of the total system. To 

protect personnel, the complete system must be designed and installed in accordance with the 

safety requirements set forth in the standards and regulations of the country where the robot 

is installed. 

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws 

and regulations in the country concerned are observed and that the safety devices necessary 

to protect people working with the robot system have been designed and installed correctly. 

Personnel working with robots must be familiar with the operation and handling of the 

industrial robot, described in the applicable documents, e.g. User’s Guide and Product 

Manual. 

Connection of external safety devices 

Apart from the built-in safety functions, the robot is also supplied with an interface for the 

connection of external safety devices. Via this interface, an external safety function can 

interact with other machines and peripheral equipment. This means that control signals can 

act on safety signals received from the peripheral equipment as well as from the robot. 

In the Product Manual - Installation and Commissioning, instructions are provided for 

connecting safety devices between the robot and the peripheral equipment. 

3HAC 023297-001 Revision: - 

15

1 Safety 

1.2.2.2. Limitation of Liability 

1.2.2.2. Limitation of Liability 

General 

Any information given in this manual regarding safety, must not be construed as a warranty 

by ABB that the industrial robot will not cause injury or damage even if all safety instructions 

have been complied with. 

16 


1 Safety 

1.2.2.3. Related information 

1.2.2.3. Related information 

General 

The list below specifies documents which contain useful information: 

Documents 

Type of information Detailed in document Section 

Installation of safety devices Product manual for the Installation and commissioning 

manipulator 

Changing robot modes User’s Guide Start-up 

Restricting the working space Product manual for the Installation and commissioning 

manipulator 

3HAC 023297-001 Revision: - 

17

1 Safety 

1.2.3.1. Safety risks during service work on robot 

1.2.3. Safety risks 


Overview 

This section includes information of general safety risks to be considered when performing 

service work on the robot. 

18 


1 Safety 


Complete robot 

Safety risk 

Hot components! 

Description 

Removed parts may result in 

collapse of robot! 

Caution! 

Motors and gears are HOT after running the robot! 

Touching the motors and gears may result in burns! 

Warning! 

Take any necessary measures to ensure that the robot 

does not collapse as parts are removed, e.g. secure the 

lower arm with fixtures if removing motor, axis 2. 

Cabling 

Safety risk 

Cable packs are sensitive to 

mechanical damage! 

Description 

Caution! 

The cable packs are sensitive to mechanical damage! 

They must be handled with care, especially the 

connectors, in order to avoid damaging them! 

Gearboxes and motors 

Safety risk 

Gears may be damaged if 

excessive force is used! 

Description 

Caution! 

Whenever parting/mating motor and gearbox, the gears 

may be damaged if excessive force is used! 

3HAC 023297-001 Revision: - 

19

1 Safety 


Balancing device 

Safety risk 

Dangerous balancing device! 

Description 

Warning! 

Do not under any circumstances, deal with the balancing 

device in any other way than that detailed in the product 

documentation! For example, attempting to open the 

balancing device is potentially lethal! 

20 


1 Safety 

1.2.3.2. Safety risks related to gripper 

1.2.3.2. Safety risks related to gripper 

CAUTION! 

Ensure that a gripper is prevented from dropping a workpiece, if such is used. 

3HAC 023297-001 Revision: - 

21

1 Safety 

1.2.3.3. Safety risks related to tools/workpieces 

1.2.3.3. Safety risks related to tools/workpieces 

Safe handling 

Safe design 

It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards 

remain closed until the cutters stop rotating. 

It should be possible to release parts by manual operation (valves). 

Grippers/end effectors must be designed so that they retain workpieces in the event of a power 

failure or a disturbance of the controller. 

22 


1 Safety 

1.2.3.4. Safety risks related to pneumatic/hydraulic systems 

1.2.3.4. Safety risks related to pneumatic/hydraulic systems 

General 

Residual energy 

Safe design 

Special safety regulations apply to pneumatic and hydraulic systems. 

• Residual energy may be present in these systems so, after shutdown, particular care 

must be taken. 

• The pressure in pneumatic and hydraulic systems must be released before starting to 

repair them. 

• Gravity may cause any parts or objects held by these systems to drop. 

• Dump valves should be used in case of emergency. 

• Shot bolts should be used to prevent tools, etc., from falling due to gravity. 

3HAC 023297-001 Revision: - 

23

1 Safety 

1.2.3.5. Safety risks during operational disturbances 

1.2.3.5. Safety risks during operational disturbances 

General 

Qualified personnel 

Extraordinary risks 

• The industrial robot is a flexible tool which can be used in many different industrial 

applications. 

• All work must be carried out professionally and in accordance with the applicable 

safety regulations. 

• Care must be taken at all times. 

• Remedial action must only be carried out by qualified personnel who are familiar with 

the entire installation as well as the special risks associated with its different parts. 

If the working process is interrupted, extra care must be taken due to risks other than those 

associated with regular operation. Such an interruption may have to be rectified manually. 

24 


1 Safety 

1.2.3.6. Safety risks during installation and service 

1.2.3.6. Safety risks during installation and service 

General risks during installation and service 

• The instructions in the Product Manual - Installation and Commissioning must always 

be followed. 

• Emergency stop buttons must be positioned in easily accessible places so that the robot 

can be stopped quickly. 

• Those in charge of operations must make sure that safety instructions are available for 

the installation in question. 

• Those who install the robot must have the appropriate training for the robot system in 

question and in any safety matters associated with it. 

Nation/region specific regulations 

To prevent injuries and damage during the installation of the robot system, the regulations 

applicable in the country concerned and the instructions of ABB Robotics must be complied 

with. 

Non-voltage related risks 

• Safety zones, which have to be crossed before admittance, must be set up in front of 

the robot's working space. Light beams or sensitive mats are suitable devices. 

• Turntables or the like should be used to keep the operator out of the robot's working 

space. 

• The axes are affected by the force of gravity when the brakes are released. In addition 

to the risk of being hit by moving robot parts, you run the risk of being crushed by the 

parallel arm. 

• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be 

released if the robot, or parts thereof, is dismantled. 

• When dismantling/assembling mechanical units, watch out for falling objects. 

• Be aware of stored heat energy in the controller. 

• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part 

during service work. There is a serious risk of slipping because of the high temperature 

of the motors or oil spills that can occur on the robot. 

To be observed by the supplier of the complete system 

• The supplier of the complete system must ensure that all circuits used in the safety 

function are interlocked in accordance with the applicable standards for that function. 

• The supplier of the complete system must ensure that all circuits used in the 

emergency stop function are interlocked in a safe manner, in accordance with the 

applicable standards for the emergency stop function. 

3HAC 023297-001 Revision: - 

25

1 Safety 

1.2.3.7. Risks associated with live electric parts 

1.2.3.7. Risks associated with live electric parts 

Voltage related risks, general 

• Although troubleshooting may, on occasion, have to be carried out while the power 

supply is turned on, the robot must be turned off (by setting the mains switch to OFF) 

when repairing faults, disconnecting electric leads and disconnecting or connecting 

units. 

• The mains supply to the robot must be connected in such a way that it can be turned 

off outside the robot’s working space. 

Voltage related risks, controller 

A danger of high voltage is associated with the following parts: 

• Be aware of stored electrical energy (DC link) in the controller. 

• Units inside the controller, e.g. I/O modules, can be supplied with power from an 

external source. 

• The mains supply/mains switch 

• The power unit 

• The power supply unit for the computer system (230 VAC) 

• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!) 

• The drive unit (700 VDC) 

• The service outlets (115/230 VAC) 

• The power supply unit for tools, or special power supply units for the machining 

process 

• The external voltage connected to the control cabinet remains live even when the robot 

is disconnected from the mains. 

• Additional connections 

Voltage related risks, robot 

A danger of high voltage is associated with the robot in: 

• The power supply for the motors (up to 800 VDC) 

• The user connections for tools or other parts of the installation (max. 230 VAC, see 

Installation and Commissioning Manual) 

Voltage related risks, tools, material handling devices, etc 

Tools, material handling devices, etc., may be live even if the robot system is in the OFF 

position. Power supply cables which are in motion during the working process may be 

damaged. 

26 


1 Safety 

1.2.4.1. Safety fence dimensions 

1.2.4. Safety actions 

1.2.4.1. Safety fence dimensions 

General 

Dimensioning 

Install a safety cell around the robot to ensure safe robot installation and operation. 

Dimension the fence or enclosure to enable it to withstand the force created if the load being 

handled by the robot is dropped or released at maximum speed. Determine the maximum 

speed from the maximum velocities of the robot axes and from the position at which the robot 

is working in the work cell (see Product Specification - Description, Robot Motion). 

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating 

tool or other device fitted to the manipulator. 

3HAC 023297-001 Revision: - 

27

1 Safety 

1.2.4.2. Fire extinguishing 

1.2.4.2. Fire extinguishing 

NOTE! 

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator 

or controller)! 

28 


1 Safety 

1.2.4.3. Emergency release of the robot’s arm 

1.2.4.3. Emergency release of the robot’s arm 

Description 

Increased injury 

In an emergency situation, any of the robot’s axes may be released manually by pushing the 

brake release buttons on the robot or on an optional external brake release unit. 

How to release the brakes is detailed in section: 

• Manually releasing the brakes on page 49. 

The robot arm may be moved manually on smaller robot models, but larger models may 

require using an overhead crane or similar. 

Before releasing the brakes, make sure that the weight of the arms does not increase the 

pressure on the trapped person, further increasing any injury! 

3HAC 023297-001 Revision: - 

29

1 Safety 

1.2.4.4. Brake testing 

1.2.4.4. Brake testing 

When to test 

How to test 

During operation the holding brakes of each axis motor wear normally. A test may be 

performed to determine whether the brake can still perform its function. 

The function of each axis’ motor holding brakes may be checked as detailed below: 

1. Run each manipulator axis to a position where the combined weight of the manipulator 

arm and any load is maximized (max. static load). 

2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the 

controller. 

3. Check that the axis maintains its position. 

If the manipulator does not change position as the motors are switched off, then the brake 

function is adequate. 

30 


1 Safety 

1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s" 

1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s" 

NOTE! 

Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant 

Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 

3HAC 023297-001 Revision: - 

31

1 Safety 

1.2.4.6. Safe use of the Teach Pendant Unit 

1.2.4.6. Safe use of the Teach Pendant Unit 

NOTE! 

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) 

which, when pressed halfway in, takes the system to MOTORS ON. When the enabling 

device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. 

To ensure safe use of the Teach Pendant Unit, the following must be implemented: 

• The enabling device must never be rendered inoperative in any way. 

• During programming and testing, the enabling device must be released as soon as 

there is no need for the robot to move. 

• The programmer must always bring the Teach Pendant Unit with him/her, when 

entering the robot's working space. This is to prevent anyone else taking control over 

the robot without the programmer knowing. 

32 


1 Safety 

1.2.4.7. Work inside the manipulator’s working range 

1.2.4.7. Work inside the manipulator’s working range 

WARNING! 

If work must be carried out within the robot’s work envelope, the following points must be 

observed: 

• The operating mode selector on the controller must be in the manual mode position to 

render the enabling device operative and to block operation from a computer link or 

remote control panel. 

• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in 

position < 250 mm/s. This should be the normal position when entering the working 

space. The position 100% ”full speed” may only be used by trained personnel who are 

aware of the risks that this entails. 

• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in 

order not to get entangled with hair or clothing. Also be aware of any danger that may 

be caused by rotating tools or other devices mounted on the manipulator or inside the 

cell. 

• Test the motor brake on each axis, according to section Brake testing on page 30. 

3HAC 023297-001 Revision: - 

33

1 Safety 

1.3.1. Safety signals, general 

1.3 Safety related instructions 


General 

Danger levels 

This section specifies all dangers that may arise from performing the work detailed in the 

manual. Each danger is detailed in its own section consisting of: 

• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the 

type of danger. 

• A brief description of what will happen if the operator/service personnel does not 

eliminate the danger. 

• An instruction of how to eliminate the danger to facilitate performing the activity at 

hand. 

The table below defines the captions specifying the danger levels used throughout this 

manual. 

Symbol Designation Signification 

danger 

warning 

DANGER 

WARNING 

ELECTRICAL 

SHOCK 

Warns that an accident will occur if the instructions 

are not followed, resulting in a serious or fatal injury 

and/or severe damage to the product. It applies to 

warnings that apply to danger with, for example, 

contact with high voltage electrical units, explosion 

or fire risk, risk of poisonous gases, risk of crushing, 

impact, fall from height etc. 

Warns that an accident may occur if the instructions 

are not followed, that can lead to serious injury, 

possibly fatal, and/or great damage to the product. It 

applies to warnings that apply to danger with, for 

example, contact with high voltage electrical units, 

explosion or fire risk, risk of poisonous gases, risk of 

crushing, impact, fall from height etc. 

The electrocution or electrical shock symbol 

indicates electrical hazards which could result in 

severe personal injury or death. 

Electrical shock 

caution 

CAUTION 

Warns that an accident may occur if the instructions 

are not followed, that can result in injury and/or 

damage to the product. It also applies to warnings of 

risks that include burns, eye injury, skin injury, 

hearing damage, crushing or slipping, tripping, 

impact, fall from height etc. Furthermore, it applies to 

warnings that include function requirements when 

fitting and removing equipment, where there is a risk 

of damaging the product or causing a breakdown. 

34 


1 Safety 


Symbol Designation Signification 

ELECTROSTATIC 

DISCHARGE (ESD) 

The electrostatic discharge (ESD) symbol indicates 

electrostatic hazards which could result in severe 

damage to the product. 

Electrostatic discharge 

(ESD) 

NOTE 

Note symbols alert you to important facts and 

conditions. 

Note 

TIP 

Tip symbols direct you to specific instructions, where 

to find additional information or how to perform a 

certain operation in an easier way. 

Tip 

3HAC 023297-001 Revision: - 

35

1 Safety 

1.3.2. DANGER - Moving manipulators are potentially lethal! 

1.3.2. DANGER - Moving manipulators are potentially lethal! 

Description 

Any moving manipulator is a potentially lethal machine. 

When running the manipulator, it may perform unexpected and sometimes irrational 

movements. However, all movements are performed with great force and may seriously 

injure any personnel and/or damage any piece of equipment located within the manipulator 

working range. 

Elimination 

Step Action Info/Illustration 

1. Before attempting to run the manipulator, 

make sure all emergency stop equipment 

has been correctly installed and connected. 

2. If possible, use the hold-to-run button 

whenever possible. 

The hold-to-run button is used in manual 

mode, not in automatic mode. 

3. Make sure no personnel is present within 

the manipulator working range before 

pressing the start button. 

Emergency stop equipment such as 

gates, tread mats, light curtains, etc. 

How to use the hold-to-run control in 

RobotWare 5.0 is detailed in section 

How to use the hold-to-run switch in 

the Operator’s Manual, IRC5. 

How to use the hold-to-run control in 

RobotWare 4.0 is detailed in section 

The Teach Pendant unit in the User’s 

Guide. 

36 


1 Safety 

1.3.3. WARNING - The unit is sensitive to ESD! 

1.3.3. WARNING - The unit is sensitive to ESD! 

Description 

ESD (electro static discharge) is the transfer of electrical static charge between two bodies at 

different potentials, either through direct contact or through an induced electrical field. When 

handling parts or their containers, personnel not connected to ground potential may transfer 

high static charges. This discharge may destroy sensitive electronics. 

Elimination 


1. Use a wrist strap Wrist straps must be tested frequently to 

ensure that they are not damaged and are 

operating correctly. 

2. Use an ESD protective floor mat. The mat must be grounded through a currentlimiting 

resistor. 

3. Use a dissipative table mat. The mat should provide a controlled discharge 

of static voltages and must be grounded. 

3HAC 023297-001 Revision: - 

37

1 Safety 

1.3.4. 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 

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. 

- 

Hot oil! 

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. 

- 

Possible pressure build 

up in gearbox! 

- 

Do not overfill! 

- 

Do not mix types of oil! 

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. 

Mixing types of oil may cause 

severe damage to the 

gearbox! 

Make sure not to overfill the 

gearbox when filling with oil! 

After filling, check the correct oil 

levels. 

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! 

38 


1 Safety 


Warning Description Elimination / Action 

Warm oil drains quicker than 

cold oil. 

When changing gearbox oil, first 

run the robot for a time to heat 

up the oil. 

- 

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. 

3HAC 023297-001 Revision: - 

39

1 Safety 


40 


2 Installation and commissioning 




General 

This chapter contains information for installing the robot to the working site. 

More detailed technical data, such as load diagram, permitted extra loads (equipment) and 

location of extra loads (equipment), may be found in the Product Specification for the robot. 

3HAC 023297-001 Revision: - 

41


2.2.1. Pre-installation procedure 

2.2 Unpacking 


General 

This instruction is primarily intended for use when unpacking and installing the robot for the 

first time. It also contains information useful during later re-installation of the robot. 

Checking the pre-requisites for installation 

The check-list below details what must be observed before proceeding with the actual 

installation of the manipulator: 


1. Make sure only qualified installation 

personnel conforming to all national and 

local codes are allowed to perform the 

installation. 

2. Make sure the manipulator has not been 

damaged, by visually inspecting the 

manipulator and control cabinet exterior. 

3. Make sure the lifting device to be used is 

dimensioned to handle the weight of the 

manipulator. 

4. If the manipulator is not to be installed 

directly, it must be stored. 

5. Make sure the appointed operating 

environment of the manipulator conforms to 

the specifications. 

6. Before taking the manipulator to its 

installation site, make sure the site conforms 

to applicable requirements. 

7. Before moving the manipulator, make sure it 

does not tip over! 

8. When these prerequisites have been met, 

the manipulator may be taken to its 

installation site. 

Specified in section Weight, 

manipulator on page 42. 

Specified in section Storage 

conditions, manipulator on page 43. 

Specified in section Operating 

conditions, manipulator on page 43. 

Specified in section : 

• Loads on foundation, 

manipulator on page 43 

• Requirements on foundation, 

manipulator on page 43 

• Protection classes on page 44 

Described in section Risk of tipping/ 

Stability on page 47. 

Detailed in section Lifting manipulator 

with lifting slings on page 48. 

Weight, manipulator 

The net weight of the manipulator is approximately: 100 kg. 

42 




Loads on foundation, manipulator 

The table below shows the different forces and torques working on the manipulator during 

different kinds of operation. 

NOTE! These forces and torques are extreme values that are rarely encountered during 

operation. The values also never reach their maximum simultaneously! 

Force 

Endurance load 

(operation) 

Max. load (emergency 

stop) 

Force xy (upright/suspended) ± 1300 N ± 3200 N 

Force z (upright) -1000 ± 1000 N -1000 ± 2000 N 

Forze z (suspended) -2800 ± 1000 N +1000 ± 2000 N 

Torque 

Mxy ± 1300 Nm ± 220 Nm 

Mz ± 300 Nm ± 750 Nm 

Requirements on foundation, manipulator 

Requirement 

Value 

Min. levelity 

0.5 mm 

Max. tilt 5° 

Min. resonance frequency 

22 Hz 

Storage conditions, manipulator 

The table below shows the allowed storage conditions for the manipulator: 

Parameter 

Max. ambient temperature 

Max. ambient temperature (less than 24 hrs) 

Min. ambient temperature 

Max. ambient humidity 

Value 

+55° C 

+70° C 

-25° C 

Max. 95% at constant temperature 

Operating conditions, manipulator 

The table below shows the allowed operating conditions for manipulator: 

Parameter 

Max. ambient temperature 

Min. ambient temperature 

Max. ambient humidity 

Value 

+45° C 

+5° C 

Max. 95% at constant temperature 

3HAC 023297-001 Revision: - 

43



Protection classes 

The table below shows the protection class of the main parts of the robot system: 

Equipment 

Protection class 

Manipulator IP 67 

Control cabinet IP 54 

Programming unit IP 54 

44 



2.2.2. Working range, IRB 140 


Working range axis 2 -3 

The illustration below shows the unrestricted working range axis 2-3. 

xx0200000058 

Pos Position at wrist centre Angle (degrees) 

X Z Axis 2 Axis 3 

0 450 712 0° 0° 

1 70 1092 0° -90° 

2 314 421 0° +50° 

3 765 99 +110° -90° 

4 255 -119 +110° +4° 

5 -480 23 -90° -150° 

6 1 596 -90° +50° 

7 218 558 +110° -230° 

8 -670 352 -90° -90° 

3HAC 023297-001 Revision: - 

45



Working range axis 1 

The illustrations below shows the unrestricted working range of axis 1. 

xx0200000061 

46 



2.2.3. Risk of tipping/Stability 

2.2.3. Risk of tipping/Stability 

General 

Procedure 

The section below details instructions for making sure the manipulator does not tip over when 

it has not been safely secured to the foundation. 

The procedure below details how to make sure the manipulator does not tip during installation 

while not secured to the foundation. 

CAUTION! 

When the manipulator is not fastened to the floor, it will not be stable in any part of its 

working area. 

1. DO NOT change the manipulator position before securing it to its foundation. The 

shipping position is the most stable. 

2. If the manipulator, for some reason, must be move from its original position, ensure that 

the centre of gravity not is displaced. 

3HAC 023297-001 Revision: - 

47


2.3.1. Lifting manipulator with lifting slings 

2.3 On-site installation 

2.3.1. Lifting manipulator with lifting slings 

General 

This section details how to lift the manipulator using lifting slings. 

Equipment 

Sling line 

Note 

Length: 2 m. Load: 500 kg. 

Illustration 

The following figures shows how to lift the manipulator with lifting slings. 

xx0200000084 

1 Sling line for manipulator 

2 Sling line for manipulator 

3 Sling line for control cable 

How to lift the manipulator 

1. Adjust the manipulator to lifting position according to the picture. 

2. Put one sling line around each leg on the lower arm (Pos. 1 and 2). 

3. Use further one sling line to secure the lifting of the control cable (Pos. 3). 

48 



2.3.2. Manually releasing the brakes 


General 

The section below details how to release the holding brakes of each axis’ motor. 

This may be done in one of three ways: 

• using the pushbutton when the manipulator is connected to the controller. 

• using the pushbutton on the manipulator with an external power supply. 

• using an external voltage supply. 

DANGER! 

When releasing the holding brakes, the manipulator axes may move very quickly and 

sometimes in unexpected ways! Make sure no personnel is near the manipulator arm! 

Using the pushbutton when the manipulator is connected to the controller 

This section details how to release the holding brakes using the internal brake release unit. 


1. Push the "brake release button" to release the 

holding brakes. 

xx0200000069 

• A: Pushbutton 

3HAC 023297-001 Revision: - 

49



Using the pushbutton on the manipulator with an external power supply 

This section details how to release the holding brakes with the pushbutton using an external 

voltage supply. 


1. Connect an external power supply to connector XP1. 

2. Push the "brake release button" to release the 

holding brakes. 

xx0200000071 

• A: B16 24V DC 

• B: B14 0V 

NOTE! 

Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can 

be caused to a resistor diode and to the system board. 

Using External power supply 

This section details how to release the holding brakes using a external voltage supply. If the 

positions of the manipulator axes are to be changed without connecting the controller, an 

external voltage supply (24 V DC) must be connected to enable the brake release buttons on 

the manipulator. 


1. Remove the screws and dismount the 

cover on the back of the manipulator 

base. 

xx0200000072 

• A: 13 0 V 

• B: 15 24 V DC 

50 





2. Locate the R1.MP4-6 connector and 

disconnect. 

3. Connect an external power supply to 

release the holding brake on all axis. 

3HAC 023297-001 Revision: - 

51


2.3.3. Orienting and securing the manipulator 

2.3.3. Orienting and securing the manipulator 

General 

This section details how to orient and secure the manipulator to the foundation in order to 

safely run the robot. 

Bolting requirements 

When bolting a mounting plate or frame to a concrete floor, follow the general instructions 

for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined 

in section Loads on foundation, manipulator on page 43. 

NOTE! 

When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must 

be used to secure the bolted joint. 

Attachment screws 

The table below specifies the type of securing screws and washers to be used for securing the 

manipulator to the base plate/foundation. 

Suitable screws, lightly lubricated: M12 

Quality Quality 8.8 

Suitable washer: 

Thickness: 2.5 mm 

Outer diameter: 24 mm 

Inner diameter: 13.4 mm 

Tightening torque: 

85 Nm 

Hole configuration and cross section 

The bolt pattern requirements are shown in section Bolt pattern on page 59. 

Guide sleeves 

Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be 

remounted without re-adjusting the program. 

Equipment 

Art. no. 

Guide sleeves 3HAC 9519-1 

52 



2.3.4. Restricting the working space 

2.3.4. Restricting the working space 

General 

Limiting devices 

When installing the manipulator, make sure that it can move freely within its entire working 

space. If there is a risk that it may collide with other objects, its working space should be 

limited. 

WARNING! 

The working space can only be limited using soft ware, for this reason the limited area can 

not be classified as a safe zone. All work within this zone is prohibited. 

Limiting devices is listed below. 

1. Light curtains. 

2. Tread mats. 

3. Other similar devices. 

4. SoftWare. 

Limiting the working space using software is described in the User’s Guide chapter: System 

Parameters. 

3HAC 023297-001 Revision: - 

53


2.3.5. Fitting equipment on manipulator 


General 

The manipulator features mounting holes for additional equipment. 

In addition to the stock mounting holes, extra mounting holes may be added on the 

manipulator under certain conditions. These special conditions are specified in the Product 

Specification. 

Illustration, holes on upper arm 

The illustration below shows the stock holes available for fitting extra equipment on the upper 

arm. 

xx0200000062 

54 




Illustration, holes on mounting flange 

The illustration below shows the stock holes available for fitting equipment on the mounting 

flange. 

xx0200000063 

Fastener quality 

When fitting tools on the mounting flange (see the figures in sections Illustration, holes on 

upper arm on page 54 and Illustration, holes on mounting flange on page 55), use only screws 

with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be 

used. 

3HAC 023297-001 Revision: - 

55


2.3.6. Loads 

2.3.6. Loads 

General 

References 

Brake performance 

Any loads mounted on the manipulator must be defined correctly and carefully (with regard 

to the position of centre of gravity and inertia factor) in order to avoid jolting movements and 

overloading the motors. If this is not done correctly operation stops may result. 

Load diagrams, permitted extra loads (equipment) and their positions as specified in the 

Product Specification. The loads must also be defined in the software as detailed in User’s 

Guide. 

Manipulator motor brake performance depends on any loads attached. For further 

information about brake performance, please contact ABB. 

56 



2.3.7. Suspended mounting 


General 

Initially the system is configured for mounting on the floor, without leaning. The method for 

mounting the manipulator in a suspended position is basically the same as for floor mounting. 

NOTE! 

With inverted installation, make sure that the gantry or corresponding structure is rigid 

enough to prevent unacceptable vibrations and deflections, so that optimum performance can 

be achieved. 

System Parameters 

If the robot is mounted at any other angle, the system parameter “gravity beta” must be 

updated. Gravity beta specifies the robot’s mounting angle expressed in radians. 

NOTE! 

It is very important to configure gravity beta correctly so that the robot system can control the 

movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will 

result in: 

• Overloading the mechanical structure. 

• Lower path performance and path accuracy. 

• Some S4 functions will not work properly: e.g Load Identification & Collision 

detection. 

Mounting Angles and Values 

The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated 

in the following way for a mounting angle of 45°. 

Gravity beta = 45° x 3.141593/180 = 0.785398 radians. 

Examples of Position Mounting Angle Gravity Beta 

Floor (pos 1) 0° 0.000000 (Default) 

Tilted (pos 2) 45° 0.785398 

Wall (pos 3) 90° 1.570796 

Ceiling (pos 4) 180° 3.141593 

3HAC 023297-001 Revision: - 

57



xx0200000066 

Defining the parameters 

Following steps describes how to enter the correct gravity beta values. 


1. Choose Topics: Manipulator. 

2. Choose Types: Robot. 

3. Select Master and press Enter. 

4. Select the desired parameter “gravity beta” and 

change its value. 

5. Press OK to confirm. 

xx0200000073 

58 



2.3.8. Bolt pattern 


Hole configuration 

The illustration below shows the hole configuration used when securing the manipulator: 

xx0200000085 

3HAC 023297-001 Revision: - 

59



Cross section, guide sleeve hole 

The illustration below shows the cross section of the guide sleeve holes: 

xx0200000086 

60 



2.4.1. Customer connections on manipulator 

2.4 Electrical connections 


General 

For connection of extra equipment on the manipulator there are cables integrated into the 

manipulator’s cabling. There are both air and electrical connectors on the manipulator. 

xx0200000074 

Connections 

Connections 

Description 

1. For air on base / upper arm R1/4" Max. 8 bar/hose inner diameter: 6.5 mm 

2. Signal connector on upper arm FCI UT 071412SH44N connector 

Number of signals: 12 signals, 49V, 500mA 

3HAC 023297-001 Revision: - 

61



Recommended parts 

To connect power and signal conductors to the upper arm connector, the following parts are 

recommended 

xx0200000132 

ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains: 

• Multipole connector 12 pin 

• Adapter Tin plated 12 pin 

• Pins for cable area 0.25-0.5 mm 2 

• Pins for cable area 0.5-1.5 mm 2 

• Shrinking hose, bootled shaped 

• Shrinking hose angled 

The connection set is delivered in a plastic bag also containing a Technical and assembly 

instruction. 

62 


3 Maintenance 


3 Maintenance 


Structure of this chapter 

This chapter details all maintenance activities recommended for the robot and any external 

units of the robot. 

It is based on the maintenance schedule, located in the beginning of the chapter. The schedule 

contains information about required maintenance activities including periodicity and refers to 

procedures for the activities. 

Each procedure contains all information required to perform the activity, e.g. required tools 

and materials. 

The procedures are gathered in different sections, divided according to the maintenance 

activity. 


Before any service work is commenced, it is extremely important that all safety information 

is observed! 

There are general safety aspects that must be read through, as well as more specific safety 

information that describe danger and safety risks when performing the procedures. Make sure 

to read through the chapter Safety on page 13. 

3HAC 023297-001 Revision: - 

63

3 Maintenance 

3.2.1. Maintenance schedule, IRB 140 

3.2 Maintenance schedules 


General 

The robot, consisting of manipulator and controller cabinet, must be maintained regularly to 

ensure its function. The maintenance activities and their respective intervals are specified in 

the table below. 

Non-predictable situations also give rise to inspections of the robot. Any damages must be 

attended to immediately! 

The inspection intervals do not specify the life of each component. 

Activities and intervals, standard equipment 

The sections referred to in the table can be found in the different chapters for every 

maintenance activity. 

The table below specifies the required maintenance activities and intervals: 

Maintenance 

activity 

Equipment Interval Detailed in section: 

Inspection Damper, axes 2-3 Regularly *) Inspection, damper axes 

2-3 on page 66 

Inspection Cable harnesses Regularly *) Inspection, robot cabling 

on page 68 

Inspection Timing belts 36 mths Inspection, timing belts on 

page 69 

Change Gearbox 5, oil 36 mths Oil change, gearbox, 

axes 5 and 6 on page 73 

Change Gearbox 6, oil 36 mths Oil change, gearbox, 

axes 5 and 6 on page 73 

Change 

Clean 

Measurement 

system, battery 

Complete 

manipulator 

Depending on battery type 

and operation pattern as 

specified in section Battery 

type selection on page 65. 

Regularly *) 

Replacement of serial 

measurement unit and 

battery pack on page 122. 

Cleaning, complete robot 

on page 72 

*) "Regularly" implies that the activity is to be performed regularly, but the actual interval 

may not be specified by the robot manufacturer. The interval depends on the operation cycle 

of the robot, its working environment and movement pattern. 

Generally, the more contaminated environment, the shorter intervals. The more demanding 

movement pattern (sharper bending cable harness), the shorter intervals. 

64 


3 Maintenance 


Battery type selection 

The table below shows the selection criteria for the three available battery types. 

Operation pattern 

Change interval, 

3-cell lithium 

Change interval, 

6-cell lithium 

Max. 4 weeks power off per year 60 mths 60 mths 

Weekend power off + operation pattern 1 24 mths 48 mths 

Nightly power off + operation patterns 1 and 2 12 mths 

24 mths 

No longer change interval than 60 months are allowed regardless of the operation pattern due 

to material ageing, etc. 

3HAC 023297-001 Revision: - 

65

3 Maintenance 

3.3.1. Inspection, damper axes 2-3 

3.3 Inspection activities 


Location of dampers, axes 2-3 

The figure below shows the location of all the dampers to be inspected. 

xx0200000426 

A Damper, axis 2 

xx0200000427 


66 


3 Maintenance 


Required equipment 

Equipment Art. no. Note 

Standard toolkit 3HAC020812-001 The contents are defined in section 

Standard toolkit in the Product manual, 

reference information! 

Inspection, damper axis 2-3 

The procedure below details how to inspect the dampers, axis 2-3 

WARNING! 

Please observe the following before commencing any repair work on the manipulator: 

• Motors and gears are HOT after running the robot! Touching the motors and gears may 

result in burns! 

• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 

• Take any necessary measures to ensure that the manipulator does not collapse as parts 

are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. 

Step Action Note 

1. Check all dampers for damage, such as cracks or 

existing impressions larger than 1 mm. 

2. Check attachment screws for deformation. 

3. If any damage is detected, the damper must be 

replaced with a new one! 

Shown in the figure in 

section Location of dampers, 

axes 2-3 on page 66! 

Art. no. specified in section 

Required equipment on 

page 67! 

Replacement is detailed in 

section Replacement of 

damper, axis 2 on page 111 

and Replacement of 

damper, axis 3 on page 102. 

3HAC 023297-001 Revision: - 

67

3 Maintenance 

3.3.2. Inspection, robot cabling 

3.3.2. Inspection, robot cabling 

Location, robot cabling 

The robot cabling comprises the cabling between the manipulator and controller cabinet as 

well as the externally visible cabling around motors 1 and 2. 

A more detailed view of the component and its position may be found in chapter Foldouts in 

the Product manual, reference information. 


Equipment Art. no. Note 

Standard toolkit 3HAC020812-001 The contents are defined in 

section Standard toolkit in the 

Product manual, reference 

information! 

Other tools and procedures may 

be required. See references to 

these procedures in the stepby-step 

instructions below. 

Circuit diagram 3HAC 6816-3 

These procedures include 

references to the tools required. 

WARNING! 







CAUTION! 

The cable packs are sensitive to mechanical damage! They must be handled with care, 

especially the connectors, in order to avoid damaging them! 

Inspection 

The procedure below details how to inspect the robot cabling. 


1. Visually inspect the control cabling between the 

manipulator and control cabinet. 

Look for abrasions, cuts or crush damages. 

2. Replace the cabling if wear or damage is detected. This is detailed in 

Replacement of cable 

harness on page 78. 

68 


3 Maintenance 

3.3.3. Inspection, timing belts 


Location of timing belts 

Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below. 



xx0200000448 

G Timing belt, axis 3 

3HAC 023297-001 Revision: - 

69

3 Maintenance 


xx0200000453 

R Timing belt, axis 6 

V Timing belt, axis 5 


Equipment, etc. Art. no. Note 




Other tools and procedures 

may be required. See 

references to these 

procedures in the step-bystep 


These procedures include references to 

the tools required. 

70 


3 Maintenance 


Inspection 

The procedure below details how to inspect the timing belts. 

WARNING! 


• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result 

from touching them! 

• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! 

• When replacing motors/reducers, make sure that those parts of the robot which could 

move unexpectedly are mechanically blocked as specified in the individual 

procedures. 


1. Gain access to each belt by 

removing covers, etc. 

These procedures are detailed in sections 

Replacement of motor and timing belt, axis 3 

on page 139 and Replacement of motor and 

timing belt, axes 5 or 6 on page 147. 

2. Check each belt for damage. Replace the timing belts if found defective as 

detailed in sections Replacement of motor 

and timing belt, axis 3 on page 139 and 

Replacement of motor and timing belt, axes 5 

or 6 on page 147. 

3. Check each belt for tension. 

If the belt tension is not correct, it 

should be adjusted. 

The belt tension should be: 

• Axis 3: F = 35-60 N 

• Axis 5: F = 35-60 N 

• Axis 6: F = 35-60 N 

xx0200000474 

Belt tension adjustment is detailed in sections 

Replacement of motor and timing belt, axis 3 

on page 139 and Replacement of motor and 

timing belt, axes 5 or 6 on page 147. 

3HAC 023297-001 Revision: - 

71

3 Maintenance 

3.4.1. Cleaning, complete robot 

3.4 Cleaning activities 

3.4.1. Cleaning, complete robot 

General 

The protection class is IP 67, i.e. the manipulator is watertight. 



May be used on Foundry 

versions only! 

Steam cleaner 

May be used on Foundry 

versions only! 

High pressure water cleaner 

Vacuum cleaner 

Cloth with mild detergent 

- • Water pressure at nozzle: max. 2,500 kN/ 

m 2 (25 bar) 

• Type of nozzle: fan jet, min. 45° spread 

• Flow: max. 100 litres/min. 

• Water temperature: max. 80° C 

- • Max. water pressure on enclosures: 50 kN/ 

m 2 (0.5 bar) 

• Fan jet nozzle should be used, min. 45° 

spread 

• Flow: max. 100 litres/min. 

- May be used on Standard version 

Do’s and don’ts! 

Always! 

Never! 

The section below specifies some special considerations when cleaning the manipulator. 

• Always use cleaning equipment as specified above! Any other cleaning equipment 

may shorten the life of paintwork, rust inhibitors, signs, or labels! 

• Always check that all protective covers are fitted to the robot before cleaning! 

• Never point the water jet at bearing seals, contacts, and other seals! 

• Never spray from a distance closer than 0.4 m! 

• Never remove any covers or other protective devices before cleaning the robot! 

• Never use any cleaning agents, e.g. compressed air or solvents, other than those 

specified above! 

• Although the manipulator is watertight, avoid spraying connectors and similar items 

with a high pressure cleaner! 

72 


3 Maintenance 

3.5.1. Oil change, gearbox, axes 5 and 6 

3.5 Changing/ replacing activities 


Location of oil plugs 

The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. 



xx0200000475 

A Oil plug, gearbox axis 5 

B Oil plug, gearbox, axis 6 



Lubricating oil 1171 2016-604 

3HAC 0860-1 

Oil collecting vessel 

Corresponds to: 

• Optimol, BM 100 

Amount, gearbox 5 and 6: 350 ml 

Capacity: 400 ml. 

Standard Toolkit, IRB 140 3HAC020812-001 The contents are defined in section 










3HAC 023297-001 Revision: - 

73

3 Maintenance 


WARNING! 







TIP! 

When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains 

quicker than cold oil. 

WARNING! 

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! 

WARNING! 

When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside 

the gearbox which in turn may: 

• damage seals and gaskets 

• completely press out seals and gaskets 

• prevent the manipulator from moving freely 

WARNING! 

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. 

Also, be aware of 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! 

Draining, axes 5 and 6 

The procedure below details how to drain the oil from gearboxes, axes 5 and 6. 


1. Move the robot to a position where the upper arm is 

close to horizontal and axis 4 in the calibration 

position. 

2. Remove the oil plugs. 

The cavity behind the plugs, containing the oil, is 

common to gearboxes 5 and 6, but during draining, 

both must be removed. 

Shown in the figure Location 

of oil plugs on page 73! 

3. Move axis 4 90° to a position where the axis 6 oil plug 

faces downwards. 

4. Drain the oil from the gearbox. Vessel capacity specified in 

section Required equipment 

on page 73! 

5. Move axis 4 another 90°. This allows the remaining oil 

to be drained. 

6. Refit the oil plug. 

74 


3 Maintenance 


Refill, axes 5 and 6 

The procedure below details how to refill the oil in gearboxes, axes 5 and 6. 


1. Run the robot to a position where the upper arm 

is close to horizontal and axis 4 in the calibration 

position. 

2. Remove the oil plug, axis 5.. 

The cavity behind the plugs, containing the oil, is 

common to gearboxes 5 and 6, but during 

draining, both must be removed. 

3. Fill oil in gearbox 5 until the oil level reaches the 

oil plug hole on the side of the wrist. 

Shown in the figure Location of 

oil plugs on page 73! 

The figure shows the 

manipulator positions for filling 

and draining respectively for a 

standing manipulator: 

xx0300000161 

Positions: 

• A: Draining position 

• B: Filling position 

The figure shows the 

manipulator positions for filling 

and draining respectively for an 

inverted manipulator: 

4. Refit the oil plug. 

xx0300000162 

Positions: 

• A: Draining position 

• B: Filling position 

The oil quality is specified in 

section Required equipment on 

page 73! 

3HAC 023297-001 Revision: - 

75

3 Maintenance 


76 


4 Repair 


4 Repair 


Structure of this chapter 

This chapter details all repair activities recommended for the robot and any external units of 

the robot. 

It is made up of separate units, each detailing a specific repair activity. Each unit contains all 

information required to perform the activity, e.g. spare parts numbers, required special tools 

and materials. 

The units are gathered in different sections, divided according to the component location on 

the robot. 


All equipment required to perform a specific repair activity is listed together with the current 

procedure. 

The equipment is also gathered in different lists in the Product manual, reference information. 


Before any service work is commenced, it is extremely important that all safety information 

is observed! 

There are general safety aspects that must be read through, as well as more specific safety 

information that describe danger and safety risks when performing specific steps in a 

procedure. Make sure to read through the chapter Safety on page 13 before commencing any 

service work. 

3HAC 023297-001 Revision: - 

77

4 Repair 

4.2.1. Replacement of cable harness 

4.2 Complete robot 


Location of cable harness 

The cable harness runs from the base to the motors of axes 3-6. 




Equipment, etc. Spare part no. Art. no. Note 

Cable harness 3HAC 7370-1 Standard and Foundry 

versions 

Clean room version 

Includes cabling: 

• Cable harness, 

power axis 1-3 


power axis 4-6 


signals axis 1-3 


signals axis 4-6 


customer 

connections 

Standard toolkit 3HAC020812-001 The contents are defined 

in section Standard toolkit 

in the Product manual, 


Other tools and 

procedures may be 

required. See 


procedures in the stepby-step 

instructions 

below. 


references to the tools 

required. 

Circuit Diagram 3HAC 6816-3 See chapter Circuit 

diagram in the Product 

manual, reference 

information. 

78 


4 Repair 


Removal, cable harness 

The procedure below details how to remove the cable harness. 

WARNING! 







CAUTION! 




1. Remove the serial 

measurement board. 

2. Disconnect connectors in the 

manipulator base. 

Detailed in section Replacement of serial 

measurement unit and battery pack on page 122. 

3. Remove the cable holder by 

unscrewing its attachment 

screws. 

xx0300000090 

Connectors: 

• A: R1.MP1-3 

• B: R1.CS 

• C: Air hose 

• D: R1.MP4-6 

xx0300000091 

• A: Cable holder 

• B: Attachment screws 

• C: Cable securing screws 

3HAC 023297-001 Revision: - 

79

4 Repair 



4. Remove the cables from the 

cable holder by unscrewing the 

cable securing screws. 

5. Remove the cover, arm 

housing. 

See figure above! 

Detailed in section Replacement of cover, arm 

housing, IRB 140. 

6. Remove the lower arm cover. Detailed in section Replacement of lower arm 

cover and gasket on page 108. 

7. Gently knock out the VK cover. Detailed in section Removing the VK cover on 

page 88. 

8. Disconnect connectors in the 

rear of the upper arm. 

9. Remove the shield by 


screws. 

10. Cut any cable ties securing the 

cabling inside the lower arm. 

xx0300000092 

Connectors: 

• A: R2.CS 

• B: Pressurized air connection 

• C: R3.FB4 

• D: R3.FB5 

• E: R3.FB6 

• F: R3.MP5 

• G: R3.MP4 

• H: R3.MP6 

Parts: 

• J: Shield 

See figure above! 

80 


4 Repair 



11. Disconnect the connectors 

inside the lower arm. 

xx0200000449 

• G: Connectors R3.MP3 and R3.FB3 

12. Pull the cables out of the upper 

arm. 

13. Remove the cover, console. Detailed in section Replacement of cover, console 

on page 115. 

14. Disconnect the connectors 

inside the console and undo 

the cable holders. 

15. Gently pull the cabling from the 

base up through the console. 

16. Gently pull the cabling out of 

the lower arm. 

Connectors: 

• R3.MP1 

• R3.MP2 

• R3.FB1 

• R3.FB2 

3HAC 023297-001 Revision: - 

81

4 Repair 


Refitting, cable harness 

The procedure below details how to refit the cable harness. 

WARNING! 


• Motors and gears are HOT after running the robot! Burns may result from touching 

the motors or gears! 



are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2. 

CAUTION! 




1. Refit in reverse order to what is 

detailed above. 

Detailed below are some 

recommendations on how to 

route the cables. 

2. Cable distribution in the cable 

holder in the manipulator base. 

xx0300000093 

Cables: 

• A: Signal 

• B: Signal 

• C: Customer signal 

• D: Power cable, axes 4-6 

• E: Pressurized air supply 

• F: Power cable, axes 1-3 

82 


4 Repair 



3. Cable layout in the lower arm. 

xx0200000449 

• A: Cable ties 

• B: Pressurized air hose 

• C: Power cables, axes 4, 5 and 6 

• D: Customer cables, signal 

• E: Signal cables, axes 4, 5 and 6 

• F: Signal cable, axis 3 


3HAC 023297-001 Revision: - 

83

4 Repair 



4. Cable holder in the upper arm. 

xx0300000094 

Cables: 

• A: Customer signal 

• B: Signal 

• C: Pressurized air supply 

• D: Power cables 

84 


4 Repair 

4.2.2. Replacement of complete upper arm 


Location of upper arm 

The upper arm is located on top of the manipulator as shown in the figure below. 



xx0200000446 

A 

B 

C 

D 

E 

F 

G 

H 

J 

Cover, armhousing 

Attachment screws, cover armhousing, (4 pcs) 

CS-connector 

Pressurized air connector 

VK cover 

Cable guide 

Attachment screws, cable guide 

Attachment screws, upper arm (6 pcs) 

Sealing ring 

3HAC 023297-001 Revision: - 

85

4 Repair 



Equipment Spare part no. Art. no. Note 

Upper arm, spare Std/F 3HAC 10466-1 Standard and Foundry 

versions 

Includes all required 

sealings and gaskets. 

Upper arm, spare CR 3HAC 10466-3 Clean room versions 


sealings and gaskets. 

Sealing ring 3HAB 3732-13 To be replaced if 

damaged only 

Included in the upper arm 

assembly 

VK cover 3HAC 2166-13 

Gasket upper arm cover 3HAC 7867-1 To be replaced if 

damaged only 

Included in the upper arm 

assembly 

Standard toolkit 

3HAC020812-001 The contents are defined 




Special socket - For fitting the CSconnector 



required. See references 

to these procedures in 

the step-by-step 


WARNING! 







Removal, upper arm 

The procedure below details how to remove the complete upper arm. 



required. 


1. Run the manipulator arm to a horizontal position. 

2. Remove all brackets securing any exterior cabling 

to the upper arm by unscrewing their attachment 

screws respectively. 

86 


4 Repair 



3. Remove the rear cover armhousing by unscrewing 

its four attachment screws. 

4. DO NOT under any circumstance unscrew the six 

screws on top of the lower arm! Doing so will cause 

the manipulator to require a complete rebuild! 


upper arm on page 85! 

xx0300000101 

• A: DO NOT touch these 

screws! (NOTE! Only 

two screws shown!) 

5. Disconnect all cables to/from motors 4-6. Connectors 

• R3.MP4 

• R3.MP5 

• R3.MP6 

• R3.FB4 

• R3.FB5 

• R3.FB6 

6. Disconnect any connector from the CS-connector. Shown in the figure Location of 


7. Use a special socket to remove the CS-connector 

from the housing and pull it into the upper arm 

assembly. 

8. Remove the pressurized air connector from the 

housing and pull it into the upper arm assembly. 

9. Remove the VK-cover from the upper arm/lower 

arm joint. 

10. Remove the cable guide by unscrewing its two 

attachment screws. 

11. Gently pull all cables and hoses out. 

12. Remove the upper arm by unscrewing its six 


13. Lift the upper arm and place it on a secure surface. 




Required equipment on page 

86! 





86! 



Detailed in section Removing 

the VK cover on page 88. 





3HAC 023297-001 Revision: - 

87

4 Repair 


Removing the VK cover 

The procedure below details how to remove the VK cover from the upper arm. 

xx0200000433 

A 

B 

C 

D 

Lower arm 

Lower arm cover gasket 

Cover l. arm, spare (without lamp unit) 

Cover l. arm, spare (with lamp unit) 


1. Remove the lower arm cover by unscrewing its 


2. Tap the VK coverwith a long blunt edged bar 

through the hole in the lower arm to press it out. 

3. If the VK cover is damaged, it must be replaced 

on refitting. 

Make sure to press the 

circumference of the VK cover 

evenly to avoid damaging it. 

Shown in the figure in section 

Location of upper arm on page 85! 

Specified in section Refitting of 

complete upper arm. 

88 


4 Repair 


Refitting 

The procedure below details how to refit the complete upper arm. 


1. Check the sealing ring to see whether it is 

damaged. 

Replace if it is damaged! 

2. Lift the upper arm into position. 

3. Secure the upper arm with its six attachment 

screws. 

4. Gently pull all cables and hoses through the 

hole in the upper arm. 

5. Reconnect all connectors to motors 4-6. Connectors 

• R3.MP4 

• R3.MP5 

• R3.MP6 

• R3.FB4 

• R3.FB5 

• R3.FB6 

6. Refit the cable guide with its two attachment 

screws. 

7. Pull the pressurized air connector through the 

housing and secure it into fitting in the upper 

arm assembly. 

8. Pull the CS-connector through the housing 

and secure it into the fitting in the upper arm 

assembly. 

Use a special socketto secure it. 

9. Reconnect any connector previously 

connected externally to the CS connector. 

10. Fit a newVK-cover to the upper arm/lower arm 

joint. 

Gently knock it into position. 

11. Refit the rear cover armhousing with its four 





Required equipment on page 86! 



Tightening torque: 35 Nm ± 3 Nm 













Use a plastic mallet or similar. 



12. Refit any brackets securing any exterior 

cabling to the upper arm with their attachment 

screws respectively. 

13. Recalibrate the robot. Calibration is detailed in separate 

calibration manuals. 

Art. no. for the manuals are 

specified in section Document 

references in the Product manual, 

reference information. 

3HAC 023297-001 Revision: - 

89

4 Repair 


DANGER! 

When performing the first test run after a service activity (repair, installation or maintenance, 

it is vital that: 

• all the service tools and other foreign objects are removed from the manipulator! 

• all normal safety equipment is installed properly, e.g. TPU enabling device. 

• all personnel are standing at a safe distance from the manipulator, i.e. out of its reach 

behind any safety fences, etc. 

• special attention is paid to the function of the part previously serviced. 

90 


4 Repair 

4.2.3. Replacement of complete lower arm 


Location of lower arm 

The lower arm is located between upper arm and frame as shown in the figure below. 



xx0200000469 

A 

Lower arm 

3HAC 023297-001 Revision: - 

91

4 Repair 




Lower arm, spare 3HAC 10468-1 Standard and Foundry 

versions 


bearings, oil and VK cover. 

Lower arm, spare 3HAC 10468-4 Clean room versions 


bearings, oil and VK cover. 


3HAC020812-001 The contents are defined in 

section Standard toolkit in 

the Product manual, 


Lifting device for lower 

Lifting capacity xx kg 

arm 

Special socket - For fitting the CSconnector 









required. 

Removal, lower arm 

The procedure below details how to remove the complete lower arm. 

WARNING! 







92 


4 Repair 



1. Remove the console. Detailed in section Replacement of console on 

page 118. 

2. DO NOT under any 

circumstance unscrew the six 

screws on top of the lower arm! 

Doing so will cause the 

manipulator to require a 

complete rebuild! 

3. Remove the VK cover by 

pressing a screwdriver, or 

similar, through it and pulling. 

xx0300000101 

Parts: 

• A: DO NOT touch these screws! (Note! 

Only 2 screws are shown.) 

4. Unscrew thelower arm 


Also remove the washer. 

5. Raise the lifting device to 

remove the lower arm. 

xx0300000097 

Parts: 

• A: Washer 

• B: Lower arm attachment screws (10 pcs) 

• C: VK cover 

Shown in the figure above! 

3HAC 023297-001 Revision: - 

93

4 Repair 


Refitting, lower arm 

The procedure below details how to refit the complete lower arm. 


1. Fit the lifting device and lift the 

lower arm into position. 

2. Fit the lower arm to gearbox, axis 

2, and secure it with its 

attachment screws and washers. 

3. Fit a new VK cover by gently 

tapping it into position. 

xx0300000097 

Parts: 

• A: Washer 

• B: Lower arm attachment screws (10 pcs) 

• C: VK cover 



4. Refit the console. Detailed in section Replacement of console on 

page 118. 

5. Recalibrate the robot. Calibration is detailed in separate calibration 

manuals. 

Art. no. for the manuals are specified in section 

Document references in the Product manual, 


94 


4 Repair 

4.2.4. Replacement of base, spare 


Location of base 

The base is located at the bottom of the manipulator as shown in the figure below. 



xx0200000423 

A 

Base 

B 

Bottom plate 

C 

Bottom plate attachment screws (26 pcs) 

D 

Gearbox/base attachment screws and washers (20 pcs each) 

E 

Joint, gearbox/base 

F Damper, axis 1 

G 

Washer 



Base, spare 3HAC 10470-1 Standard and Foundry 

versions 

Includes Parallel pin 3HAC 

3785-2 

Base, spare 3HAC 10470-3 Clean room versions 

Includes Parallel pin 3HAC 

3785-2 

Lifting slings - Min. capacity 20 kg 

3HAC 023297-001 Revision: - 

95

4 Repair 



LocTite 574 

For sealing the base to the 

gearbox 1-2 







required. See 


procedures in the 

step-by-step 




required. 

Removal, base 

The procedure below details how to remove the base. 

WARNING! 







Step Action Info 

1. Remove motors 1 and 2. Detailed in sections Replacement of 

motor, axis 1 on page 130 and 

Replacement of motor, axis 2 on page 

135 respectively. 

2. Remove the cable harness. Detailed in section Replacement of 

cable harness on page 78. 

3. Remove the serial measurement board. Detailed in section Replacement of 

serial measurement unit and battery 

pack on page 122. 

4. Remove the complete upper arm. Detailed in section Replacement of 

complete upper arm on page 85. 

5. Remove the complete lower arm. Detailed in section Replacement of 

complete lower arm on page 91. 

6. Place the remaining base/gearbox axes 1- 

2 assembly upside down on a work bench. 

Remove the bottom plate. 

7. Remove the gearbox/base attachment 

screws. 

8. Separate the base from the gearbox 1-2. 

Shown in the figure Location of base. 


96 


4 Repair 


Refitting 

The procedure below details how to refit the complete lower arm. 

WARNING! 








1. Place the gearbox 1-2 and the base on a 

workbench. 

2. After making sure the mating surface 

between the base and gearbox is completely 

clean, apply Loctite to it. 

3. Secure the gearbox to the base with the 

gearbox/base attachment screws and 

washers. 

4. Refit the bottom plate and secure it with its 


5. Turn the base into standing upright. 

Art. no. is specified in section 

Required equipment on page 95. 


Tightening torque: 35 Nm ± 3Nm 


6. Refit the complete lower arm. Detailed in section Replacement of 

complete lower arm on page 91. 

7. Refit the complete upper arm. Detailed in section Replacement of 

complete upper arm on page 85. 

8. Refit motors 1 and 2. Detailed in sections Replacement of 

motor, axis 1 on page 130 and 

Replacement of motor, axis 2 on page 

135 respectively. 

9. Refit the serial measurement board. Detailed in section Replacement of 

serial measurement unit and battery 

pack on page 122. 

10. Refit the cable harness. Detailed in section Replacement of 

cable harness on page 78. 



Art. no. for the manuals are specified 

in section Document references in 

the Product manual, reference 

information. 

DANGER! 





3HAC 023297-001 Revision: - 

97

4 Repair 





98 


4 Repair 

4.3.1. Replacement of wrist unit 

4.3 Upper arm 


Location of wrist unit 

The wrist unit is located in the frontmost part of the upper arm. 



xx0200000438 

A 

B 

C 

Wrist unit attachment screws (3 pcs) 

Oil plug (one shown) 

Wrist unit 



Wrist unit (Std/F) 3HAC 10475-1 Standard and Foundry 

versions 

O-ring sealing plate not 

included! 

Wrist unit (CR) 3HAC 10475-4 Clean room versions 

O-ring sealing plate not 

included! 

O-ring sealing plate 3HAC 7191-1 Must be replaced 

Grease 3HAC 3537-1 For lubricating the o-ring 

sealing plate 

3HAC 023297-001 Revision: - 

99

4 Repair 







Arm 3HAC 9037-1 For adjusting the gear play, 

motor/pinion 



required. See 



instructions 

below. 



required. 

Removal, wrist unit 

The procedure below details how to remove the complete wrist unit. 


1. 

- 

Danger! 

Turn off all electric power, hydraulic and pneumatic 

pressure supplies to the robot! 

2. Drain the oil from the wrist unit. Detailed in section Oil 

change, gearbox, axes 5 

and 6 on page 73. 

3. Remove the wrist unit by unscrewing its three 



section Location of wrist unit 

on page 99. 

Refitting, wrist unit 

The procedure below details how to refit the complete wrist unit. 


1. 

- 

Danger! 

Turn off all electric power, hydraulic and 

pneumatic pressure supplies to the robot! 

2. Run the robot to a position where the upper 

arm is vertical. The axis 5 motion plane 

should be horizontal. 

3. Lightly lubricate the o-ring sealing plate with 

grease. 

Art. no. is specified in section Required 

equipment on page 99. 

100 


4 Repair 



4. Fit the o-ring sealing plate and the wrist unit 

to the upper arm with the attachment 

screws, but do not tighten them. 

5. In order to release the brake, connect the 

24 VDC power supply to motors: 

Do not tighten its attachment screws! 

Connect to connector R3.MP5 or 6: 

• +: pin 7 

• -: pin 8 

6. Fit the Arm to the rear of the motor. Art. no. is specified in section Required 


7. Manually push the motor to adjust the motor 

in relation to the gear in the gearbox. 

Minimize the gear play as shown in the 

figure. 

xx0200000445 

• A: Wrist unit, axes 5 and 6 

gears 

• B: Drive shafts from motors, 

axes 5 and 6 gears 

• C: Adjustment direction 

• D: Gear play 

8. Tighten the wrist unit attachment screws. Tightening torque: 28 Nm ± 3 Nm 

9. Check the gear play by moving axes 5 and 

6 by hand. 

The gear play should be xx to pass the 

test. 

10. Perform a leak-down test. Detailed in section Leak-down test. 

11. Refill the wrist unit with oil. Detailed in section Oil change, 

gearbox, axes 5 and 6 on page 73. 

12. Recalibrate the robot! Calibration is detailed in separate 


Art. no. for the manuals are specified in 

section Document references in the 


information. 

DANGER! 








3HAC 023297-001 Revision: - 

101

4 Repair 

4.3.2. Replacement of damper, axis 3 


Location of damper, axis 3 

The damper, axis 3, is shown in the figure below! 



xx0200000427 




Damper axis 3 3HAC 7881-1 












These procedures 

include references to the 

tools required. 

102 


4 Repair 


Removal, damper axis 3 

The procedure below details how to remove the damper, axis 3. 


1. 

- 

Danger! 

Turn off all electric power, hydraulic and 

pneumatic pressure supplies to the robot! 

2. Run the robot to a position that enables access to 

damper, axis 3. 

3. Remove the damper by gently prying it from the 

cast tab. 


damper, axis 3 on page 102. 

Refitting, damper axis 3 

The procedure below details how to refit the damper, axis 3. 


1. 

- 

Danger! 



2. Run the robot to a position that enables access to the 

location where the damper, axis 3, is fitted. 

3. Refit the damper by gently pressing it onto the cast 

tab on the upper arm. 


of damper, axis 3 on page 

102. 

DANGER! 








3HAC 023297-001 Revision: - 

103

4 Repair 




The damper, axis 5, is located as shown in the figure below! 

xx0200000429 


B Recess 



Damper axis 5 3HAC 8964-1 

Standard toolkit 3HAC020812-001 The contents are defined 













104 


4 Repair 





1. 

- 

Danger! 



2. Run the robot to a position that enables the end of the 

damper to be pushed into the recess in the wrist unit 

3. Unhook the end of the damper, and push it into the 

recess. 

4. Manually move the wrist (robot axis 5) away from the 

damper to pull it out. 


section Location of damper, 

axis 5 on page 104. 




1. 

- 

Danger! 



2. Push the end of the damper into the gap between the 

wrist unit and upper arm. 

3. Manually move the wrist (robot axis 5) in order to pull 

the damper into position. 

4. Fold out the damper hooks to secure it in position. 

Make sure the damper is 

turned the correct way! 

DANGER! 

When performing the first test run after a service activity (repair, installation or maintenance), 


• - all the service tools and other foreign objects are removed from the manipulator! 

• - all normal safety equipment is installed properly, e.g. TPU enabling device. 

• - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach 


• - special attention is paid to the function of the part previously serviced. 

3HAC 023297-001 Revision: - 

105

4 Repair 

4.3.4. Replacement of cover, arm housing 


Location of cover, armhousing 

The cover, armhousing is located on the rear of the upper arm as shown in the figure below. 



xx0200000464 

A 

B 

C 

Cover, arm housing 

Attachment screws, cover, armhousing 

Gasket, upper arm cover 


Equipment, etc. Spare part. no. Art. no. Note 

Cover, arm housing 3HAC 10473-1 Standard and Foundry 

version 

Includes gasket 3HAC 

7867-1 

Cover, arm housing 3HAC 10473-3 Clean Room versions 


7867-1 

Gasket, upper arm cover 3HAC 7867-1 

Standard toolkit 3HAC020812-001 The contents are 

defined in section 

Standard toolkit in the 

Product manual, 









include references to 


106 


4 Repair 


Removal 

The procedure below details how to remove the cover, armhousing. 

WARNING! 








1. Manually, run the robot to a position that enables 

access to the rear of the upper arm. 

2. Remove the cover, armhousing by unscrewing its 



of cover, armhousing on 

page 106. 

NOTE! Do not damage the 

gasket inside the cover! 

Refitting 

The procedure below details how to refit cover, armhousing. 

WARNING! 









access to the rear of the upper arm. 

2. Make sure the gasket inside the cover, arm housing 

has not been damaged. 

3. Secure the cover, arm housing to the upper arm with 

its attachment screws. 



page 106. 

Replace if damaged. 



page 106. 

3HAC 023297-001 Revision: - 

107

4 Repair 

4.4.1. Replacement of lower arm cover and gasket 

4.4 Lower arm 


Location of lower arm cover and gasket 

The lower arm cover and gasket are located as shown in the figure below. 



xx0200000433 

A 

B 

C 

D 

Lower arm 

Gasket lower-arm cover 

Cover l. arm, spare (without lamp unit) 

Cover l. arm, spare (with lamp unit) 

108 


4 Repair 




Cover l. arm, spare, Std/F 3HAC 10471-1 Standard and Foundry 

versions 

No lamp unit included 


7869-1 

Cover l. arm, spare, CR 3HAC 10471-3 Clean room versions 

No lamp unit included 


7869-1 

Gasket lower-arm cover 3HAC 7869-1 

Isopropanol 1177 1012-208 For cleaning sealing 

surfaces 














Removal, lower arm cover and gasket 

The procedure below details how to remove the lower arm cover and gasket. 

WARNING! 








1. Remove the lower arm cover by unscrewing its 


2. If the gasket is to be replaced, proceed below! 

Use a knife to gently remove the old gasket from the 

cover. 

3. Clean the sealing surface with isopropanol, making 

sure it is completely clean and free from scratches 

and burrs. 


of lower arm cover and 

gasket on page 108. 


Required equipment on 

page 109. 

3HAC 023297-001 Revision: - 

109

4 Repair 


Refitting, lower arm cover and gasket 

The procedure below details how to refit the lower arm cover and gasket. 

WARNING! 


• - Motors and gears are HOT after running the robot! Burns may result from touching 


• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 

• - Take any necessary measures to ensure that the manipulator does not collapse as 

parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2. 


1. If the Gasket lower-arm cover is to be replaced, 

proceed below. If not, see further down! 

2. Remove the protective backing from the selfadhesive 

gasket and fit it onto the cover sealing 

surface. 




Make absolutely sure it is 

correctly located! 

3. Refit the lower arm coverwith its attachment screws. Shown in the figure Location 



110 


4 Repair 




The damper, axis 2, is located as shown in the figure below! 



xx0200000426 




Damper ax. 2 3HAC 7880-1 




required. See 



instructions 

below. 







required. 

3HAC 023297-001 Revision: - 

111

4 Repair 





1. 

- 

Danger! 



2. Run the robot to a position that enables you to access the 

attachment screw of damper, axis 2. 

3. Remove the damper by unscrewing the single attachment 

screw and washer. 




1. 

- 

Danger! 



2. Run the robot to a position that enables access to the 

attachment screw of the damper, axis 2. 

3. Secure the damper with its single attachment screw 

and washer. 

1 pc: M6 x 16. 

DANGER! 








112 


4 Repair 

4.4.3. Replacement of indicator lamp 


Location of indicator lamp 

The indicator lamp is located on the side of the lower arm as shown in the figure below. 



xx0200000472 

A 

B 

Indication lamp 

Lower arm cover 


Equipment, etc. Spare part no. Art. no. 

Note 

Indicator lamp 3HAC 9258-1 




information! 



required. See 



step-by-step 




required. 

3HAC 023297-001 Revision: - 

113

4 Repair 


Removal 

The procedure below details how to remove the indicator lamp. 

WARNING! 








1. Remove the lower arm cover. Detailed in section 

Replacement of lower arm 

cover and gasket on page 

108. 

2. Remove the damper by gently prying the plastic semitransparent 

damper from the cast tab. 

Refitting 

The procedure below details how to refit the indicator lamp. 

WARNING! 








1. Run the robot to a position that enables access to 

damper, axis 3. 

2. Refit the damper by gently pressing it onto the cast 

tab on the upper arm. 

DANGER! 








114 


4 Repair 

4.5.1. Replacement of cover, console 

4.5 Frame and base 


Location of cover, console 

The cover, console is located on top of the console as shown in the figure below. 



xx0200000462 

A 

B 

C 

D 

Cover, console 

Attachment screws, cover, console (4 pcs) 

Gasket 

Console 



Cover, console, spare 3HAC 10472-1 Standard and Foundry 

version 


7868-1 

Cover, console, spare 3HAC 10472-3 Clean Room versions 


7868-1 

Gasket, cover console 3HAC 7868-1 

3HAC 023297-001 Revision: - 

115

4 Repair 






required. See 



instructions 

below. 


in section Standard 

toolkit in the Product 


information! 




Removal 

The procedure below details how to remove the cover, console. 

WARNING! 









access to the top of the console. 

2. Remove the cover, console by unscrewing its 



cover, console on page 115. 

NOTE! Do not damage the 

gasket inside the cover! 

Refitting 

The procedure below details how to refit cover, console. 

WARNING! 








1. Manually, move the robot to a position that enables 

access to the top of the console. 



116 


4 Repair 



2. Make sure the gasket inside the cover, console 


3. Secure the cover, console to the console with its 


Replace if damaged. 



3HAC 023297-001 Revision: - 

117

4 Repair 

4.5.2. Replacement of console 


Location of console 

The console is located on top of gearbox, axes 1-2 as shown in the figure below. 



xx0200000462 

A 

B 

C 

D 

Cover, console 

Attachment screws, cover, console (4 pcs) 

Gasket 

Console 



Console, spare 3HAC 10478-1 Standard and Foundry 

version 

Console, spare 3HAC 10478-3 Clean Room versions 














118 


4 Repair 


Removal 

The procedure below details how to remove the cover, console. 

WARNING! 








1. Remove the cable harness. Detailed in section Replacement of cable harness 

on page 78. 

2. Remove the serial 

measurement board. 

3. Remove the complete upper 

arm. 

4. DO NOT under any 

circumstance unscrew the six 

screws on top of the lower 

arm! Doing so will cause the 

manipulator to require a 

complete rebuild! 



Detailed in section Replacement of complete upper 

arm on page 85. 

xx0300000101 

Parts: 

• A: DO NOT touch these screws! (Note! Only 

two screws shown!) 

5. Remove the motor of axis 3. Detailed in section Replacement of motor and 

timing belt, axis 3 on page 139. 

6. Attach the lifting device to the 

lower arm. 

3HAC 023297-001 Revision: - 

119

4 Repair 



7. Remove the bearing hub by 


screws. 

8. Remove the console by 


screws. 

xx0300000096 

Parts: 

• A: Console 

• B: Bearing hub 

• C: Bearing hub attachment screws (6 pcs) 

• D: Console attachment screws (10 pcs) 

• E: Washers (10 pcs) 


Refitting 

The procedure below details how to refit cover, console. 

WARNING! 







120 


4 Repair 



1. Refit the console and secure it with 

its attachment screws and washers. 

2. Refit the bearing hub and secure it 

with its attachment screws. 

xx0300000096 

Parts: 

• A: Console 

• B: Bearing hub 

• C: Bearing hub attachment screws (6 

pcs) 

• D: Console attachment screws (10 pcs) 

• E: Washers (10 pcs) 




3. Refit the complete upper arm. Detailed in section Replacement of complete 

upper arm on page 85. 

4. Refit motor 3 and timing belt. Detailed in section Replacement of motor and 

timing belt, axis 3 on page 139. 

5. Refit the serial measurement board. Detailed in section Replacement of serial 

measurement unit and battery pack on page 

122. 

6. Refit the cable harness. Detailed in section Replacement of cable 

harness on page 78. 

7. Recalibrate the robot! Calibration is detailed in separate calibration 





3HAC 023297-001 Revision: - 

121

4 Repair 

4.5.3. Replacement of serial measurement unit and battery pack 


Location of serial measurement unit and battery pack 

The serial measurement unit and battery pack are located inside the manipulator base as 

shown in the figure below. 



xx0200000432 

A 

B 

C 

D 

E 

Rear cable cover 

Battery pack 

Serial measurement board (SMB) 

SMB attachment screws (4 pcs) 

Manipulator base bottom plate 



Serial measurement unit 3HAC 9522-1 

Battery pack 4944 026-4 NiCd type 

Battery pack 3HAB 9999-1 3 cell, lithium type 

Battery pack 3HAB 9999-2 6 cell, lithium type 

Cable tie 

Indoors 

Gasket base-cover 3HAC 7870-1 Replace only if required! 

122 


4 Repair 



Standard Toolkit, IRB 140 




to these procedures in the 

step-by-step instructions 

below. 


in section Standard 

toolkit in the Product 


information! 







information. 

Removal 

The procedure below details how to remove the serial measurement unit and battery pack. 

WARNING! 







DANGER! 

Follow these instruction to prevent the unit to be damaged from ESD: 

• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to 

electrostatic voltages. 

• Before handling, make sure you are grounded through a special ESD wrist bracelet or 

similar. 

CAUTION! 

This component is classified as Hazardous waste and must be disposed of accordingly! 

If in doubt of the correct disposal procedure, please contact your local environmental 

authority! 

3HAC 023297-001 Revision: - 

123

4 Repair 


CAUTION! 




1. Set the robot system to MOTORS OFF state. This will simplify calibration of the 

robot after replacement since no 

coarse calibration will be required. 

2. Remove the rear cable cover from the base of 

the robot by unscrewing its attachment screws. 

3. Remove the serial measurement unit by 

unscrewing its attachment screws . 

The removal is simplified by pushing the unit to 

the side and then pulling it backwards. 

4. If only the battery is to be replaced, disconnect 

the cables to the battery only! 

Disconnect all connectors from the serial 

measurement unit. 

5. Lift the board out. 

6. If the battery pack is to be replaced, proceed 

below! 

Cut the cable tie and disconnect the battery 

connector to remove the battery pack. 

Battery includes protection circuits. Replace it 

only with the specified spare part in the refitting 

instruction or with an ABB approved eqvivalent. 


serial measurement unit and 

battery pack on page 122! 




Connectors 

• R2.SMB 

• R2.FB1-3 

• R2.FB4-6 

• R2.G 




Refitting 

The procedure below details how to refit the serial measurement unit and battery pack. 

WARNING! 







DANGER! 

Follow these instruction to prevent the unit to be damaged from ESD: 

• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to 

electrostatic voltages. 

• Before handling, make sure you are connected to earth through a special ESD wrist 

bracelet or similar. 

124 


4 Repair 


CAUTION! 

This component is classified as Hazardous waste and must be disposed of accordingly! 

If in doubt of the correct disposal procedure, please contact your local environmental 

authority! 

CAUTION! 




1. Connect the new battery pack to the serial 

measurement unit and secure it with a cable tie. 

2. Reconnect all connectors to the unit. Connectors 

• R2.SMB 

• R2.FB1-3 

• R2.FB4-6 

• R2.G 

3. Place the serial measurement unit in position 

inside the manipulator base and secure it with its 

four attachment screws. 

4. Make sure the gasket sealing the rear cable cover 


Replace the gasket if required. 

5. Making sure all cables are correctly located 

behind the rear cable cover, refit it into position. 

Make sure no cables or other equipment fitted 

behind the cover get pinched by the cover. 

6. Secure the rear cable cover to the base of the 

robot with its attachment screws. 









122! 







7. This is valid if NiCd type batteries are used only! 

Lithium batteries do not require charging before 

use. 

Recharge the battery for at least 36 hrs by leaving 

the mains supply switched on for this amount of 

time. 

8. Recalibrate the robot! Calibration is detailed in 

separate calibration manuals. 



references in the Product 

manual, reference information. 

3HAC 023297-001 Revision: - 

125

4 Repair 

4.5.4. Replacement of control cable 


Location of control cable 

The control cable is located on the rear of the manipulator base as shown in the figure below. 



xx0200000467 

A 

B 

C 

Gasket, base-cover 

Attachment screws and washers (9 pcs each), control cable 

Control cable, spare 



Control cable, spare 3HAC 10476-1 3 m 

Standard and Foundry 

versions 

Cover gasket included 



versions 




versions 




versions 


126 


4 Repair 





versions 



Clean Room versions 



























required. 

Removal 

The procedure below details how to remove the control cable. 

WARNING! 







3HAC 023297-001 Revision: - 

127

4 Repair 



1. Make sure the robot system has been 

switched off, and that no power is 

supplied to the manipulator. 

2. Remove the Control cable, spareby 

unscrewing its attachment screws. 

3. Disconnect connectors inside the 

manipulator base. 

Shown in the figure Location of control cable 

on page 126. 

Make sure the gasket does not get 

damaged! 

4. Pull the cable out of the manipulator 

base. 

5. Disconnect the connectors from the 

control cabinet. 

xx0300000090 

Connectors: 

• A: R1.MP1-3 

• B: R1.CS 


• D: R1.MP4-6 

128 


4 Repair 


Refitting 

The procedure below details how to refit control cable. 

WARNING! 








1. Place the control cable on the floor with 

the manipulator base cover close to the 

manipulator. 

2. Connect the connectors inside the 

manipulators base. 

Shown in the figure Location of control 

cable on page 126. 

xx0300000090 

Connectors: 

• A: R1.MP1-3 

• B: R1.CS 


• D: R1.MP4-6 

3. Fit a new gasket when refitting the cover. Included in the spare part 

4. Fit the cover onto the manipulator base 

and secure it with its attachment screws. 

Shown in the figure Location of control 

cable on page 126. 

3HAC 023297-001 Revision: - 

129

4 Repair 

4.6.1. Replacement of motor, axis 1 

4.6 Motors 


Location of motor axis 1 

The motor axis 1 is located on the rear of the manipulator as shown in the figure below: 



xx0200000407 

A Motor, axis 1 

B 

Cover for connector access 

C 

Motor attachment screws (4 pcs) 

D 

Cable gland attachment screws (4 pcs) 

E 

Console 


Equipment, etc. Spare part no. Art no. Note 

Rot. ac motor with 

pinion 


pinion 

Rot. ac motor w 

pinion TStd/TF 

3HAC 10469-3 

3HAC 021966-001 

3HAC 10469-1 

3HAC 021965-001 

3HAC 10469-4 

Clean room versions. 


versions. 

High performance version. 

O-ring 2152 2012-426 Must be replaced when 

replacing motor! 

Included in the spare parts 

motor kits 

Cable gland gasket 3HAC xx Fitted onto the console 

cable gland 

130 


4 Repair 


Equipment, etc. Spare part no. Art no. Note 

Grease 3HAB 3537-1 Used to lubricate the o-ring 







motor/pinion 

Power supply 

24 VDC, max. 1,5 A 

For releasing the brakes 



required. See 



step-by-step 




required. 

Circuit Diagram 3HAC 6816-3 See chapter Circuit diagram 



3HAC 023297-001 Revision: - 

131

4 Repair 


Removal 

The procedure below details how to remove motor, axis 1. 

CAUTION! 

If the manipulator normally works in an inverted position, it must be removed from this 

position and placed on the floor before the work detailed in this instruction may be carried 

out ! 

WARNING! 







NOTE! 

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is 

used! 


1. Remove the Cover for connector access on top of 

the motor by unscrewing its four attachment screws. 

2. Disconnect the motor 1 connectors inside the 

console. 

3. Cut any cable ties and remove any brackets securing 

the cables. 

4. Remove the cable gland by removing its attachment 

screws, and pull the cables out from the console. 

5. In order to release the brakes, connect the 24 VDC 

power supply: 

6. Remove the motor by unscrewing its four attachment 

screws and plain washers. 

7. Lift the motor to get the pinion away from the gear and 

disconnect the brake release voltage. 

8. Remove the motor by gently lifting it straight up. 


of motor axis 1 on page 130. 

Detailed in section 

Replacement of cover, 

console on page 115. 

Connectors: 

• R3.MP1 

• R3.FB1 



Connect to connector 

R3.MP1 

• +: pin 7 

• -: pin 8 



132 


4 Repair 


Refitting 

The procedure below details how to refit motor, axis 1. 

WARNING! 







NOTE! 


used! 


1. Make sure the mating surfaces on the motor 

and the gearbox are clean and free from burrs. 

2. Make sure the o-ring on the circumference of 

the motor is seated properly. Lightly lubricate 

the o-ring with grease . 

3. In order to release the brake, connect the 24 

VDC power supply: 

4. Fit the motor, making sure the motor pinion is 

properly mated to gearbox 1. 

5. Fit the motor with four attachment screws and 

plain washers. 



Connect to connector R2.MP1 

• +: pin 7 

• -: pin 8 

Make sure the motor is turned the 

right way, i.e. connections 

rearwards. 

Make sure the motor pinion does not 

get damaged! 

Tightening torque: approx 2 Nm 

6. Fit the Arm to the end of the motor shaft. Art. no. is specified in section 


7. Adjust the motor in relation to the gear in the 

gearbox. 

Use the Arm tool to wiggle the motor shaft 

back and forth to feel the play. 

There should be a barely noticable 

gear play. 

8. Tighten the motor attachment screws. Tightening torque: approx 11 Nm ± 1 

Nm 

9. Disconnect the brake release voltage. 

10. Make sure the cable gland gasket has not 

been damaged. Replace, if it has. 

11. Push the cables into the console, and refit the 

cable gland with its attachment screws. 



3HAC 023297-001 Revision: - 

133

4 Repair 



12. Perform a leak-down test. Detailed in section . 







134 


4 Repair 




The motor axis 2 is located on the front of the manipulator as shown in the figure below. 



xx0200000408 

A Motor, axis 2 

B 

Cover for connector access 

C 

Motor attachment screws (4 pcs) 

D 

Cable gland attachment screws (4 pcs) 

E 

Console 




pinion, spare 


pinion, spare 


pinion, spare, 

TStd/TF 

3HAC 10469-3 

3HAC 021966-001 

3HAC 10469-1 

3HAC 021965-001 

3HAC 10469-4 

Clean room versions. 


versions. 

High performance version. 

O-ring 2152 2012-426 Must be replaced when 


Cable gland gasket 3HAC xx Fitted onto the console cable 

gland 

Grease 3HAB 3537-1 For lubricating the o-ring. 





information! 

3HAC 023297-001 Revision: - 

135

4 Repair 




motor/pinion 

Power supply 24 VDC, 1.5 A. 

For releasing the brakes. 



required. See 



step-by-step 




required. 

Circuit Diagram 3HAC 6816-3 See chapter Circuit diagram in 



Removal 


WARNING! 







NOTE! 


used! 


1. Remove the Cover for connector access on top of 

the motor by unscrewing its four attachment screws. 

2. Disconnect the motor 2 connectors inside the 

console. 

3. Cut any cable ties and remove any brackets securing 

the cables. 

4. Remove the cable gland by removing its attachment 

screws, and pull the cables out from the console. 

5. In order to release the brakes, connect the 24 VDC 

power supply: 

6. Remove the motor by unscrewing its four attachment 

screws and plain washers. 

7. Lift the motor to get the pinion away from the gear. 


section Location of motor 


Connectors: 

• R3.MP2 

• R3.FB2 


section Location of motor 


Connect to connector 

R3.MP2 

• +: pin 2 

• -: pin 5 



136 


4 Repair 




9. Remove the motor by gently pulling it out. 

There is a real danger of oil running out of the motor 

attachment hole when removing the motor. Take any 

necessary measures to collect the oil. 

10. Remove any remaining oil from the gearbox by 

siphoning it out. 

Refitting 


WARNING! 







NOTE! 


used! 


1. Make sure the mating surfaces on the motor and 

the gearbox are clean and free from burrs. 

2. Make sure the o-ring on the circumference of the 

motor is seated properly. Lightly lubricate the o- 

ring with grease . 

3. In order to release the brake, connect the 24 VDC 

power supply: 

4. Fit the motor, making sure the motor pinion is 

properly mated to gearbox 2. 

5. Fit the motor with four attachment screws and plain 

washers. 

Art no. is specified in section 


135. 


• +: pin 7 

• -: pin 8 

Make sure the motor is turned 

the right way, i.e. connections 

rearwards. 

Make sure the motor pinion 

does not get damaged! 

Tightening torque: approx 2 

Nm 

6. Fit the Arm to the end of the motor shaft. Art no. is specified in section 


135. 


gearbox. 

Use the Arm tool to wiggle the motor shaft back and 

forth to feel the play. 

There should be a barely 

noticable gear play. 

8. Tighten the motor attachment screws. Tightening torque: approx 11 

Nm ± 1 Nm 

3HAC 023297-001 Revision: - 

137

4 Repair 




10. Make sure the cable gland cover gasket has not 

been damaged. Replace if it has. 

Art no. is specified in section 


135. 

11. Push the cables into the console, and refit the cable 

gland with its attachment screws. 

12. Perform a leak-down test. Detailed in section Leak-down 

test. 

13. Refill the gearbox with oil. 

14. Recalibrate the robot! Calibration is detailed in 

separate calibration manuals. 



references in the Product 

manual, reference information. 

138 


4 Repair 

4.6.3. Replacement of motor and timing belt, axis 3 



The motor axis 3 is located behind the lower arm cover on the right hand side of the 

manipulator as shown in the figure below. 



xx0200000448 

A 


B 

Attachment screws, lower arm cover (13 pcs) 

C 

Belt shield 

D Motor 3 

E 

Attachment screws, belt shield (3 pcs) 

F 

Attachment screws, motor 3 (4 pcs) 

G 

Belt 

3HAC 023297-001 Revision: - 

139

4 Repair 





pinion 

3HAC 7866-1 

3HAC 021756-001 

Includes timing belt 

pulley. 

Timing belt 3HAC 6793-1 

Grease 3HAB 3537-1 For lubricating the o- 

ring. 








required. See 



instructions 

below. 







information. 

Removal 


WARNING! 







NOTE! 


used! 


1. Remove any equipment hindering 

access to the lower arm cover. 

2. Remove the lower arm cover by 


Shown in the figure in section Location of 

motor axis 3 on page 139. 



140 


4 Repair 



3. Cut the cable ties to facilitate 

accessing the motor. 

xx0200000449 








4. Disconnect motor connectors. Connectors: 

• R3.MP3 

• R3.FB3 

• R3.H1 (if Safety lamp is fitted) 

• R3.H2 (if Safety lamp is fitted) 

3HAC 023297-001 Revision: - 

141

4 Repair 



5. DO NOT under any circumstance 

unscrew the three screws securing the 

belt wheel! Doing so will cause the 

manipulator to require a complete 

rebuild! 

6. Remove the belt shield by unscrewing 

its twoattachment screws. 

7. Remove the remaining 

motorattachment screws. 

xx0300000102 

Parts: 

• DO NOT touch these screws! (3 pcs) 





8. Remove the belt. Shown in the figure in section Location of 


9. Remove the motor. Shown in the figure in section Location of 


Refitting 


WARNING! 








1. Make sure the mating surfaces on the 

motor and the lower arm are clean and 

free from burrs. 

2. Fit the motor in the lower arm. 

3. Fit the belt. Shown in the figure in section Location of 


4. Tighten the two motor attachment 

screws slightly, but not completely. 

142 


4 Repair 



5. Adjust the position of the motor in such a 

way that the correct belt tension is 

achieved. 

6. DO NOT adjust the belt tension using the 

intermediate wheel securing screws. 

7. Fit the belt shield and secure it with the 

two remaining screws. 

8. Tighten the last motor attachment 

screws. 

9. Refit the cabling as shown. 

Correct belt tension F=35 - 60 N 

Tightening torque: 4 Nm ± 0.5 Nm 


xx0200000449 









Art. no. for the manuals are specified in 

section Document references in the 

Product manual, reference information. 

3HAC 023297-001 Revision: - 

143

4 Repair 



Location of motor, axis 4 

The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. 



xx0200000455 

A 

Attachment screws, motor 4 (4 pcs) 

B Motor, axis 4 

C 

O-ring 




pinion 

3HAC 7842-1 

3HAC 021757-001 

Standard, Clean Room and 

Foundry versions 

Does not include the o-ring! 

O-ring 3HAC 3772-24 Must be replaced when 


Grease 3HAC 3537-1 Used to lubricate the o-ring. 






Power supply 24 VDC, max. 1,5 A. 

For releasing the brakes. 

Arm 3HAC 9037-1 For adjusting the gear play 

144 


4 Repair 





required. See 



step-by-step 




required. 




information. 

Removal 


WARNING! 







NOTE! 


used! 


1. Remove the motors for axes 5 and 6. Detailed in section 

Replacement of motor and 

timing belt, axes 5 or 6 on page 

147. 

2. Manually run the manipulator to a position where 

the upper arm points straight down. 

3. Remove the motor, axis 4 by unscrewing the motor 


4. In order to release the brake, connect the 24 VDC 

power supply: 

This will enable the motor 4 to 

be removed without draining 

the oil in the gearbox. 


motor, axis 4 on page 144. 


• +: pin 7 

• -: pin 8 

5. Lift the motor to get the pinion away from the gear 

and disconnect the brake release voltage. 

6. Remove the motor by gently lifting it straight out. Make sure the motor pinion is 

not damaged! 

3HAC 023297-001 Revision: - 

145

4 Repair 


Refitting 


WARNING! 







NOTE! 


used! 



and the gearbox are clean and free from burrs. 

2. Make sure the o-ring on the circumference of 

the motor is seated properly. Lightly lubricate 

the o-ring with grease . 

3. In order to release the brake, connect the 24 

VDC power supply: 






• +: pin 7 

• -: pin 8 

4. Fit the motor with the attachment screws. Tightening torque: approx. 2 Nm 

5. Fit the Arm to the end of the motor shaft. Art. no. is specified in section 



gearbox. 

Use the Arm tool to wiggle the motor shaft 

back and forth to feel the play. 

There should be a barely noticable 

gear play. 

7. Tighten the motor attachment screws. Shown in the figure Location of 



8. Refit motors 5 and 6. Detailed in section Replacement of 

motor and timing belt, axes 5 or 6 on 

page 147. 








146 


4 Repair 

4.6.5. Replacement of motor and timing belt, axes 5 or 6 


Location of motor and timing belt, axes 5 or 6 

The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the 

figure below. 



xx0200000453 

A 

B 

C 

D 

E 

F 


Attachment screws, lower arm cover 

Cover, armhousing 

Attachment screws, cover armhousing (4 pcs) 

VK cover 

Pressurized air hose (on front of upper arm) 

3HAC 023297-001 Revision: - 

147

4 Repair 


G 

CS connector 

H 

Cable guide 

J 

Attachment screws, cable guide 

K 

Belt shield 

L 

Attachment screws, belt shield 

M 

Motor attachment screws, 4 pcs per motor 

N 

Attachment screws, motor console 

P 

Clamping unit screws 

Q 

Clamping unit 

R Timing belt, axis 6 

S Pulley, axis 6 

T 

Screws securing the pulley to the axis 5 drive shaft 

U Timing belt, axis 5 

V Pulley, axis 5 

W Motor console, ax. 5-6 

X Motor, axis 4 

Y Motor, axis 5 

Z Motor, axis 6 



Rot. ac motor with pinion 3HAC 7842-1 

3HAC 021757-001 

Rot. ac motor with pinion 3HAC 7841-1 

3HAC 021758-001 

Axis 4 

Standard, Clean room 

and Foundry versions. 

Axes 5 and 6 

Standard, Clean room 

and Foundry versions. 

Timing belt 3HAC 6779-1 Axes 5 and 6 

VK cover 3HAC 2166-13 

Clamping unit 3HAC 7939-1 


3HAC020812-001 The contents are 





Special socket xx 3HAC xx For fitting the CSconnector 










diagram in the 



148 


4 Repair 


Removal 

The procedure below details how to remove motor, axis 5 or 6. 

WARNING! 







NOTE! 


used! 


1. Run the robot to a position where the upper 

arm is close to horizontal 

2. Remove the lower arm cover by 


3. Remove the rear cover armhousing by 

unscrewing its four attachment screws. 

4. Disconnect all cables to/from motors 4-6. Connectors: 

• R3.MP4 

• R3.MP5 

• R3.MP6 

• R3.FB4 

• R3.FB5 

• R3.FB6 

5. Disconnect any connector from the CSconnector. 

6. Use a special socket to remove the CSconnector 

from the housing and pull it into 

the upper arm assembly. 

7. Remove the pressurized air connector from 

the housing and pull it into the upper arm 

assembly. 

8. Remove the VK-cover from the upper arm/ 

lower arm joint. 

Shown in the figure in section Location 

of motor and timing belt, axes 5 or 6 on 

page 147! 



page 147! 



page 147! 



page 147! 

Art. no. specified in section Required 

equipment 



page 147! 


equipment! 



page 147! 

Detailed in section Removing the VK 

cover on page 88. 

3HAC 023297-001 Revision: - 

149

4 Repair 



9. Remove the cable guide by unscrewing its 

two attachment screws. 

10. Gently pull the cables out of the upper arm. 

11. Remove the belt shield by unscrewing its 




page 147! 



page 147! 

12. Unscrew the motor attachment screws. Shown in the figure in section Location 


page 147! 

13. Unscrew the clamping unit screws Shown in the figure in section Location 


page 147! 

14. Use the previously removed clamping unit 

screws to press the clamping unit apart by 

inserting them into the adjacent holes in the 

clamping unit. 

15. Remove the clamping unit. 

16. Remove the pulley and belt from motor, 

axis 6. 

17. Remove the screws securing the pulley to 

the axis 5 drive shaft. 

18. Remove the pulley and belt from motor, 

axis 5. 

19. Remove the motor console, ax. 5-6 by 




page 147! 



page 147! 



page 147! 



page 147! 



page 147! 

150 


4 Repair 


Refitting 


WARNING! 







NOTE! 


used! 



and the console are clean and free from 

burrs. 

2. Fit the motors in the motor console without 

tightening the attachment screws. 

3. Fit the motor console in the upper arm 

housing. Secure with its attachment screws. 

4. Fit pulley, axis 5 and timing belt, axis 5 with 

their attachment screws and washers. 

5. Tighten the motor attachment screws to 

enable the motor to be shifted slightly. 


Location of motor and timing belt, 

axes 5 or 6 on page 147! 









This will facilitate adjustment of the 

belt tension. 

6. Adjust the belt tension by xx. Correct belt tension F=35 - 60 N 

7. Secure the motor with its attachment screws Tightening torque: 4 Nm ± 0.5 Nm 

including the ones in the motor console. 

8. Fit pulley, axis 6 and timing belt, axis 6 with 

their attachment screws and washers. 

9. Fit the clamping unit and secure it with its 

clamping unit attachment screws. 









10. Repeat the belt adjustment procedure 

detailed above for the remaining motor. 

11. Secure the motor with its attachment screws. Tightening torque: 4 Nm ± 0.5 Nm 

12. Fit the belt shield with its attachment screws. Shown in the figure in section 




3HAC 023297-001 Revision: - 

151

4 Repair 



13. Pull the pressurized air connector through 

the housing and secure it into fitting in the 

upper arm assembly. 

14. Pull the CS-connector through the housing 

and secure it into the fitting in the upper arm 

assembly. 

Use a special socketto secure it. 

15. Reconnect any connector to the CSconnector. 

16. Reconnect all cables to/from motors 4-6. Connectors 

• R3.MP4 

• R3.MP5 

• R3.MP6 

• R3.FB4 

• R3.FB5 

• R3.FB6 

17. Refit the cable guide with its two attachment 

screws. 

18. Fit a newVK-cover to the upper arm/lower 

arm joint. 

Gently knock it into position. 

19. Refit the rear cover armhousing with its four 






equipment 





equipment 











equipment 

Use a plastic mallet or similar. 




20. Refit any brackets securing any exterior 

cabling to the upper arm with their 

attachment screws respectively. 



Art. no. for the manuals are specified 

in section Document references in the 


information. 

152 


4 Repair 

4.6.6.1. Measuring the gear play, axis 5 

4.6.6. Adjustments and measurements 


General 

After reassembly due to repair work or any other reason, the gear play must be checked to 

ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed 

below. 

Certain measurement tools must be fashioned to enable measuring. The dimensions of these 

are specified. 


Equipment, etc. Art no. Note 




Arm 3HAC 9037-1 For adjusting the gear play, motor/pinion 

Measurement dial with 

Measuring range 0-xx mm, accuracy xx 

magnetic base 

Power supply 

24 VDC, max. 1,5 A 









WARNING! 







3HAC 023297-001 Revision: - 

153

4 Repair 


Measurement 

The procedure below details how to measure the gear play for axis 5. 


1. Manually, turn axis 4 90°. 

2. Fit the dial fitting arm and dial 

to the manipulator turning disk 

as shown in the figure. 

Apply the 40 N load as shown. 

3. Remove the load and read 

Value 1. 

4. Apply 40 N load as shown. 

xx0200000457 


Value 2. 

xx0200000458 

6. Calculate the gear play value. Gear play value = value 1 - value 2 

7. Determine whether or not the OK < 0.18 mm (4.1 arc minutes) 

value is OK. 

154 


4 Repair 



General 

After reassembly due to repair work or any other reason, the gear play must be checked to 

ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed 

below. 

Certain measurement tools must be fashioned to enable measuring. The dimensions of these 

are specified. 


Equipment, etc. Art no. Note 




Arm 3HAC 9037-1 For adjusting the gear play, motor/pinion 

Measurement dial with 

Measuring range 0-xx mm, accuracy xx 

magnetic base 

Power supply 

24 VDC, max. 1,5 A 





to these procedures in the 

step-by-step instructions 

below. 



WARNING! 







3HAC 023297-001 Revision: - 

155

4 Repair 


Measurement 

The procedure below details how to measure the gear play for axis 6. 


1. Manually, turn axis 4 90°. 

2. Fit the dial fitting arm and dial to 

the manipulator turning disk as 

shown in the figure. 

Apply the 40 N load as shown. 


Value 1. 

4. Apply 40 N load as shown. 

xx0200000460 


Value 2. 

xx0200000461 

6. Calculate the gear play value. Gear play value = value 1 - value 2 

7. Determine whether or not the OK < 0.30 mm (10.3 arc minutes) 

value is OK. 

156 


4 Repair 

4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 

4.7 Gearboxes 


Location of gearbox axes 1-2 

The axes 1-2 gearbox is located as shown in the figure below. Note that both gearboxes, 1 and 

2, are a single unit! 

The damper, axis 1, is shown in the figure in the procedure! 



xx0200000422 

A Gearbox, axis 1-2 



Note 

Gearbox, ax. 1-2 

spare, Std/F 

Gearbox, ax. 1-2 

spare, CR 

3HAC 10467-1 

3HAC 10467-3 

Standard and Foundry versions 

Includes gearbox 3HAC 6603-1 

Includes all required lubricant! 

Includes all o-rings and sealing 

rings! 

Clean room version 

Includes gearbox 3HAC 6603-1 

Includes all required lubricant! 

Includes all o-rings and sealing 

rings! 

Damper, axis 1 3HAC 7527-1 

Flange sealing 1234 0011-116 2 ml 

LocTite, 574 3HAC xx For sealing gearbox/base 

Sealing ring 3HAC 6965-1 Replace only when damaged! 

3HAC 023297-001 Revision: - 

157

4 Repair 



Note 




information! 

Lifting device, 

gearbox 1-2 


procedures may 

be required. See 

references to 

these procedures 

in the step-by-step 


3HAC xx 


references to the tools required. 

Removal, gearbox 1-2 

The procedure below details how to remove gearbox, axes 1-2. 

WARNING! 







NOTE! 


used! 

CAUTION! 

Caution! 

The gear box weighs 39 kg! All lifting equipment used must be dimensioned accordingly! 


1. Remove motor 1. Detailed in section Replacement of motor, axis 1 

on page 130. 

2. Remove motor 2. Detailed in section Replacement of motor, axis 2 

on page 135. 

3. Remove the cable harnesses. Detailed in section Replacement of cable harness 

on page 78. 

4. Remove the serial measurement 

board. 


measurement unit and battery pack on page 

122Replacement of serial measurement unit and 

battery pack on page 122. 

5. Remove the upper arm. Detailed in section Replacement of complete 

upper arm on page 85. 

6. Remove the lower arm. Detailed in section Removal of complete lower 

arm. 

7. Drain the oil from gearbox 1. 

158 


4 Repair 



8. Fit the lifting tool to the base/ 

frame and turn it upside down on 

top of a suitable workbench. 

9. Remove the bottom plate by 

unscrewing its 26 attachment 

screws. 

Art. no. is specified in section Required 


10. Remove the gearbox/base 

attachment screws and lift the 

gearbox 1-2 away from the base. 

xx0200000423 

• A: Gearbox 1-2 

• B: Bottom plate 

• C: Bottom plate attachment screws (26 

pcs) 

• D: Gearbox/base attachment screws (20 

pcs) 

• E: Joint, gearbox/base 

• F: Damper, axis 1 

Shown in the figure Location of gearbox axes 1-2 

on page 157. 

Removal of damper, axis 1 



1. Open the base of the robot. Detailed in section Removal, 

gearbox 1-2 on page 158. 

2. Remove the damper, axis 1. 

Refitting of damper, axis 1 



1. Fit the damper, axis 1. Shown in the illustration 

Refitting, gearbox 1-2 on 

page 160. 

2. Proceed with assembling the robot. Detailed in section Refitting, 

gearbox 1-2 on page 160. 

3HAC 023297-001 Revision: - 

159

4 Repair 


Refitting, gearbox 1-2 

The procedure below details how to refit gearbox, axes 1-2. 

WARNING! 







NOTE! 


used! 

CAUTION! 

The gearbox weighs 39 kg! All lifting equipment used must be dimensioned accordingly! 


1. Place the gearbox 1-2 on a 

suitable workbench. 

2. Fit a small amount of LocTite 

574 onto the Joint, gearbox/ 

base. 

3. Fit the base to the gearbox unit 

and secure it with the 

attachment screws and the flat 

washer. 

4. Refit the bottom plate and 

secure it with its attachment 

screws. 

xx0200000423 

• A: Gearbox 1-2 

• B: Bottom plate 

• C: Bottom plate attachment screws (26 pcs) 

• D: Gearbox/base attachment screws (20 

pcs) 

• E: Joint, gearbox/base 

• F: Damper, axis 1 

• G: Washer 

Shown in the figure Location of gearbox axes 1-2 on 

page 157. 

Quality Gleitmo, tightening torque: 35 Nm ± 3 Nm. 

Shown in the figure Location of gearbox axes 1-2 on 

page 157. 

160 


4 Repair 



5. Fit the lifting tool to the base/ 

frame and turn it right side up 

on top of a suitable 

workbench. 

Art. no. is specified in section Required equipment 

on page 157. 

6. Refit the lower arm. Detailed in section Refitting of complete lower arm. 

7. Refit the upper arm. Detailed in section Refitting of complete upper arm. 

8. Refit the serial measurement 

board. 



9. Refit the cable harnesses. Detailed in section Refitting of cable harness. 

10. Refit motors 1 and 2. Detailed in section Refitting of motor 1 and Refitting 

of motor 2 respectively. 


12. Refill the gear box with oil. 

13. Recalibrate the robot. Calibration is detailed in separate calibration 





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161

4 Repair 

4.7.2. Service work on gearbox, axis 4 

4.7.2. Service work on gearbox, axis 4 

General 

The gearbox, axis 4, is intended to run without requiring any repairs or maintenance work. 

This implies that it must under no circumstances be opened or serviced. 

If it requires replacement, the complete upper arm is to be replaced. This procedure is detailed 

in section Replacement of complete upper arm on page 85. 

162 


5 Calibration information 




General 

This chapter includes general information about different calibration methods and details also 

procedures that does not require specific calibration equipment. 

When the robot system must be recalibrated, it is done according to documentation enclosed 

with the calibration tools. 

When to calibrate 

The system must be calibrated if any of the below occurs. 

The resolver values are changed 

If resolver values are changed, the robot must be recalibrated using the calibration methods 

supplied from ABB. Calibrate the robot carefully with standard calibration. The different 

methods are briefly described in section Calibration methods on page 164, and further 

detailed in separate Calibration manuals. 

If the robot has Absolute Accuracy calibration, it is also recommended but not always needed 

to be calibrated for new Absolute Accuracy. 

The resolver values will change when parts affecting the calibration position are replaced on 

the robot, e.g. motors, wrist or part of transmission. 

Contents of the revolution counter memory are lost 

If the contents of the revolution counter memory are lost, the counters must be updated as 

detailed in section Updating revolution counters on page 168. This will occur when: 

• the battery is discharged 

• a resolver error occurs 

• the signal between a resolver and measurement board is interrupted 

• a robot axis is moved with the control system disconnected 

The revolution counters must also be updated after the robot and controller are connected at 

the first installation. 

The robot is rebuilt 

If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other 

reachability, it needs to be recalibrated for new resolver values. 

If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute 

Accuracy. 

References 

The article numbers for the Calibration manuals are listed in section Document references in 

the Product manual (part 2 of 2), reference information. Article numbers for the calibration 

tools are also listed in part 2 of the Product manual. 

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163


5.2. Calibration methods 


Overview 

This section specifies the different types of calibration and the calibration methods that are 

supplied from ABB. 

Types of calibration 

Type of 

calibration 

Description 

Calibration method 

Standard 

calibration 

Absolute Accuracy 

calibration 

(optional) 

The calibrated robot is positioned at home 

position, i.e. the axes positions (angles) are 

set to 0º. 

Standard calibration data is found in the file 

calib.cfg, supplied with the robot at delivery. 

The file identifies the correct resolver/motor 

position corresponding to the robot home 

position. 

From deliveries together with RobotWare 5.0.5 

and higher, the data will instead be found on 

the SMB (serial measurement board) in the 

robot, and not in a separate file. 

Based on standard calibration, but besides 

positioning the robot at home position, the 

Absolute Accuracy calibration also 

compensates for: 

• mechanical tolerances in the robot 

structure 

• deflection due to load. 

Absolute Accuracy calibration focuses on 

positioning accuracy in the Cartesian 

coordinate system for the robot. 

Absolute Accuracy data is found in the file 

absacc.cfg, supplied with the robot at delivery. 

The file replaces the calib.cfg file and identifies 

motor positions as well as absacccompensation 

parameters. 

From deliveries together with RobotWare 5.0.6 

and higher, the data will instead be found on 

the SMB (serial measurement board) in the 

robot, and not in a separate file. 

A robot calibrated with AbsAcc has a sticker 

next to the identification plate of the robot. 

To regain 100% Absolute Accuracy 

performance, the robot must be recalibrated 

for Absolute Accuracy! 

Calibration Pendulum 

(standard method) 

or 

Levelmeter calibration 

(alternative method) 

CalibWare 

xx0400001197 

164 




Calibration methods 

Each calibration method is detailed in separate manuals. Below is a brief description of the 

methods available. 

Calibration Pendulum - standard method 

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 

6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the 

standard type of calibration. It is the recommended method in order to achieve proper 

performance. 

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, 

including the manual Calibration Pendulum Instruction. 

Levelmeter Calibration - alternative method 

Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots, 

because of the less accurate values obtained during calibration. The method uses the same 

principles as Calibration Pendulum but has not as good mechanical tolerances to the toolkit 

parts as the standard method with Calibration Pendulum. 

This method may, after calibration, require modifications in the robot program, and is 

therefore not recommended. 

The calibration equipment for Levelmeter Calibration is ordered as separate parts for each 

robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter 

2000. 

CalibWare - Absolute Accuracy calibration 

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy 

is used as a TCP calibration. The tool CalibWare guides through the calibration process and 

calculates new compensation parameters. This is detailed further in the manual CalibWare 2.0 

Users Guide. 

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy 

calibration is required in order to establish full performance. For most cases after motor and 

transmission replacements that do not include taking apart the robot structure, standard 

calibration is sufficient. Standard calibration also supports wrist exchange. 

3HAC 023297-001 Revision: - 

165


5.3. Calibration scales and correct axis position 

5.3. Calibration scales and correct axis position 

Introduction 

This section specifies the calibration scale positions and/or correct axis position for all robot 

models. 

Calibration scales, IRB 140 

The illustration below shows the calibration scale positions on IRB 140: 

xx0200000157 

166 



5.4. Calibration movement directions for all axes 

5.4. Calibration movement directions for all axes 

Calibration movement directions 

When calibrating, the axis must consistently be run towards the calibration position in the 

same direction, in order to avoid position errors caused by backlash in gears etc. Positive 

directions are shown in the figure below. 

This is normally handled by the robot calibration software. 

Note! The figure shows an IRB 7600, but the positive direction is the same for all robots, 

except the positive direction of axis 3 for IRB 6400R which is in the opposite direction! 

xx0200000089 

3HAC 023297-001 Revision: - 

167


5.5. Updating revolution counters 


General 

This section details how to perform a rough calibration of each robot axis, i.e. updating the 

revolution counter value for each axis, using either the TPU or the FlexPendant. 

Manually running the robot to the calibration position 

This procedure details the first step when updating the revolution counter; manually running 

the robot to the calibration position. 


1. Select axis-by-axis motion mode. 

2. Jog the robot so that the calibration marks lie 

within the tolerance zone. 

3. When all axes are positioned, store the 

revolution counter settings. 

Shown in section Calibration scales 

and correct axis position on page 

166. 

Detailed in sections: 

Storing the revolution counter setting 

with the TPU on page 169 

(RobotWare 4.0). 

Storing the revolution counter setting 

with the FlexPendant on page 170 

(RobotWare 5.0). 

Correct calibration position of axis 4 and 6 

When running the robot to calibration position, it is extremely important to make sure that 

axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have 

any mechanical stops and can therefore be calibrated at the wrong turn. 

Make sure the axes are positioned according to the correct calibration values, not only 

according to the calibration marks. The correct values are found on a label, located either on 

the lower arm or underneath the flange plate on the base. 

At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before 

the revolution counters are updated. 

If one of the below mentioned axes are rotated one or more turns from its calibration position 

before updating the revolution counter, the exact calibration position will be lost due to 

uneven gear ratio. This affects the following robots: 

Robot variant Axis 4 Axis 6 

IRB 140 Yes Yes 

168 




Storing the revolution counter setting with the TPU 

This section details the second step when updating the revolution counter; storing the 

revolution counter setting with the TPU (RobotWare 4.0). 


1. Press the button "Miscellaneous" then ENTER to select the 

service window. 

xx0100000194 

2. Select Calibration from the View menu. 

The Calibration window appears. 

If there is more than one unit connected to the robot, they will 

be listed in the window. 

xx0100000201 

3. Select the desired unit and choose Rev Counter Update 

from the Calib menu. 

The Revolution Counter Update window appears. 

xx0100000202 

4. Select the desired axis and press Incl to include it (it will 

be marked with an x) or press All to select all axes. 

5. Press OK when all axes that are to be updated are marked 

with an x. 

CANCEL returns to the Calibration window. 

3HAC 023297-001 Revision: - 

169




6. Press OK again to confirm and start the update. 

CANCEL returns to the Revolution Counter Update window. 

7. At this point, it is recommended that the revolution counter 

values are saved to a diskette. 

8. 

Not required. 

- 

Caution! 

If a revolution counter is incorrectly updated, it will cause 

incorrect robot positioning, which in turn may cause damage or 

injury! 

Check the calibration position very carefully after each update. 

How to perform the check is detailed in section Checking the 

calibration position on page 172. 

Storing the revolution counter setting with the FlexPendant 

This procedure details the second step when updating the revolution counter; storing the 

revolution counter setting with the FlexPendant (RobotWare 5.0). 

Step 

Action 

1. On the ABB menu, tap Calibration. 

All mechanical units connected to the system are shown along with their calibration 

status. 

2. Tap the mechanical unit in question. 

A screen is displayed: tap Rev. Counters. 

en0400000771 

170 




Step 

Action 

3. Tap Update revolution counters.... 

A dialog box is displayed, warning that updating the revolution counters may change 

programmed robot positions: 

• Tap Yes to update the revolution counters. 

• Tap No to cancel updating the revolution counters. 

Tapping Yes displays the axis selection window. 

4. Select the axis to have its revolution counter updated by: 

• Ticking in the box to the left 

• Tapping Select all to update all axes. 

Then tap Update. 

5. A dialog box is displayed, warning that the updating operation cannot be undone: 

• Tap Update to proceed with updating the revolution counters. 

• Tap Cancel to cancel updating the revolution counters. 

Tapping Update updates the ticked revolution counters and removes the tick from 

the list of axes. 

6. 

- 

Caution! 

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, 

which in turn may cause damage or injury! 

Check the calibration position very carefully after each update. 

See section Checking the calibration position on page 172. 

3HAC 023297-001 Revision: - 

171


5.6. Checking the calibration position 


General 

Check the calibration position before beginning any programming of the robot system. This 

may be done in one of two ways: 

• Using a MoveAbsJ instruction with argument zero on all axes 

• Using the Jogging window on the teach pendant 

Using a MoveAbsJ instruction on the TPU, S4Cplus 

This section describes how to create a program, which runs all the robot axes to their zero 

position 


1. Crate a new program 

2. Use MoveAbsJ 

3. Create the following program: MoveAbsJ 

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs 

, v1000, z50, Tool0 

4. Run the program in manual mode 

5. Check that the calibration marks for the axes align 

correctly. If they do not, update the revolution 

counters! 

The calibration marks are 

shown in section Calibration 

scales and correct axis 

position on page 166. 

How to update the revolution 

counters is detailed in section 

Updating revolution counters 

on page 168 

Using a MoveAbsJ instruction on the FlexPendant, IRC5 

This section describes how to create a program, which runs all the robot axes to their zero 

position. 


1. On ABB menu tap Program Editor. 

2. Create a new program. 

3. Use MoveAbsJ in the Motion&Proc menu. 

4. Create the following program: MoveAbsJ 

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff 

s, v1000, z50, Tool0 

5. Run the program in manual mode. 



counters! 





How to update the revolution 

counters is detailed in section 


on page 168. 

172 




Using the Jogging window on the TPU, S4Cplus 

This section describes how to jog the robot to all axes zero position. 

Step Action Illustration/information 

1. Open the Jogging window. 

2. Choose running axes-by-axes. 

xx0100000195 

3. Manually run the robot axes to a position where the 

axis position value read on the TPU, is equal to 

zero. 



counters! 

xx0100000196 





Detailed in section Updating 

revolution counters on page 

168. 

Using the Jogging window on the FlexPendant, IRC5 

This section describes how to jog the robot to all axes zero position. 


1. Tap Jogging in the ABB menu. 

2. Tap Motion mode to choose group of axes to jog. 

3. Tap axes 1-3 to jog axes 1, 2 or 3. 

4. Manually run the robots axes to a position where the 

axis position value read on the FlexPendant, is equal 

to zero. 



counters! 





How to update the counters 

is detailed in section 


on page 168. 

3HAC 023297-001 Revision: - 

173



174 


Index 

C 

Calibration position 168 

calibration position, checking 172 

calibration position, jog to 173 

Connection of external safety devices 15 

D 

direction of axes 167 

L 

Limitation of Liability 16 

N 

negative directions, axes 167 

P 

positive directions, axes 167 

R 

Revolution counters 168 

S 

Safety, service 15 

U 

Updating revolution counters 168 

V 

Validity and responsibility 15 

3HAC 023297-001 Revision: - 

175



176

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