IRC5-IRB140 Prod Man 3HAC023297-001 Procedures Rev - en

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 ABBs 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 Vsters 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 robots 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
3HAC 023297-001 Revision: -
Table of Contents
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.4 Replacement of base, spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78 85 91 95
4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4.3.3 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 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 4.4.2 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 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 4.6.2 Replacement of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 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 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 163 164 166 167
Table of Contents
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Table of Contents
Overview
Overview
About this manual This manual contains instructions for 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. mechanical and electrical installation of the robot maintenance of the robot mechanical and electrical repair of the robot.
Who should read this manual? This manual is intended for: Prerequisites The reader should... be a trained maintenance/repair craftsman have the required knowledge of mechanical and electrical installation/repair/ maintenance work. installation personnel maintenance personnel repair personnel.
Organization of chapters The manual is organized in the following chapters: Chapter

Safety, service
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.
Installation and commissioning Maintenance
Repair Calibration information Decommissioning
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.
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 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 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
In addition, spare part information is supplied for the entire option.
Product documentation, M2004

General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including intervals) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning)
Product manual, reference information 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. 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
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:
10
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)
Operators manuals
How to use the application Examples of how to use the application
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: 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) Operators manual - IRC5 with FlexPendant Operators manual - RobotStudioOnline Trouble shooting Manual for the controller and robot
11
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
8. Remove the rear attachment screws, gearbox.
Note/Illustration
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
3. Fit a new sealing, axis 2 to the gearbox.
Note/Illustration
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
1.1. Introduction
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.
13
1 Safety
1.2.1. Introduction
1.2 General safety information 1.2.1. Introduction

Definitions This section details general safety information for service personnel i.e. personnel performing installation, repair and maintenance work. Sections 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 manipulators arm Brake testing Risk of disabling function "Reduced speed 250 mm/s" Safe use of the Teach Pendant Unit enabling device Work inside the manipulators 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. Users 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.
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
Installation of safety devices Changing robot modes
Detailed in document
Product manual for the manipulator Users Guide
Section
Installation and commissioning Start-up Installation and commissioning
Restricting the working space Product manual for the manipulator
17
1 Safety
1.2.3.1. Safety risks during service work on robot
1.2.3. Safety risks 1.2.3.1. Safety risks during service work on robot
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
Caution!
Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot!
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!
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.
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 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). Safe design 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 Special safety regulations apply to pneumatic and hydraulic systems. Residual energy 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.
Safe design 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.
23
1 Safety
1.2.3.5. Safety risks during operational disturbances
1.2.3.5. Safety risks during operational disturbances

General Qualified personnel 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. 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.
Extraordinary risks 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.
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 robots 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 Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning 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.
27
1 Safety
1.2.4.2. Fire extinguishing
1.2.4.2. Fire extinguishing

NOTE! Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator or controller)!
28
1 Safety
1.2.4.3. Emergency release of the robots arm
1.2.4.3. Emergency release of the robots arm

Description In an emergency situation, any of the robots 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. Increased injury 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!
29
1 Safety
1.2.4.4. Brake testing
1.2.4.4. Brake testing

When 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. How to test 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.
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 manipulators working range
1.2.4.7. Work inside the manipulators working range

WARNING! If work must be carried out within the robots 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 robots 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.
33
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions 1.3.1. Safety signals, general

General 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.
Danger levels The table below defines the captions specifying the danger levels used throughout this manual.
Symbol
Designation
DANGER
Signification
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.
danger
WARNING
warning
ELECTRICAL SHOCK
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
1.3.1. Safety signals, general
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) 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
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
1.
Action
Info/Illustration
Before attempting to run the manipulator, Emergency stop equipment such as make sure all emergency stop equipment gates, tread mats, light curtains, etc. has been correctly installed and connected. If possible, use the hold-to-run button whenever possible. The hold-to-run button is used in manual mode, not in automatic mode. 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 Operators Manual, IRC5. How to use the hold-to-run control in RobotWare 4.0 is detailed in section The Teach Pendant unit in the Users Guide.
2.
3.
Make sure no personnel is present within the manipulator working range before pressing the start button.
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 Step
1.
Action
Use a wrist strap
Note/Illustration
Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. The mat must be grounded through a currentlimiting resistor. The mat should provide a controlled discharge of static voltages and must be grounded.
2. 3.
Use an ESD protective floor mat. Use a dissipative table mat.
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 Make sure that protective gear gearbox oil may require like goggles and gloves are handling hot oil of up to 90 C! always worn during this activity.
Hot oil! When opening the oil plug, Open oil plug carefully and keep there may be pressure present away from the opening. Do not in the gearbox, causing oil to overfill the gearbox when filling. spray from the opening!
-
Possible pressure build up in gearbox! 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.
Do not overfill!
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!
Do not mix types of oil!
38
1 Safety
Warning
Description
Warm oil drains quicker than cold oil.
Elimination / Action
When changing gearbox oil, first run the robot for a time to heat up the oil.
Heat up the oil! The specified amount of oil is After refilling, check the oil level. 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.
Specified amount depends on drained volume!
39
1 Safety
40
2 Installation and commissioning

2.1. Introduction

2.1. Introduction
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.
41

2.2.1. Pre-installation procedure
2.2 Unpacking 2.2.1. Pre-installation procedure

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: Step
1.
Action
Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation. Make sure the manipulator has not been damaged, by visually inspecting the manipulator and control cabinet exterior. Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator. If the manipulator is not to be installed directly, it must be stored.
Info/Illustration
2.
3.
Specified in section Weight, manipulator on page 42. Specified in section Storage conditions, manipulator on page 43.
4. 5.
Make sure the appointed operating Specified in section Operating environment of the manipulator conforms to conditions, manipulator on page 43. the specifications. Before taking the manipulator to its Specified in section : installation site, make sure the site conforms Loads on foundation, to applicable requirements. manipulator on page 43 Requirements on foundation, manipulator on page 43 Protection classes on page 44 Before moving the manipulator, make sure it Described in section Risk of tipping/ does not tip over! Stability on page 47. When these prerequisites have been met, the manipulator may be taken to its installation site. Detailed in section Lifting manipulator with lifting slings on page 48.
6.
7. 8.
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
Force xy (upright/suspended) Force z (upright) Forze z (suspended) Torque Mxy Mz
Endurance load (operation)

1300 N -1000 1000 N -2800 1000 N 1300 Nm 300 Nm
Max. load (emergency stop)

3200 N -1000 2000 N +1000 2000 N 220 Nm 750 Nm
Requirements on foundation, manipulator Requirement

Min. levelity Max. tilt Min. resonance frequency
Value
0.5 mm 5 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
43

Protection classes The table below shows the protection class of the main parts of the robot system:
Equipment
Manipulator Control cabinet Programming unit
Protection class
IP 67 IP 54 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
0 1 2 3 4 5 6 7 8
Position at wrist centre

X 450 70 314 765 255 -480 1 218 -670 Z 712 1092 421 99 -119 23 596 558 352
Angle (degrees)
Axis 2 0 0 0 +110 +110 -90 -90 +110 -90 Axis 3 0 -90 +50 -90 +4 -150 +50 -230 -90
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 The section below details instructions for making sure the manipulator does not tip over when it has not been safely secured to the foundation. Procedure 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.
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 2 3
Sling line for manipulator Sling line for manipulator 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. Step
1.
Action
Push the "brake release button" to release the holding brakes.
Info/Illustration
xx0200000069
A: Pushbutton
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. Step
1.
Action
Connect an external power supply to connector XP1.
Info/Illustration
xx0200000071
2. Push the "brake release button" to release the holding brakes.
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. Step
1.
Action
Remove the screws and dismount the cover on the back of the manipulator base.
Info/Illustration
xx0200000072
A: 13 0 V B: 15 24 V DC
50

Step
2. 3.
Action
Locate the R1.MP4-6 connector and disconnect. Connect an external power supply to release the holding brake on all axis.
Info/Illustration
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: Quality Suitable washer:
M12 Quality 8.8 Thickness: 2.5 mm Outer diameter: 24 mm Inner diameter: 13.4 mm 85 Nm
Tightening torque:
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
Guide sleeves
Art. no.
3HAC 9519-1
52

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

General 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 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 Users Guide chapter: System Parameters.
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.
55

2.3.6. Loads
2.3.6. Loads
General 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. References 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 Users Guide. Brake performance 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 robots 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 robots 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
Floor (pos 1) Tilted (pos 2) Wall (pos 3) Ceiling (pos 4)
Mounting Angle
0 45 90 180
Gravity Beta
0.000000 (Default) 0.785398 1.570796 3.141593
57

xx0200000066
Defining the parameters Following steps describes how to enter the correct gravity beta values. Step
1. 2. 3.
Action
Choose Topics: Manipulator. Choose Types: Robot. Select Master and press Enter.
Info/Illustration
xx0200000073
4. 5.
Select the desired parameter gravity beta and change its value. Press OK to confirm.
58

2.3.8. Bolt pattern
2.3.8. Bolt pattern

Hole configuration The illustration below shows the hole configuration used when securing the manipulator:
xx0200000085
59

2.3.8. Bolt pattern
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 2.4.1. Customer connections on manipulator

General For connection of extra equipment on the manipulator there are cables integrated into the manipulators cabling. There are both air and electrical connectors on the manipulator.
xx0200000074
Connections Connections
1. For air on base / upper arm 2. Signal connector on upper arm
Description
R1/4" Max. 8 bar/hose inner diameter: 6.5 mm FCI UT 071412SH44N connector Number of signals: 12 signals, 49V, 500mA
61

2.4.1. Customer connections on manipulator
Recommended parts To connect power and signal conductors to the upper arm connector, the following parts are recommended
xx0200000132
ABBs 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
3.1. Introduction
3 Maintenance
3.1. Introduction
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. Safety 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 the procedures. Make sure to read through the chapter Safety on page 13.
63
3 Maintenance
3.2.1. Maintenance schedule, IRB 140
3.2 Maintenance schedules 3.2.1. Maintenance schedule, IRB 140

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
Inspection Inspection Inspection Change Change Change
Equipment
Interval
Detailed in section:
Inspection, damper axes 2-3 on page 66 Inspection, robot cabling on page 68 Inspection, timing belts on page 69 Oil change, gearbox, axes 5 and 6 on page 73 Oil change, gearbox, axes 5 and 6 on page 73
Damper, axes 2-3 Regularly *) Cable harnesses Timing belts Gearbox 5, oil Gearbox 6, oil Measurement system, battery Regularly *) 36 mths 36 mths 36 mths
Depending on battery type Replacement of serial and operation pattern as measurement unit and specified in section Battery battery pack on page 122. type selection on page 65. Regularly *) Cleaning, complete robot on page 72
Clean
Complete manipulator
*) "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
3.2.1. Maintenance schedule, IRB 140
Battery type selection The table below shows the selection criteria for the three available battery types.
Operation pattern
Max. 4 weeks power off per year Weekend power off + operation pattern 1
Change interval, 3-cell lithium

60 mths 24 mths
Change interval, 6-cell lithium

60 mths 48 mths 24 mths
Nightly power off + operation patterns 1 and 2 12 mths
No longer change interval than 60 months are allowed regardless of the operation pattern due to material ageing, etc.
65
3 Maintenance
3.3.1. Inspection, damper axes 2-3
3.3 Inspection activities 3.3.1. Inspection, damper axes 2-3

Location of dampers, axes 2-3 The figure below shows the location of all the dampers to be inspected.
xx0200000426
Damper, axis 2
xx0200000427
Damper, axis 3
66
3 Maintenance
3.3.1. Inspection, damper axes 2-3
Required equipment Equipment

Standard toolkit
Art. no.
3HAC020812-001
Note
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. Action
Check all dampers for damage, such as cracks or existing impressions larger than 1 mm. Check attachment screws for deformation. If any damage is detected, the damper must be replaced with a new one! 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.
Step
1.
Note
Shown in the figure in section Location of dampers, axes 2-3 on page 66!
2. 3.
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. Required equipment Equipment
Standard toolkit
Art. no.
3HAC020812-001
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Circuit diagram 3HAC 6816-3
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.
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. Step
1.
Action
Visually inspect the control cabling between the manipulator and control cabinet. Look for abrasions, cuts or crush damages. Replace the cabling if wear or damage is detected.
Note
2.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000448
Timing belt, axis 3
69
3 Maintenance
xx0200000453
R V
Timing belt, axis 6 Timing belt, axis 5
Required equipment Equipment, etc.

Standard toolkit
Art. no.
3HAC020812-001
Note
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
70
3 Maintenance
Inspection The procedure below details how to inspect the timing belts. WARNING! Please observe the following before commencing any repair work on the manipulator: 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. Action
Gain access to each belt by removing covers, etc.
Step
1.
Note
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. 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. The belt tension should be: Axis 3: F = 35-60 N Axis 5: F = 35-60 N Axis 6: F = 35-60 N
2.
Check each belt for damage.
3.
Check each belt for tension. If the belt tension is not correct, it should be adjusted.
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.
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. Required equipment Equipment, etc.
May be used on Foundry versions only! Steam cleaner
Art. no. Note

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 Foundry versions only! High pressure water cleaner
Vacuum cleaner Cloth with mild detergent
May be used on Standard version
Dos and donts! The section below specifies some special considerations when cleaning the manipulator. Always! Never! 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! 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!
72
3 Maintenance
3.5.1. Oil change, gearbox, axes 5 and 6
3.5 Changing/ replacing activities 3.5.1. Oil change, gearbox, axes 5 and 6
Location of oil plugs The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000475
A B
Oil plug, gearbox axis 5 Oil plug, gearbox, axis 6

Lubricating oil
Art. no.
1171 2016-604 3HAC 0860-1
Note
Corresponds to: Optimol, BM 100 Amount, gearbox 5 and 6: 350 ml Capacity: 400 ml. The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Oil collecting vessel Standard Toolkit, IRB 140 3HAC020812-001
73
3 Maintenance
WARNING! Please observe the following before commencing any repair work on the manipulator: 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 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.
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. Step
1.
Action
Move the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position. 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. Move axis 4 90 to a position where the axis 6 oil plug faces downwards. Drain the oil from the gearbox.
Note
2.
Shown in the figure Location of oil plugs on page 73!
3. 4.
Vessel capacity specified in section Required equipment on page 73! This allows the remaining oil to be drained.
5. 6.
Move axis 4 another 90. 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. Step
1.
Action
Run the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position.
Note
2.
Remove the oil plug, axis 5.. Shown in the figure Location of The cavity behind the plugs, containing the oil, is oil plugs on page 73! common to gearboxes 5 and 6, but during draining, both must be removed. Fill oil in gearbox 5 until the oil level reaches the The figure shows the oil plug hole on the side of the wrist. manipulator positions for filling and draining respectively for a standing manipulator:
3.
xx0300000161
Positions: A: Draining position B: Filling position The figure shows the manipulator positions for filling and draining respectively for an inverted manipulator:
xx0300000162
Positions: A: Draining position B: Filling position The oil quality is specified in section Required equipment on page 73! 4. Refit the oil plug.
75
3 Maintenance
76
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
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. Required equipment 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. Safety 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.
77
4 Repair
4.2.1. Replacement of cable harness
4.2 Complete robot 4.2.1. Replacement of cable harness

Location of cable harness The cable harness runs from the base to the motors of axes 3-6. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. Required equipment Equipment, etc.
Cable harness
Spare part no. Art. no.

3HAC 7370-1
Note
Standard and Foundry versions Clean room version Includes cabling: Cable harness, power axis 1-3 Cable harness, power axis 4-6 Cable harness, signals axis 1-3 Cable harness, signals axis 4-6 Cable harness, customer connections
Standard toolkit
3HAC020812-001
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. 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! 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.
CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step
1. 2.
Action
Remove the serial measurement board. Disconnect connectors in the manipulator base.
Note/Illustration
Detailed in section Replacement of serial measurement unit and battery pack on page 122.
xx0300000090
Connectors: A: R1.MP1-3 B: R1.CS C: Air hose D: R1.MP4-6 3. Remove the cable holder by unscrewing its attachment screws.
xx0300000091
A: Cable holder B: Attachment screws C: Cable securing screws
79
4 Repair
Step
4.
Action
Note/Illustration
Remove the cables from the See figure above! cable holder by unscrewing the cable securing screws. Remove the cover, arm housing. Remove the lower arm cover. Detailed in section Replacement of cover, arm housing, IRB 140. Detailed in section Replacement of lower arm cover and gasket on page 108.
5. 6. 7. 8.
Gently knock out the VK cover. Detailed in section Removing the VK cover on page 88. Disconnect connectors in the rear of the upper 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 9. Remove the shield by unscrewing its attachment screws. See figure above!
10. Cut any cable ties securing the cabling inside the lower arm.
80
4 Repair
Step
Action
Note/Illustration
11. Disconnect the connectors inside the lower arm.
xx0200000449
12. Pull the cables out of the upper arm. 13. Remove the cover, console. 14. Disconnect the connectors inside the console and undo the cable holders.
G: Connectors R3.MP3 and R3.FB3
Detailed in section Replacement of cover, console on page 115. Connectors: R3.MP1 R3.MP2 R3.FB1 R3.FB2
15. Gently pull the cabling from the base up through the console. 16. Gently pull the cabling out of the lower arm.
81
4 Repair
Refitting, cable harness The procedure below details how to refit the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! 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.
Action
Refit in reverse order to what is detailed above. Detailed below are some recommendations on how to route the cables. Cable distribution in the cable holder in the manipulator base.
Note/Illustration
2.
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
Step
3.
Action
Cable layout in the lower arm.
Note/Illustration
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 G: Connectors R3.MP3 and R3.FB3
83
4 Repair
Step
4.
Action
Cable holder in the upper arm.
Note/Illustration
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
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
85
4 Repair

Upper arm, spare Std/F

3HAC 10466-1
Note
Standard and Foundry versions Includes all required sealings and gaskets. Clean room versions Includes all required sealings and gaskets.
Upper arm, spare CR
3HAC 10466-3
Sealing ring
3HAB 3732-13
To be replaced if damaged only Included in the upper arm assembly To be replaced if damaged only Included in the upper arm assembly The contents are defined in section Standard toolkit in the Product manual, reference information! For fitting the CSconnector These procedures include references to the tools required.
VK cover Gasket upper arm cover
3HAC 2166-13 3HAC 7867-1
Standard toolkit
3HAC020812-001
Special socket Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Removal, upper arm The procedure below details how to remove the complete upper arm. Step
1. 2.
Action
Run the manipulator arm to a horizontal position. Remove all brackets securing any exterior cabling to the upper arm by unscrewing their attachment screws respectively.
Note/Illustration
86
4 Repair
Step
3. 4.
Action
Note/Illustration
Remove the rear cover armhousing by unscrewing Shown in the figure Location of its four attachment screws. upper arm on page 85! 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!
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. 7.
Disconnect any connector from the CS-connector. Shown in the figure Location of upper arm on page 85! Use a special socket to remove the CS-connector from the housing and pull it into the upper arm assembly. Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! Shown in the figure Location of upper arm on page 85! Detailed in section Removing the VK cover on page 88. Shown in the figure Location of upper arm on page 85! Shown in the figure Location of upper arm on page 85!
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 attachment screws. 13. Lift the upper arm and place it on a secure surface.
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)
Step
1. 2.
Action
Remove the lower arm cover by unscrewing its attachment screws.
Note
Tap the VK coverwith a long blunt edged bar Make sure to press the through the hole in the lower arm to press it out. circumference of the VK cover evenly to avoid damaging it. Shown in the figure in section Location of upper arm on page 85! If the VK cover is damaged, it must be replaced Specified in section Refitting of on refitting. complete upper arm.
3.
88
4 Repair
Refitting The procedure below details how to refit the complete upper arm. Step
1.
Action
Check the sealing ring to see whether it is damaged. Replace if it is damaged! Lift the upper arm into position. Secure the upper arm with its six attachment screws. Gently pull all cables and hoses through the hole in the upper arm. Reconnect all connectors to motors 4-6.
Note
Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! Shown in the figure Location of upper arm on page 85! Tightening torque: 35 Nm 3 Nm
2. 3.
4. 5.
Connectors R3.MP4 R3.MP5 R3.MP6 R3.FB4 R3.FB5 R3.FB6 Shown in the figure Location of upper arm on page 85!
6. 7.
Refit the cable guide with its two attachment screws.
Pull the pressurized air connector through the Shown in the figure Location of housing and secure it into fitting in the upper upper arm on page 85! arm assembly. Pull the CS-connector through the housing and secure it into the fitting in the upper arm assembly. Use a special socketto secure it. Reconnect any connector previously connected externally to the CS connector. Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86!
8.
9.
10. Fit a newVK-cover to the upper arm/lower arm Shown in the figure Location of joint. upper arm on page 85! Gently knock it into position. Art. no. specified in section Required equipment on page 86! Use a plastic mallet or similar. 11. Refit the rear cover armhousing with its four attachment screws. 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. Shown in the figure Location of upper arm on page 85!
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000469
Lower arm
91
4 Repair

Lower arm, spare

3HAC 10468-1
Note
Standard and Foundry versions Includes all required bearings, oil and VK cover. Clean room versions Includes all required bearings, oil and VK cover.
Lower arm, spare
3HAC 10468-4
Standard toolkit
3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Lifting capacity xx kg For fitting the CSconnector These procedures include references to the tools required.
Lifting device for lower arm Special socket Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Removal, lower arm The procedure below details how to remove the complete lower arm. 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.
92
4 Repair
Step
1. 2.
Action
Remove the console. 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!
Info/Illustration
Detailed in section Replacement of console on page 118.
xx0300000101
Parts: A: DO NOT touch these screws! (Note! Only 2 screws are shown.) 3. Remove the VK cover by pressing a screwdriver, or similar, through it and pulling.
xx0300000097
Parts: A: Washer B: Lower arm attachment screws (10 pcs) C: VK cover 4. Unscrew thelower arm attachment screws. Also remove the washer. Raise the lifting device to remove the lower arm. Shown in the figure above!
5.
93
4 Repair
Refitting, lower arm The procedure below details how to refit the complete lower arm. Step
1. 2.
Action
Fit the lifting device and lift the lower arm into position. Fit the lower arm to gearbox, axis 2, and secure it with its attachment screws and washers.
Info/Illustration
xx0300000097
Parts: A: Washer B: Lower arm attachment screws (10 pcs) C: VK cover Tightening torque: 35 Nm 3 Nm 3. 4. 5. Fit a new VK cover by gently tapping it into position. Refit the console. Recalibrate the robot. Shown in the figure above! Detailed in section Replacement of console on page 118. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000423
A B C D E F G
Base Bottom plate Bottom plate attachment screws (26 pcs) Gearbox/base attachment screws and washers (20 pcs each) Joint, gearbox/base Damper, axis 1 Washer

Base, spare

3HAC 10470-1
Note
Standard and Foundry versions Includes Parallel pin 3HAC 3785-2 Clean room versions Includes Parallel pin 3HAC 3785-2
Base, spare
3HAC 10470-3
Lifting slings
Min. capacity 20 kg
95
4 Repair
Equipment
LocTite 574 Standard toolkit
Note
For sealing the base to the gearbox 1-2
3HAC020812-001
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Removal, base The procedure below details how to remove the base. 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. Action
Remove motors 1 and 2.
Step
1.
Info
Detailed in sections Replacement of motor, axis 1 on page 130 and Replacement of motor, axis 2 on page 135 respectively. Detailed in section Replacement of cable harness on page 78. Detailed in section Replacement of serial measurement unit and battery pack on page 122. Detailed in section Replacement of complete upper arm on page 85. Detailed in section Replacement of complete lower arm on page 91.
2. 3.
Remove the cable harness. Remove the serial measurement board.
4. 5. 6.
Remove the complete upper arm. Remove the complete lower arm.
Place the remaining base/gearbox axes 1- Shown in the figure Location of base. 2 assembly upside down on a work bench. Remove the bottom plate. Remove the gearbox/base attachment screws. Separate the base from the gearbox 1-2. Shown in the figure Location of base.
7. 8.
96
4 Repair
Refitting The procedure below details how to refit the complete lower arm. 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. Action
Place the gearbox 1-2 and the base on a workbench. After making sure the mating surface Art. no. is specified in section between the base and gearbox is completely Required equipment on page 95. clean, apply Loctite to it. Secure the gearbox to the base with the gearbox/base attachment screws and washers. Refit the bottom plate and secure it with its attachment screws. Turn the base into standing upright. Refit the complete lower arm. Refit the complete upper arm. Refit motors 1 and 2. Detailed in section Replacement of complete lower arm on page 91. Detailed in section Replacement of complete upper arm on page 85. Detailed in sections Replacement of motor, axis 1 on page 130 and Replacement of motor, axis 2 on page 135 respectively. Detailed in section Replacement of serial measurement unit and battery pack on page 122. Detailed in section Replacement of cable harness on page 78. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information. Shown in the figure Location of base. Tightening torque: 35 Nm 3Nm Shown in the figure Location of base.
Step
1. 2.
Note
3.
4. 5. 6. 7. 8.
9.
Refit the serial measurement board.
10. Refit the cable harness. 11. Recalibrate the robot.
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.
97
4 Repair
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.
98
4 Repair
4.3.1. Replacement of wrist unit
4.3 Upper arm 4.3.1. Replacement of wrist unit

Location of wrist unit The wrist unit is located in the frontmost part of the upper arm. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000438
A B C
Wrist unit attachment screws (3 pcs) Oil plug (one shown) Wrist unit

Wrist unit (Std/F)

3HAC 10475-1
Note
Standard and Foundry versions O-ring sealing plate not included! Clean room versions O-ring sealing plate not included!
Wrist unit (CR)
3HAC 10475-4
O-ring sealing plate Grease
3HAC 7191-1 3HAC 3537-1
Must be replaced For lubricating the o-ring sealing plate
99
4 Repair
Equipment, etc.
Standard toolkit

3HAC020812-001
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! For adjusting the gear play, motor/pinion These procedures include references to the tools required.
Arm Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.
3HAC 9037-1
Removal, wrist unit The procedure below details how to remove the complete wrist unit. Step
1.
Action
Note
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. Shown in the figure in section Location of wrist unit on page 99.
3.
Remove the wrist unit by unscrewing its three attachment screws.
Refitting, wrist unit The procedure below details how to refit the complete wrist unit. Step
1.
Action
Note
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. Lightly lubricate the o-ring sealing plate with Art. no. is specified in section Required grease. equipment on page 99.
3.
100
4 Repair
Step
4.
Action
Note
Fit the o-ring sealing plate and the wrist unit Do not tighten its attachment screws! to the upper arm with the attachment screws, but do not tighten them. In order to release the brake, connect the 24 VDC power supply to motors: Fit the Arm to the rear of the motor. 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. Connect to connector R3.MP5 or 6: +: pin 7 -: pin 8 Art. no. is specified in section Required equipment on page 99.
5.
6. 7.
xx0200000445
8. 9. Tighten the wrist unit attachment screws.
A: Wrist unit, axes 5 and 6 gears B: Drive shafts from motors, axes 5 and 6 gears C: Adjustment direction D: Gear play
Tightening torque: 28 Nm 3 Nm
Check the gear play by moving axes 5 and The gear play should be xx to pass the 6 by hand. test. Detailed in section Leak-down test. Detailed in section Oil change, gearbox, axes 5 and 6 on page 73. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
10. Perform a leak-down test. 11. Refill the wrist unit with oil. 12. Recalibrate the robot!
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! A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000427
Damper, axis 3

Damper axis 3 Standard toolkit

3HAC 7881-1
Note
3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! 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. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Run the robot to a position that enables access to Shown in the figure Location of damper, axis 3. damper, axis 3 on page 102. Remove the damper by gently prying it from the cast tab.
Refitting, damper axis 3 The procedure below details how to refit the damper, axis 3. Step
1.
Action
Note
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 the Shown in the figure Location location where the damper, axis 3, is fitted. of damper, axis 3 on page 102. Refit the damper by gently pressing it onto the cast tab on the upper arm.
3.
103
4 Repair

Location of damper, axis 5 The damper, axis 5, is located as shown in the figure below!
xx0200000429
A B
Damper, axis 5 Recess

Damper axis 5 Standard toolkit

3HAC 8964-1 3HAC020812-001
Note
104
4 Repair
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Run the robot to a position that enables the end of the Shown in the figure in damper to be pushed into the recess in the wrist unit section Location of damper, axis 5 on page 104. Unhook the end of the damper, and push it into the recess. Manually move the wrist (robot axis 5) away from the damper to pull it out.
3. 4.
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Push the end of the damper into the gap between the Make sure the damper is wrist unit and upper arm. turned the correct way! Manually move the wrist (robot axis 5) in order to pull the damper into position. Fold out the damper hooks to secure it in position.
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 is 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.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000464
A B C
Cover, arm housing Attachment screws, cover, armhousing Gasket, upper arm cover

Cover, arm housing
Spare part. no.

3HAC 10473-1
Art. no.
Note
Standard and Foundry version Includes gasket 3HAC 7867-1 Clean Room versions Includes gasket 3HAC 7867-1
Cover, arm housing
3HAC 10473-3
Gasket, upper arm cover Standard toolkit
3HAC 7867-1 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
106
4 Repair
Removal The procedure below details how to remove the cover, armhousing. 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. Action
Manually, run the robot to a position that enables access to the rear of the upper arm. Remove the cover, armhousing by unscrewing its attachment screws. Shown in the figure Location of cover, armhousing on page 106. NOTE! Do not damage the gasket inside the cover!
Step
1. 2.
Note
Refitting The procedure below details how to refit cover, armhousing. 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. Action
Manually, run the robot to a position that enables access to the rear of the upper arm. Make sure the gasket inside the cover, arm housing has not been damaged.
Step
1.
Note
Shown in the figure Location of cover, armhousing on page 106. Replace if damaged. Shown in the figure Location of cover, armhousing on page 106.
2.
3.
Secure the cover, arm housing to the upper arm with its attachment screws.
107
4 Repair
4.4.1. Replacement of lower arm cover and gasket
4.4 Lower arm 4.4.1. Replacement of lower arm cover and gasket
Location of lower arm cover and gasket The lower arm cover and gasket are located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000433
A B C D 108
Lower arm Gasket lower-arm cover Cover l. arm, spare (without lamp unit) Cover l. arm, spare (with lamp unit) 3HAC 023297-001 Revision: -
4 Repair

Cover l. arm, spare, Std/F

3HAC 10471-1
Note
Standard and Foundry versions No lamp unit included Includes gasket 3HAC 7869-1 Clean room versions No lamp unit included Includes gasket 3HAC 7869-1
Cover l. arm, spare, CR
3HAC 10471-3
Gasket lower-arm cover Isopropanol Standard toolkit
3HAC 7869-1 1177 1012-208 3HAC020812-001 For cleaning sealing surfaces The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Removal, lower arm cover and gasket The procedure below details how to remove the lower arm cover and gasket. 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. Action
Remove the lower arm cover by unscrewing its attachment screws. If the gasket is to be replaced, proceed below! Use a knife to gently remove the old gasket from the cover. Clean the sealing surface with isopropanol, making sure it is completely clean and free from scratches and burrs. Art. no. specified in section Required equipment on page 109.
Step
1.
Note
Shown in the figure Location of lower arm cover and gasket on page 108.
2.
3.
109
4 Repair
Refitting, lower arm cover and gasket The procedure below details how to refit the lower arm cover and gasket. WARNING! Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - 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. Action
If the Gasket lower-arm cover is to be replaced, proceed below. If not, see further down! Remove the protective backing from the selfadhesive gasket and fit it onto the cover sealing surface.
Step
1.
Note
Shown in the figure Location of lower arm cover and gasket on page 108. Make absolutely sure it is correctly located!
2.
3.
Refit the lower arm coverwith its attachment screws. Shown in the figure Location of lower arm cover and gasket on page 108.
110
4 Repair

Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below! A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000426
Damper, axis 2

Damper ax. 2 Standard toolkit
Spare part no.

3HAC 7880-1
Art. no.
Note
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.
111
4 Repair
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Run the robot to a position that enables you to access the attachment screw of damper, axis 2. Remove the damper by unscrewing the single attachment screw and washer.
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Run the robot to a position that enables access to the attachment screw of the damper, axis 2. Secure the damper with its single attachment screw and washer. 1 pc: M6 x 16.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000472
A B
Indication lamp Lower arm cover
Required equipment Equipment, etc. Spare part no. Art. no.

Indicator lamp Standard toolkit 3HAC 9258-1 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Note
113
4 Repair
Removal The procedure below details how to remove the indicator lamp. 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. Action
Remove the lower arm cover.
Step
1.
Note
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! 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. Action
Run the robot to a position that enables access to damper, axis 3. Refit the damper by gently pressing it onto the cast tab on the upper arm.
Step
1. 2.
Note
114
4 Repair
4.5.1. Replacement of cover, console
4.5 Frame and base 4.5.1. Replacement of cover, console

Location of cover, console The cover, console is located on top of the console as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000462
A B C D
Cover, console Attachment screws, cover, console (4 pcs) Gasket Console

Cover, console, spare
Spare part. no.

3HAC 10472-1
Art. no.
Note
Standard and Foundry version Includes gasket 3HAC 7868-1 Clean Room versions Includes gasket 3HAC 7868-1
Cover, console, spare
3HAC 10472-3
Gasket, cover console
3HAC 7868-1
115
4 Repair
Equipment, etc.
Standard toolkit
Spare part. no.
Art. no.
Note
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.
Removal The procedure below details how to remove the cover, console. 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. Action Note
Step
1. 2.
Manually, run the robot to a position that enables Shown in the figure Location of access to the top of the console. cover, console on page 115. Remove the cover, console by unscrewing its attachment screws. NOTE! Do not damage the gasket inside the cover!
Refitting The procedure below details how to refit cover, console. 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. Action Note
Step
1.
Manually, move the robot to a position that enables Shown in the figure Location of access to the top of the console. cover, console on page 115.
116
4 Repair
Step
2.
Action
Make sure the gasket inside the cover, console has not been damaged. Secure the cover, console to the console with its attachment screws.
Note
Replace if damaged. Shown in the figure Location of cover, console on page 115.
3.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000462
A B C D
Cover, console Attachment screws, cover, console (4 pcs) Gasket Console

Console, spare Console, spare Standard toolkit
Spare part. no.

3HAC 10478-1 3HAC 10478-3
Art. no.
Note
Standard and Foundry version Clean Room versions
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. 118
4 Repair
Removal The procedure below details how to remove the cover, console. 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. Action
Remove the cable harness. Remove the serial measurement board. Remove the complete upper arm. 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!
Step
1. 2. 3. 4.
Note/Illustration
Detailed in section Replacement of cable harness on page 78. Detailed in section Replacement of serial measurement unit and battery pack on page 122. 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. 6. Remove the motor of axis 3. Attach the lifting device to the lower arm. Detailed in section Replacement of motor and timing belt, axis 3 on page 139.
119
4 Repair
Step
7.
Action
Remove the bearing hub by unscrewing its attachment screws.
Note/Illustration
xx0300000096
Parts: 8. Remove the console by unscrewing its attachment screws.
A: Console B: Bearing hub C: Bearing hub attachment screws (6 pcs) D: Console attachment screws (10 pcs) E: Washers (10 pcs)
Shown in the figure above!
Refitting The procedure below details how to refit cover, console. 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.
120
4 Repair
Step
1.
Action
Refit the console and secure it with its attachment screws and washers.
Note/Illustration
xx0300000096
Parts: A: Console B: Bearing hub C: Bearing hub attachment screws (6 pcs) D: Console attachment screws (10 pcs) E: Washers (10 pcs) Tightening torque: 11 Nm 1 Nm 2. 3. 4. 5. Refit the bearing hub and secure it with its attachment screws. Refit the complete upper arm. Refit motor 3 and timing belt. Shown in the figure above! Tightening torque: 15 Nm 1 Nm Detailed in section Replacement of complete upper arm on page 85. Detailed in section Replacement of motor and timing belt, axis 3 on page 139.
Refit the serial measurement board. Detailed in section Replacement of serial measurement unit and battery pack on page 122. Refit the cable harness. Recalibrate the robot! Detailed in section Replacement of cable harness on page 78. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
6. 7.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
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 Battery pack Battery pack Battery pack Cable tie Gasket base-cover 3HAC 7870-1
Spare part. no. Art. no.

3HAC 9522-1 4944 026-4 3HAB 9999-1 3HAB 9999-2
Note
NiCd type 3 cell, lithium type 6 cell, lithium type Indoors Replace only if required!
122
4 Repair
Equipment, etc.
Standard Toolkit, IRB 140
Note
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram 3HAC 6816-3
Removal The procedure below details how to remove the serial measurement unit and battery pack. 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.
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!
123
4 Repair
1.
Action
Set the robot system to MOTORS OFF state.
Note
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 Shown in the figure Location of the robot by unscrewing its attachment screws. serial measurement unit and battery pack on page 122! Remove the serial measurement unit by Shown in the figure Location of unscrewing its attachment screws . serial measurement unit and The removal is simplified by pushing the unit to battery pack on page 122! the side and then pulling it backwards. If only the battery is to be replaced, disconnect Connectors the cables to the battery only! R2.SMB Disconnect all connectors from the serial R2.FB1-3 measurement unit. R2.FB4-6 R2.G Lift the board out. If the battery pack is to be replaced, proceed Shown in the figure Location of below! serial measurement unit and battery pack on page 122! 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.
3.
4.
5. 6.
Refitting The procedure below details how to refit the serial measurement unit and battery pack. WARNING! Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - 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.
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! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step
1. 2.
Action
Connect the new battery pack to the serial measurement unit and secure it with a cable tie. Reconnect all connectors to the unit.
Note
Connectors R2.SMB R2.FB1-3 R2.FB4-6 R2.G
3.
Place the serial measurement unit in position Shown in the figure Location of inside the manipulator base and secure it with its serial measurement unit and four attachment screws. battery pack on page 122! Make sure the gasket sealing the rear cable cover Shown in the figure Location of has not been damaged. serial measurement unit and battery pack on page 122! Replace the gasket if required. Art. no. specified in section Required equipment on page 122! 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. Secure the rear cable cover to the base of the robot with its attachment screws. 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. 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. Shown in the figure Location of serial measurement unit and battery pack on page 122! Shown in the figure Location of serial measurement unit and battery pack on page 122!
4.
5.
6.
7.
8.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
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
Note
3m Standard and Foundry versions Cover gasket included 7m Standard and Foundry versions Cover gasket included 15 m Standard and Foundry versions Cover gasket included 22 m Standard and Foundry versions Cover gasket included
3HAC 10477-1
3HAC 11331-1
3HAC 13090-1
126
4 Repair
Equipment, etc.

3HAC 13089-1
Note
30 m Standard and Foundry versions Cover gasket included 3m Clean Room versions Cover gasket included 7m Clean Room versions Cover gasket included 15 m Clean Room versions Cover gasket included 22 m Clean Room versions Cover gasket included 30 m Clean Room versions Cover gasket included
3HAC 10476-4
3HAC 10477-2
3HAC 11331-2
3HAC 13090-2
3HAC 13089-2
Standard toolkit
Removal The procedure below details how to remove the control cable. 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.
127
4 Repair
Step
1.
Action
Make sure the robot system has been switched off, and that no power is supplied to the manipulator. Remove the Control cable, spareby unscrewing its attachment screws.
Note/Illustration
2.
Shown in the figure Location of control cable on page 126. Make sure the gasket does not get damaged!
3.
Disconnect connectors inside the manipulator base.
xx0300000090
Connectors: A: R1.MP1-3 B: R1.CS C: Air hose D: R1.MP4-6 4. 5. Pull the cable out of the manipulator base. Disconnect the connectors from the control cabinet.
128
4 Repair
Refitting The procedure below details how to refit control cable. 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. Action
Place the control cable on the floor with the manipulator base cover close to the manipulator. Connect the connectors inside the manipulators base.
Step
1.
Note/Illustration
Shown in the figure Location of control cable on page 126.
2.
xx0300000090
Connectors: A: R1.MP1-3 B: R1.CS C: Air hose D: R1.MP4-6 3. 4. Fit a new gasket when refitting the cover. Included in the spare part Fit the cover onto the manipulator base Shown in the figure Location of control and secure it with its attachment screws. cable on page 126.
129
4 Repair
4.6.1. Replacement of motor, axis 1
4.6 Motors 4.6.1. Replacement of motor, axis 1

Location of motor axis 1 The motor axis 1 is located on the rear of the manipulator as shown in the figure below: A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000407
A B C D E
Motor, axis 1 Cover for connector access Motor attachment screws (4 pcs) Cable gland attachment screws (4 pcs) Console

Rot. ac motor with pinion Rot. ac motor with pinion Rot. ac motor w pinion TStd/TF O-ring
Spare part no.

3HAC 10469-3 3HAC 021966-001 3HAC 10469-1 3HAC 021965-001 3HAC 10469-4
Art no.
Note
Clean room versions. Standard and Foundry versions. High performance version.
2152 2012-426
Must be replaced when replacing motor! Included in the spare parts motor kits Fitted onto the console cable gland
Cable gland gasket
3HAC xx
130
4 Repair
Equipment, etc.
Grease Standard toolkit
Spare part no.
Art no.
3HAB 3537-1
Note
Used to lubricate the o-ring
3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! 3HAC 9037-1 For adjusting the gear play, motor/pinion 24 VDC, max. 1,5 A For releasing the brakes These procedures include references to the tools required.
Arm Power supply Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
3HAC 6816-3
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! 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.
NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Step
1.
Action
Note
Remove the Cover for connector access on top of Shown in the figure Location the motor by unscrewing its four attachment screws. of motor axis 1 on page 130. Detailed in section Replacement of cover, console on page 115. Disconnect the motor 1 connectors inside the console. Cut any cable ties and remove any brackets securing the cables. Remove the cable gland by removing its attachment Shown in the figure Location screws, and pull the cables out from the console. of motor axis 1 on page 130. In order to release the brakes, connect the 24 VDC power supply: Connect to connector R3.MP1 +: pin 7 -: pin 8 Connectors: R3.MP1 R3.FB1
2.
3. 4. 5.
6. 7. 8.
Remove the motor by unscrewing its four attachment Shown in the figure Location screws and plain washers. of motor axis 1 on page 130. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage. Remove the motor by gently lifting it straight up.
132
4 Repair
Refitting The procedure below details how to refit motor, axis 1. WARNING! Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - 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. 2.
Action
Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs.
Note
Make sure the o-ring on the circumference of Art. no. is specified in section the motor is seated properly. Lightly lubricate Required equipment on page 130. the o-ring with grease . In order to release the brake, connect the 24 VDC power supply: Connect to connector R2.MP1 +: pin 7 -: pin 8
3.
4.
Fit the motor, making sure the motor pinion is Make sure the motor is turned the properly mated to gearbox 1. right way, i.e. connections rearwards. Make sure the motor pinion does not get damaged! Fit the motor with four attachment screws and Tightening torque: approx 2 Nm plain washers. Fit the Arm to the end of the motor shaft. 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. Tighten the motor attachment screws. Disconnect the brake release voltage. Art. no. is specified in section Required equipment on page 130. Art. no. is specified in section Required equipment on page 130. There should be a barely noticable gear play.
5. 6. 7.
8. 9.
Tightening torque: approx 11 Nm 1 Nm
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.
133
4 Repair
Step
Action
Note
Detailed in section . Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
12. Perform a leak-down test. 13. Recalibrate the robot!
134
4 Repair

Location of motor axis 2 The motor axis 2 is located on the front of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000408
A B C D E
Motor, axis 2 Cover for connector access Motor attachment screws (4 pcs) Cable gland attachment screws (4 pcs) Console
Required equipment Equipment, etc. Spare part no.

Rot. ac motor with pinion, spare Rot. ac motor with pinion, spare Rot. ac motor with pinion, spare, TStd/TF O-ring Cable gland gasket Grease Standard toolkit 3HAC 10469-3 3HAC 021966-001 3HAC 10469-1 3HAC 021965-001 3HAC 10469-4
Art. no.
Note
Clean room versions. Standard and Foundry versions. High performance version.
2152 2012-426 3HAC xx 3HAB 3537-1
Must be replaced when replacing motor! Fitted onto the console cable gland For lubricating the o-ring.
3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information!
135
4 Repair
Equipment, etc. Spare part no.

Arm Power supply Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
Art. no.
3HAC 9037-1
Note
For adjusting the gear play, motor/pinion 24 VDC, 1.5 A. For releasing the brakes. These procedures include references to the tools required.
3HAC 6816-3
Removal The procedure below details how to remove motor, axis 2. 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.
1.
Action
Note
Remove the Cover for connector access on top of Shown in the figure in the motor by unscrewing its four attachment screws. section Location of motor axis 2 on page 135. Disconnect the motor 2 connectors inside the console. Cut any cable ties and remove any brackets securing the cables. Remove the cable gland by removing its attachment Shown in the figure in screws, and pull the cables out from the console. section Location of motor axis 2 on page 135. In order to release the brakes, connect the 24 VDC power supply: Connect to connector R3.MP2 +: pin 2 -: pin 5 Connectors: R3.MP2 R3.FB2
2.
3. 4.
5.
6. 7.
Remove the motor by unscrewing its four attachment Shown in the figure Location screws and plain washers. of motor axis 2 on page 135. Lift the motor to get the pinion away from the gear.
136
4 Repair
Step
8. 9.
Action
Disconnect the brake release voltage. 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.
Note
10. Remove any remaining oil from the gearbox by siphoning it out.
1. 2.
Action
Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs.
Note
Make sure the o-ring on the circumference of the Art no. is specified in section motor is seated properly. Lightly lubricate the oRequired equipment on page ring with grease . 135. In order to release the brake, connect the 24 VDC Connect to connector R2.MP2 power supply: +: pin 7 -: pin 8 Fit the motor, making sure the motor pinion is properly mated to gearbox 2. Make sure the motor is turned the right way, i.e. connections rearwards. Make sure the motor pinion does not get damaged!
3.
4.
5. 6.
Fit the motor with four attachment screws and plain Tightening torque: approx 2 washers. Nm Fit the Arm to the end of the motor shaft. Art no. is specified in section Required equipment on page 135.
7.
Adjust the motor in relation to the gear in the There should be a barely gearbox. noticable gear play. Use the Arm tool to wiggle the motor shaft back and forth to feel the play. Tighten the motor attachment screws. Tightening torque: approx 11 Nm 1 Nm
8.
137
4 Repair
Step
9.
Action
Disconnect the brake release voltage.
Note
Art no. is specified in section Required equipment on page 135.
10. Make sure the cable gland cover 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. 12. Perform a leak-down test. 13. Refill the gearbox with oil. 14. Recalibrate the robot!
Detailed in section Leak-down test. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
138
4 Repair
4.6.3. Replacement of motor and timing belt, axis 3

Location of motor 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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000448
A B C D E F G
Lower arm cover Attachment screws, lower arm cover (13 pcs) Belt shield Motor 3 Attachment screws, belt shield (3 pcs) Attachment screws, motor 3 (4 pcs) Belt
139
4 Repair

Rot. ac motor with pinion Timing belt Grease Standard toolkit
Spare part no.

3HAC 7866-1 3HAC 021756-001
Art. no.
Note
Includes timing belt pulley.
3HAC 6793-1 3HAB 3537-1 3HAC020812-001 For lubricating the oring. The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Circuit Diagram 3HAC 6816-3
1. 2.
Action
Remove any equipment hindering access to the lower arm cover. Remove the lower arm cover by unscrewing its attachment screws.
Note/Illustration
Shown in the figure in section Location of motor axis 3 on page 139. Shown in the figure in section Location of motor axis 3 on page 139.
140
4 Repair
Step
3.
Action
Cut the cable ties to facilitate accessing the motor.
Note/Illustration
xx0200000449
4. Disconnect motor connectors.
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 G: Connectors R3.MP3 and R3.FB3
Connectors: R3.MP3 R3.FB3 R3.H1 (if Safety lamp is fitted) R3.H2 (if Safety lamp is fitted)
141
4 Repair
Step
5.
Action
DO NOT under any circumstance unscrew the three screws securing the belt wheel! Doing so will cause the manipulator to require a complete rebuild!
Note/Illustration
xx0300000102
Parts: DO NOT touch these screws! (3 pcs) 6. 7. 8. 9. Remove the belt shield by unscrewing Shown in the figure in section Location of its twoattachment screws. motor axis 3 on page 139. Remove the remaining motorattachment screws. Remove the belt. Remove the motor. Shown in the figure in section Location of motor axis 3 on page 139. Shown in the figure in section Location of motor axis 3 on page 139. Shown in the figure in section Location of motor axis 3 on page 139.
Refitting The procedure below details how to refit motor, axis 3. WARNING! Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - 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. Action
Make sure the mating surfaces on the motor and the lower arm are clean and free from burrs. Fit the motor in the lower arm. Fit the belt. Tighten the two motor attachment screws slightly, but not completely. Shown in the figure in section Location of motor axis 3 on page 139.
Step
1.
Note/Illustration
2. 3. 4.
142
4 Repair
Step
5.
Action
Note/Illustration
Adjust the position of the motor in such a Correct belt tension F=35 - 60 N way that the correct belt tension is achieved. DO NOT adjust the belt tension using the intermediate wheel securing screws. Fit the belt shield and secure it with the two remaining screws. Tighten the last motor attachment screws. Refit the cabling as shown. Tightening torque: 4 Nm 0.5 Nm Tightening torque: 4 Nm 0.5 Nm
6. 7. 8. 9.
xx0200000449
10. Recalibrate the robot!
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
Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000455
A B C
Attachment screws, motor 4 (4 pcs) Motor, axis 4 O-ring

Rot. ac motor with pinion O-ring Grease Standard toolkit
Spare part no.

3HAC 7842-1 3HAC 021757-001
Art. no.
Note
Standard, Clean Room and Foundry versions Does not include the o-ring!
3HAC 3772-24 3HAC 3537-1
Must be replaced when replacing motor! Used to lubricate the o-ring.
3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! 24 VDC, max. 1,5 A. For releasing the brakes. 3HAC 9037-1 For adjusting the gear play
Power supply Arm
144
4 Repair
Equipment, etc.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
Spare part no.
Art. no.
Note
These procedures include references to the tools required.
3HAC 6816-3
1.
Action
Remove the motors for axes 5 and 6.
Note
Detailed in section Replacement of motor and timing belt, axes 5 or 6 on page 147. This will enable the motor 4 to be removed without draining the oil in the gearbox.
2.
Manually run the manipulator to a position where the upper arm points straight down.
3. 4.
Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of attachment screws. motor, axis 4 on page 144. In order to release the brake, connect the 24 VDC Connect to connector R3.MP4 power supply: +: pin 7 -: pin 8 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage. Remove the motor by gently lifting it straight out. Make sure the motor pinion is not damaged!
5. 6.
145
4 Repair
1. 2.
Action
Note
Make sure the mating surfaces on the motor Shown in the figure Location of and the gearbox are clean and free from burrs. motor, axis 4 on page 144. Make sure the o-ring on the circumference of Art. no. is specified in section the motor is seated properly. Lightly lubricate Required equipment on page 144. the o-ring with grease . In order to release the brake, connect the 24 VDC power supply: Fit the motor with the attachment screws. Fit the Arm to the end of the motor shaft. 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. Tighten the motor attachment screws. Connect to connector R3.MP4 +: pin 7 -: pin 8 Tightening torque: approx. 2 Nm Art. no. is specified in section Required equipment on page 144. There should be a barely noticable gear play.
3.
4. 5. 6.
7.
Shown in the figure Location of motor, axis 4 on page 144. Tightening torque: 6 Nm 0.6 Nm Detailed in section Replacement of motor and timing belt, axes 5 or 6 on page 147. Detailed in section Leak-down test. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
8.
Refit motors 5 and 6.
9.
Perform a leak-down test.
10. Recalibrate the robot!
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. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000453
A B C D E F
Lower arm cover Attachment screws, lower arm cover Cover, armhousing Attachment screws, cover armhousing (4 pcs) VK cover Pressurized air hose (on front of upper arm)
147
4 Repair
G H J K L M N P Q R S T U V W X Y Z
CS connector Cable guide Attachment screws, cable guide Belt shield Attachment screws, belt shield Motor attachment screws, 4 pcs per motor Attachment screws, motor console Clamping unit screws Clamping unit Timing belt, axis 6 Pulley, axis 6 Screws securing the pulley to the axis 5 drive shaft Timing belt, axis 5 Pulley, axis 5 Motor console, ax. 5-6 Motor, axis 4 Motor, axis 5 Motor, axis 6

Rot. ac motor with pinion
Spare part no.

3HAC 7842-1 3HAC 021757-001 3HAC 7841-1 3HAC 021758-001 3HAC 6779-1
Art. no.
Note
Axis 4 Standard, Clean room and Foundry versions. Axes 5 and 6 Standard, Clean room and Foundry versions. Axes 5 and 6
Rot. ac motor with pinion
Timing belt VK cover Clamping unit Standard toolkit
3HAC 2166-13 3HAC 7939-1 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! 3HAC xx For fitting the CSconnector These procedures include references to the tools required.
Special socket xx Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Circuit Diagram
3HAC 6816-3
148
4 Repair
Removal The procedure below details how to remove motor, axis 5 or 6. 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.
1. 2.
Action
Run the robot to a position where the upper arm is close to horizontal Remove the lower arm cover by unscrewing its attachment screws. Remove the rear cover armhousing by unscrewing its four attachment screws. Disconnect all cables to/from motors 4-6.
Note
Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Connectors: R3.MP4 R3.MP5 R3.MP6 R3.FB4 R3.FB5 R3.FB6 Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!
3.
4.
5.
Disconnect any connector from the CSconnector.
6.
Use a special socket to remove the CSShown in the figure in section Location connector from the housing and pull it into of motor and timing belt, axes 5 or 6 on the upper arm assembly. page 147! Art. no. specified in section Required equipment Remove the pressurized air connector from Shown in the figure in section Location the housing and pull it into the upper arm of motor and timing belt, axes 5 or 6 on assembly. page 147! Art. no. specified in section Required equipment! Remove the VK-cover from the upper arm/ Shown in the figure in section Location lower arm joint. of motor and timing belt, axes 5 or 6 on page 147! Detailed in section Removing the VK cover on page 88.
7.
8.
149
4 Repair
Step
9.
Action
Note
Remove the cable guide by unscrewing its Shown in the figure in section Location two attachment screws. of motor and timing belt, axes 5 or 6 on page 147! Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!
10. Gently pull the cables out of the upper arm. 11. Remove the belt shield by unscrewing its attachment screws. 12. Unscrew the motor attachment screws.
13. Unscrew the clamping unit screws
14. Use the previously removed clamping unit Shown in the figure in section Location screws to press the clamping unit apart by of motor and timing belt, axes 5 or 6 on inserting them into the adjacent holes in the page 147! 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 unscrewing its attachment screws. Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!
150
4 Repair
1.
Action
Make sure the mating surfaces on the motor and the console are clean and free from burrs. Fit the motors in the motor console without tightening the attachment screws.
Note
2.
Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147!
3.
Fit the motor console in the upper arm Shown in the figure in section housing. Secure with its attachment screws. Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 4 Nm 0.5 Nm Fit pulley, axis 5 and timing belt, axis 5 with their attachment screws and washers. Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 6 Nm 0.5 Nm This will facilitate adjustment of the belt tension. Correct belt tension F=35 - 60 N
4.
5. 6. 7. 8.
Tighten the motor attachment screws to enable the motor to be shifted slightly. Adjust the belt tension by xx.
Secure the motor with its attachment screws Tightening torque: 4 Nm 0.5 Nm including the ones in the motor console. Fit pulley, axis 6 and timing belt, axis 6 with their attachment screws and washers. Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 3 Nm 0.5 Nm Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 3 Nm 0.5 Nm
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 Location of motor and timing belt, axes 5 or 6 on page 147! Tightening torque: 4 Nm 0.5 Nm
151
4 Repair
Step
Action
Note
Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Art. no. specified in section Required equipment Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Art. no. specified in section Required equipment Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Connectors R3.MP4 R3.MP5 R3.MP6 R3.FB4 R3.FB5 R3.FB6
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.
17. Refit the cable guide with its two attachment Shown in the figure in section screws. Location of motor and timing belt, axes 5 or 6 on page 147! 18. Fit a newVK-cover to the upper arm/lower arm joint. Gently knock it into position. Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 147! Art. no. specified in section Required equipment Use a plastic mallet or similar.
19. Refit the rear cover armhousing with its four Shown in the figure in section attachment screws. Location of motor and timing belt, axes 5 or 6 on page 147! 20. Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively. 21. 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.
152
4 Repair
4.6.6.1. Measuring the gear play, axis 5
4.6.6. Adjustments and measurements 4.6.6.1. Measuring the gear play, axis 5
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. Required equipment Equipment, etc.
Standard toolkit
Art no.
3HAC020812-001
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! For adjusting the gear play, motor/pinion Measuring range 0-xx mm, accuracy xx 24 VDC, max. 1,5 A For releasing the brakes These procedures include references to the tools required.
Arm Measurement dial with magnetic base Power supply Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
3HAC 9037-1
153
4 Repair
Measurement The procedure below details how to measure the gear play for axis 5. Step
1. 2.
Action
Manually, turn axis 4 90. Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure. Apply the 40 N load as shown.
Note/Illustration
xx0200000457
3. 4.
Remove the load and read Value 1. Apply 40 N load as shown.
xx0200000458
5. 6. 7.
Remove the load and read Value 2. Calculate the gear play value. Gear play value = value 1 - value 2 Determine whether or not the value is OK. OK < 0.18 mm (4.1 arc minutes)
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. Required equipment Equipment, etc.
Standard toolkit
Art no.
3HAC020812-001
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! For adjusting the gear play, motor/pinion Measuring range 0-xx mm, accuracy xx 24 VDC, max. 1,5 A For releasing the brakes These procedures include references to the tools required.
Arm Measurement dial with magnetic base Power supply Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
3HAC 9037-1
155
4 Repair
Measurement The procedure below details how to measure the gear play for axis 6. Step
1. 2.
Action
Manually, turn axis 4 90. Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure. Apply the 40 N load as shown.
Note/Illustration
xx0200000460
3. 4.
Remove the load and read Value 1. Apply 40 N load as shown.
xx0200000461
5. 6. 7.
Remove the load and read Value 2. Calculate the gear play value. Determine whether or not the value is OK. Gear play value = value 1 - value 2 OK < 0.30 mm (10.3 arc minutes)
156
4 Repair
4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1
4.7 Gearboxes 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1
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! A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information.
xx0200000422
Gearbox, axis 1-2
Required equipment Equipment, etc. Spare part no. Art. no.

Gearbox, ax. 1-2 spare, Std/F 3HAC 10467-1
Note
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!
Gearbox, ax. 1-2 spare, CR
3HAC 10467-3
Damper, axis 1 Flange sealing LocTite, 574 Sealing ring
3HAC 7527-1 1234 0011-116 3HAC xx 3HAC 6965-1 2 ml For sealing gearbox/base Replace only when damaged!
157
4 Repair
Equipment, etc. Spare part no. Art. no.

Standard toolkit 3HAC020812-001
Note
The contents are defined in section Standard toolkit in the Product manual, reference information!
Lifting device, gearbox 1-2 Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
3HAC xx These procedures include references to the tools required.
Removal, gearbox 1-2 The procedure below details how to remove gearbox, axes 1-2. 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.
NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! CAUTION! Caution! The gear box weighs 39 kg! All lifting equipment used must be dimensioned accordingly! Step
1. 2. 3. 4.
Action
Remove motor 1. Remove motor 2. Remove the cable harnesses.
Note/Illustration
Detailed in section Replacement of motor, axis 1 on page 130. Detailed in section Replacement of motor, axis 2 on page 135. Detailed in section Replacement of cable harness on page 78.
Remove the serial measurement Detailed in section Replacement of serial board. measurement unit and battery pack on page 122Replacement of serial measurement unit and battery pack on page 122. Remove the upper arm. Remove the lower arm. Drain the oil from gearbox 1. Detailed in section Replacement of complete upper arm on page 85. Detailed in section Removal of complete lower arm.
5. 6. 7.
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4 Repair
Step
8.
Action
Note/Illustration
Fit the lifting tool to the base/ Art. no. is specified in section Required frame and turn it upside down on equipment on page 157. top of a suitable workbench. Remove the bottom plate by unscrewing its 26 attachment screws.
9.
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
10. Remove the gearbox/base Shown in the figure Location of gearbox axes 1-2 attachment screws and lift the on page 157. gearbox 1-2 away from the base.
Removal of damper, axis 1 The procedure below details how to remove the damper, axis 1. Step
1. 2.
Action
Open the base of the robot. Remove the damper, axis 1.
Note
Detailed in section Removal, gearbox 1-2 on page 158.
Refitting of damper, axis 1 The procedure below details how to refit the damper, axis 1. Step
1.
Action
Fit the damper, axis 1.
Note
Shown in the illustration Refitting, gearbox 1-2 on page 160. Detailed in section Refitting, gearbox 1-2 on page 160.
2.
Proceed with assembling the robot.
159
4 Repair
Refitting, gearbox 1-2 The procedure below details how to refit gearbox, axes 1-2. WARNING! Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - 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.
NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! CAUTION! The gearbox weighs 39 kg! All lifting equipment used must be dimensioned accordingly! Step
1. 2.
Action
Place the gearbox 1-2 on a suitable workbench. Fit a small amount of LocTite 574 onto the Joint, gearbox/ base.
Note/Illustration
xx0200000423
3.
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
Fit the base to the gearbox unit Shown in the figure Location of gearbox axes 1-2 on and secure it with the page 157. attachment screws and the flat Quality Gleitmo, tightening torque: 35 Nm 3 Nm. washer. Refit the bottom plate and secure it with its attachment screws. Shown in the figure Location of gearbox axes 1-2 on page 157.
4.
160
4 Repair
Step
5.
Action
Fit the lifting tool to the base/ frame and turn it right side up on top of a suitable workbench. Refit the lower arm. Refit the upper arm. Refit the serial measurement board. Refit the cable harnesses.
Note/Illustration
Art. no. is specified in section Required equipment on page 157.
6. 7. 8. 9.
Detailed in section Refitting of complete lower arm. Detailed in section Refitting of complete upper arm. Detailed in section Replacement of serial measurement unit and battery pack on page 122. Detailed in section Refitting of cable harness. Detailed in section Refitting of motor 1 and Refitting of motor 2 respectively. Detailed in section Leak-down test. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
10. Refit motors 1 and 2. 11. Perform a leak-down test. 12. Refill the gear box with oil. 13. Recalibrate the robot.
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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
5.1. Introduction
5.1. Introduction
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.
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
Standard calibration
Description
The calibrated robot is positioned at home position, i.e. the axes positions (angles) are set to 0. 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.
Calibration method
Calibration Pendulum (standard method) or Levelmeter calibration (alternative method)
Absolute Accuracy calibration (optional)
Based on standard calibration, but besides CalibWare 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!
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.
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
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. Step
1. 2.
Action
Select axis-by-axis motion mode.
Note
Jog the robot so that the calibration marks lie Shown in section Calibration scales within the tolerance zone. and correct axis position on page 166. When all axes are positioned, store the revolution counter settings. 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).
3.
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
IRB 140
Axis 4
Yes
Axis 6
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). Step
1.
Action
Press the button "Miscellaneous" then ENTER to select the service window.
Note
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. 5.
Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes. Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window.
169
Step
6. 7. 8.
Action
Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. At this point, it is recommended that the revolution counter values are saved to a diskette.
Note
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
1.
Action
On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Tap the mechanical unit in question. A screen is displayed: tap Rev. Counters.
2.
en0400000771
170
Step
3.
Action
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. 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. 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.
4.
5.
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.
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 Step
1. 2. 3.
Action
Crate a new program Use MoveAbsJ Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs , v1000, z50, Tool0 Run the program in manual mode Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
4. 5.
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. Step
1. 2. 3. 4.
Action
On ABB menu tap Program Editor. Create a new program. Use MoveAbsJ in the Motion&Proc menu. Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff s, v1000, z50, Tool0 Run the program in manual mode. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
5. 6.
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.
172
Using the Jogging window on the TPU, S4Cplus This section describes how to jog the robot to all axes zero position. Step
1.
Action
Open the Jogging window.
Illustration/information
xx0100000195
2.
Choose running axes-by-axes.
xx0100000196
3.
Manually run the robot axes to a position where the axis position value read on the TPU, is equal to zero. Check that the calibration marks for the axes align The calibration marks are correctly. If they do not, update the revolution shown in section Calibration counters! scales and correct axis position on page 166. Detailed in section Updating revolution counters on page 168.
4.
Using the Jogging window on the FlexPendant, IRC5 This section describes how to jog the robot to all axes zero position. Step
1. 2. 3. 4.
Action
Tap Jogging in the ABB menu. Tap Motion mode to choose group of axes to jog. Tap axes 1-3 to jog axes 1, 2 or 3. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
5.
The calibration marks are shown in section Calibration scales and correct axis position on page 166. How to update the counters is detailed in section Updating revolution counters on page 168.
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
175
176

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Product manual (part 1 of 2), procedures

Product manual (part 1 of 2), procedures IRB 140

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

3HAC 023297-001 Revision: -

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

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

3.5.1 Oil change, gearbox, axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4 Repair 77

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

3HAC 023297-001 Revision: -

3HAC 023297-001 Revision: -

3HAC 023297-001 Revision: -

Organization of chapters The manual is organized in the following chapters: Chapter

Installation and commissioning Maintenance

Repair Calibration information Decommissioning

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3HAC 023297-001 Revision: -

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

In addition, spare part information is supplied for the entire option.

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Product documentation, M2004

Product documentation, M2004

Product documentation, M2004

How to use the application Examples of how to use the application

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How to read the product manual

How to read the product manual

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3HAC 023297-001 Revision: -

1.2 General safety information 1.2.1. Introduction

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1.2.2. General information 1.2.2.1. Safety, service

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1.2.2.2. Limitation of Liability

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1.2.2.3. Related information

Restricting the working space Product manual for the manipulator

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3HAC 023297-001 Revision: -

Complete robot Safety risk

Cabling Safety risk

Gearboxes and motors Safety risk

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Balancing device Safety risk

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1.2.3.2. Safety risks related to gripper

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1.2.3.3. Safety risks related to tools/workpieces

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1.2.3.4. Safety risks related to pneumatic/hydraulic systems

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1.2.3.5. Safety risks during operational disturbances

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1.2.3.6. Safety risks during installation and service

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1.2.3.7. Risks associated with live electric parts

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1.2.4. Safety actions 1.2.4.1. Safety fence dimensions

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