Product Manual (Part 1 of 2), Procedures: Articulated Robot

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: 3HAC023297-001

Revision: A
The information in this manual is subject to change without notice and
should not be construed as a commitment by ABB. ABB assumes no
responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing
herein shall be construed as any kind of guarantee or warranty by ABB
for losses, damages to persons or property, fitness for a specific purpose
or the like.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABB's written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
© Copyright 2004-2008 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Installation and commissioning 41

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.2 Working range, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2.3 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3.4 Restricting the working space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3.5 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3.7 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.8 Bolt pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4.1 Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3HAC023297-001 Revision: A 3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2.4 Replacement of base, spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3.4 Replacement of cover, arm housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4.1 Replacement of lower arm cover and gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4.3 Replacement of indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5.1 Replacement of cover, console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5.2 Replacement of console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.5.3 Replacement of serial measurement unit and battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5.4 Replacement of control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.6.5 Replacement of motor and timing belt, axes 5 or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.6.6 Adjustments and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.6.6.1 Measuring the gear play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.6.6.2 Measuring the gear play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7.2 Service work on gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5 Calibration information 163

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4 3HAC023297-001 Revision: A
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
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during
• installation, from lifting the robot to its work site and securing it to the foundation to
making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/ installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety, service 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.
Installation and Required information about lifting and installation of the robot.
commissioning
Maintenance 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.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration information Procedures that does not require specific calibration equipment.
General information about calibration.
Decommissioning Environmental information about the robot and its components.
Overview
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and commissioning manual
• Maintenance manual
• Repair manual, part 1
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.
A Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.
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
• Part list
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
• How to use the application

• Examples of how to use the application
Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudioOnline
• Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
How to read the product manual
How to read the product manual
Reading the procedures

The procedures contain references to figures, tools, material etc. The references are read as
described below.
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an procedure.
Step Action Note/Illustration

8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.
References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in an procedure.

3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in chapter Safety on page 13.
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.
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 manipulator´s arm
• Brake testing
• Risk of disabling function "Reduced speed 250 mm/s"
• Safe use of the Teach Pendant Unit enabling device
• Work inside the manipulator´s working range
• Signal lamp (optional)
1 Safety
1.2.2.1. Safety, service
1.2.2. General information
1.2.2.1. Safety, service
Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. User's Guide and Product
Manual.
Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for
connecting safety devices between the robot and the peripheral equipment.
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.
1 Safety
1.2.2.3. Related information
1.2.2.3. Related information
General
The list below specifies documents which contain useful information:
Documents
Type of information Detailed in document Section

Installation of safety devices Product manual for the Installation and commissioning
manipulator
Changing robot modes User’s Guide Start-up
Restricting the working space Product manual for the Installation and commissioning
manipulator
1 Safety
1.2.3.1. Safety risks during service work on robot
1.2.3. Safety risks
Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.
1 Safety
Complete robot
Safety risk Description

Hot components!
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

Cable packs are sensitive to
mechanical damage!
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

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

may be damaged if excessive force is used!
1 Safety
Balancing device

Dangerous balancing device!
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!
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.
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.
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.
1 Safety
1.2.3.5. Safety risks during operational disturbances
1.2.3.5. Safety risks during operational disturbances
General
• 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.
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.
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.
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.
1 Safety
1.2.3.7. Risks associated with live electric parts
1.2.3.7. Risks associated with live electric parts
Voltage related risks, general

• Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
Voltage related risks, controller

A danger of high voltage is associated with the following parts:
• Be aware of stored electrical energy (DC link) in the controller.
• Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
• The mains supply/mains switch
• The power unit
• The power supply unit for the computer system (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The service outlets (115/230 VAC)
• The power supply unit for tools, or special power supply units for the machining
process
• The external voltage connected to the control cabinet remains live even when the robot
is disconnected from the mains.
• Additional connections
Voltage related risks, robot

A danger of high voltage is associated with the robot in:
• The power supply for the motors (up to 800 VDC)
• The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.
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.
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)!
1 Safety
1.2.4.3. Emergency release of the robot’s arm
1.2.4.3. Emergency release of the robot’s arm
Description
In an emergency situation, any of the robot's axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
• Manually releasing the brakes on page 49.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
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!
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.
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.
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.
1 Safety
1.2.4.7. Work inside the manipulator's working range
1.2.4.7. Work inside the manipulator's working range
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% ”full speed” may only be used by trained personnel who are
aware of the risks that this entails.
• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
• Test the motor brake on each axis, according to section Brake testing on page 30.
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions
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 Signification

DANGER 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,
danger impact, fall from height etc.
WARNING 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
warning crushing, impact, fall from height etc.
ELECTRICAL The electrocution or electrical shock symbol
SHOCK indicates electrical hazards which could result in
severe personal injury or death.
Electrical shock
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
caution warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
1 Safety
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
1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
1.3.2. DANGER - Moving manipulators are potentially lethal!
Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.
Elimination
Step Action Info/Illustration

1. Before attempting to run the manipulator, Emergency stop equipment such as
make sure all emergency stop equipment gates, tread mats, light curtains, etc.
has been correctly installed and connected.
2. If possible, use the hold-to-run button How to use the hold-to-run control in
whenever possible. RobotWare 5.0 is detailed in section
The hold-to-run button is used in manual How to use the hold-to-run switch in
mode, not in automatic mode. the Operator's Manual, IRC5.
How to use the hold-to-run control in
RobotWare 4.0 is detailed in section
The Teach Pendant unit in the User’s
Guide.
3. Make sure no personnel is present within
the manipulator working range before
pressing the start button.
1 Safety
1.3.3. WARNING - The unit is sensitive to ESD!
1.3.3. WARNING - The unit is sensitive to ESD!
Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not connected to ground potential may transfer
high static charges. This discharge may destroy sensitive electronics.
Elimination

1. Use a wrist strap Wrist straps must be tested frequently to
ensure that they are not damaged and are
operating correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a current-
limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled discharge
of static voltages and must be grounded.
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 Make sure not to overfill the
lead to internal over-pressure gearbox when filling with oil!
inside the gearbox which in After filling, check the correct oil
turn may: levels.
• damage seals and
-
gaskets
Do not overfill! • completely press out
seals and gaskets
• prevent the manipulator
from moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the mix different types of oil unless
gearbox! specified in the instruction.
Always use the type of oil
specified by the manufacturer!
-
Do not mix types of oil!
1 Safety
Warning Description Elimination / Action

Warm oil drains quicker than When changing gearbox oil, first
cold oil. 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
Specified amount
drained from the gearbox.
depends on drained
volume!
1 Safety
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.
2.2.1. Pre-installation procedure
2.2 Unpacking
General
This instruction is primarily intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Checking the pre-requisites for installation

The check-list below details what must be observed before proceeding with the actual
installation of the manipulator:

1. Make sure only qualified installation
personnel conforming to all national and
local codes are allowed to perform the
installation.
2. Make sure the manipulator has not been
damaged, by visually inspecting the
manipulator and control cabinet exterior.
3. Make sure the lifting device to be used is Specified in section Weight,
dimensioned to handle the weight of the manipulator on page 42.
manipulator.
4. If the manipulator is not to be installed Specified in section Storage
directly, it must be stored. conditions, manipulator on page 43.
5. Make sure the appointed operating Specified in section Operating
environment of the manipulator conforms to conditions, manipulator on page 43.
the specifications.
6. 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
7. Before moving the manipulator, make sure it Described in section Risk of tipping/
does not tip over! Stability on page 47.
8. When these prerequisites have been met, Detailed in section Lifting manipulator
the manipulator may be taken to its with lifting slings on page 48.
installation site.
Weight, manipulator
The net weight of the manipulator is approximately: 100 kg.
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!
Endurance load Max. load (emergency

Force
(operation) stop)
Force xy (upright/suspended) ± 1300 N ± 3200 N
Force z (upright) -1000 ± 1000 N -1000 ± 2000 N
Forze z (suspended) -2800 ± 1000 N +1000 ± 2000 N
Torque
Mxy ± 1300 Nm ± 220 Nm
Mz ± 300 Nm ± 750 Nm
Requirements on foundation, manipulator
Requirement Value
Min. levelity 0.5 mm
Max. tilt 5°
Min. resonance frequency 22 Hz
Storage conditions, manipulator

The table below shows the allowed storage conditions for the manipulator:
Parameter Value
Max. ambient temperature +55° C
Max. ambient temperature (less than 24 hrs) +70° C
Min. ambient temperature -25° C
Max. ambient humidity Max. 95% at constant temperature
Operating conditions, manipulator

The table below shows the allowed operating conditions for manipulator:
Parameter Value
Max. ambient temperature +45° C
Min. ambient temperature +5° C
Max. ambient humidity Max. 95% at constant temperature
Protection classes
The table below shows the protection class of the main parts of the robot system:
Equipment Protection class

Manipulator IP 67
Control cabinet IP 54
Programming unit IP 54
2.2.2. Working range, IRB 140
Working range axis 2 -3

The illustration below shows the unrestricted working range axis 2-3.
xx0200000058
Pos Position at wrist centre Angle (degrees)

X Z Axis 2 Axis 3
0 450 712 0° 0°
1 70 1092 0° -90°
2 314 421 0° +50°
3 765 99 +110° -90°
4 255 -119 +110° +4°
5 -480 23 -90° -150°
6 1 596 -90° +50°
7 218 558 +110° -230°
8 -670 352 -90° -90°
Working range axis 1

The illustrations below shows the unrestricted working range of axis 1.
xx0200000061
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.
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 Note
Sling line Length: 2 m. Load: 500 kg.
Illustration
The following figures shows how to lift the manipulator with lifting slings.
xx0200000084
1 Sling line for manipulator

2 Sling line for manipulator
3 Sling line for control cable
How to lift the manipulator

1. Adjust the manipulator to lifting position according to the picture.
2. Put one sling line around each leg on the lower arm (Pos. 1 and 2).
3. Use further one sling line to secure the lifting of the control cable (Pos. 3).
2.3.2. Manually releasing the brakes
General
The section below details how to release the holding brakes of each axis' motor.
This may be done in one of three ways:
• using the pushbutton when the manipulator is connected to the controller.
• using the pushbutton on the manipulator with an external power supply.
• using an external voltage supply.
DANGER!
When releasing the holding brakes, the manipulator axes may move very quickly and
sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Using the pushbutton when the manipulator is connected to the controller

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

1. Push the "brake release button" to release the
holding brakes.
xx0200000069
• A: Pushbutton
Using the pushbutton on the manipulator with an external power supply

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

1. Connect an external power supply to connector XP1.
xx0200000071
• A: B16 24V DC
• B: B14 0V
2. Push the "brake release button" to release the
holding brakes.
NOTE!
Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can
be caused to a resistor diode and to the system board.
Using External power supply

This section details how to release the holding brakes using a external voltage supply. If the
positions of the manipulator axes are to be changed without connecting the controller, an
external voltage supply (24 V DC) must be connected to enable the brake release buttons on
the manipulator.

1. Remove the screws and dismount the
cover on the back of the manipulator
base.
xx0200000072
• A: 13 0 V
• B: 15 24 V DC

2. Locate the R1.MP4-6 connector and
disconnect.
3. Connect an external power supply to
release the holding brake on all axis.
2.3.3. Orienting and securing the manipulator
2.3.3. Orienting and securing the manipulator
General
This section details how to orient and secure the manipulator to the foundation in order to
safely run the robot.
Bolting requirements
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined
in section Loads on foundation, manipulator on page 43.
NOTE!
When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must
be used to secure the bolted joint.
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
manipulator to the base plate/foundation.
Suitable screws, lightly lubricated: M12

Quality Quality 8.8
Suitable washer: Thickness: 2.5 mm
Outer diameter: 24 mm
Inner diameter: 13.4 mm
Tightening torque: 85 Nm
Hole configuration and cross section

The bolt pattern requirements are shown in section Bolt pattern on page 59.
Guide sleeves
Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be
remounted without re-adjusting the program.
Equipment Art. no.

Guide sleeves 3HAC 9519-1
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 User's Guide chapter: System
Parameters.
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
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.
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 User's
Guide.
Brake performance
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB.
2.3.7. Suspended mounting
General
Initially the system is configured for mounting on the floor, without leaning. The method for
mounting the manipulator in a suspended position is basically the same as for floor mounting.
NOTE!
With inverted installation, make sure that the gantry or corresponding structure is rigid
enough to prevent unacceptable vibrations and deflections, so that optimum performance can
be achieved.
System Parameters
If the robot is mounted at any other angle, the system parameter “gravity beta” must be
updated. Gravity beta specifies the robot’s mounting angle expressed in radians.
NOTE!
It is very important to configure gravity beta correctly so that the robot system can control the
movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will
result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some S4 functions will not work properly: e.g Load Identification & Collision
detection.
Mounting Angles and Values

The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated
in the following way for a mounting angle of 45°.
Gravity beta = 45° x 3.141593/180 = 0.785398 radians.
Examples of Position Mounting Angle Gravity Beta

Floor (pos 1) 0° 0.000000 (Default)
Tilted (pos 2) 45° 0.785398
Wall (pos 3) 90° 1.570796
Ceiling (pos 4) 180° 3.141593
xx0200000066
Defining the parameters

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

1. Choose Topics: Manipulator.
2. Choose Types: Robot.
3. Select Master and press Enter.
xx0200000073
4. Select the desired parameter “gravity beta” and

change its value.
5. Press OK to confirm.
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
2.3.8. Bolt pattern
Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes:
xx0200000086
2.4.1. Customer connections on manipulator
2.4 Electrical connections
General
For connection of extra equipment on the manipulator there are cables integrated into the
manipulator's cabling. There are both air and electrical connectors on the manipulator.
xx0200000074
Connections
Connections Description
1. For air on base / upper arm R1/4" Max. 8 bar/hose inner diameter: 6.5 mm
2. Signal connector on upper arm FCI UT 071412SH44N connector
Number of signals: 12 signals, 49V, 500mA
Recommended parts
To connect power and signal conductors to the upper arm connector, the following parts are
recommended
xx0200000132
ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains:
• Multipole connector 12 pin
• Adapter Tin plated 12 pin
• Pins for cable area 0.25-0.5 mm 2
• Pins for cable area 0.5-1.5 mm 2
• Shrinking hose, bootled shaped
• Shrinking hose angled
The connection set is delivered in a plastic bag also containing a Technical and assembly
instruction.
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.
3 Maintenance
3.2.1. Maintenance schedule, IRB 140
3.2 Maintenance schedules
General
The robot, consisting of manipulator and controller cabinet, must be maintained regularly to
ensure its function. The maintenance activities and their respective intervals are specified in
the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Activities and intervals, standard equipment

The sections referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
Equipment Interval Detailed in section:
activity
Inspection Damper, axes 2-3 Regularly *) Inspection, damper axes
2-3 on page 66
Inspection Cable harnesses Regularly *) Inspection, robot cabling
on page 68
Inspection Timing belts 36 mths Inspection, timing belts on
page 69
Change Gearbox 5, oil 36 mths Oil change, gearbox,
axes 5 and 6 on page 73
Change Gearbox 6, oil 36 mths Oil change, gearbox,
axes 5 and 6 on page 73
Change Measurement Depending on battery type Replacement of serial
system, battery and operation pattern as measurement unit and
specified in section Battery battery pack on page 122.
type selection on page 65.
Clean Complete Regularly *) Cleaning, complete robot
manipulator on page 72
*) "Regularly" implies that the activity is to be performed regularly, but the actual interval
may not be specified by the robot manufacturer. The interval depends on the operation cycle
of the robot, its working environment and movement pattern.
Generally, the more contaminated environment, the shorter intervals. The more demanding
movement pattern (sharper bending cable harness), the shorter intervals.
3 Maintenance
Battery type selection

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

Operation pattern
3-cell lithium 6-cell lithium
Max. 4 weeks power off per year 60 mths 60 mths
Weekend power off + operation pattern 1 24 mths 48 mths
Nightly power off + operation patterns 1 and 2 12 mths 24 mths
No longer change interval than 60 months are allowed regardless of the operation pattern due
to material ageing, etc.
3 Maintenance
3.3.1. Inspection, damper axes 2-3
3.3 Inspection activities
Location of dampers, axes 2-3

The figure below shows the location of all the dampers to be inspected.
xx0200000426
A Damper, axis 2
xx0200000427
A Damper, axis 3
3 Maintenance
Required equipment
Equipment Art. no. Note

Standard toolkit 3HAC020812-001 The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Inspection, damper axis 2-3

The procedure below details how to inspect the dampers, axis 2-3
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step Action Note

1. Check all dampers for damage, such as cracks or Shown in the figure in
existing impressions larger than 1 mm. section Location of dampers,
axes 2-3 on page 66!
2. Check attachment screws for deformation.
3. If any damage is detected, the damper must be Art. no. specified in section
replaced with a new one! 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.
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 Art. no. Note

Standard toolkit 3HAC020812-001 The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-
by-step instructions below.
Circuit diagram 3HAC 6816-3
WARNING!
result in burns!
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 Action Note

1. Visually inspect the control cabling between the
manipulator and control cabinet.
Look for abrasions, cuts or crush damages.
2. Replace the cabling if wear or damage is detected. This is detailed in
Replacement of cable
harness on page 78.
3 Maintenance
3.3.3. Inspection, timing belts
Location of timing belts

Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below.
xx0200000448
G Timing belt, axis 3
3 Maintenance
xx0200000453
R Timing belt, axis 6

V Timing belt, axis 5
Required equipment
Equipment, etc. Art. no. Note

Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
3 Maintenance
Inspection
The procedure below details how to inspect the timing belts.
WARNING!
• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
• When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.
Step Action Note

1. Gain access to each belt by These procedures are detailed in sections
removing covers, etc. Replacement of motor and timing belt, axis 3
on page 139 and Replacement of motor and
timing belt, axes 5 or 6 on page 147.
2. Check each belt for damage. Replace the timing belts if found defective as
detailed in sections Replacement of motor
and timing belt, axis 3 on page 139 and
Replacement of motor and timing belt, axes 5
or 6 on page 147.
3. Check each belt for tension. The belt tension should be:
If the belt tension is not correct, it • Axis 3: F = 35-60 N
should be adjusted. • Axis 5: F = 35-60 N
• Axis 6: F = 35-60 N
xx0200000474
Belt tension adjustment is detailed in sections

Replacement of motor and timing belt, axis 3
on page 139 and Replacement of motor and
timing belt, axes 5 or 6 on page 147.
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

May be used on Foundry - • Water pressure at nozzle: max. 2,500 kN/
versions only! m 2 (25 bar)
Steam cleaner • Type of nozzle: fan jet, min. 45° spread
• Flow: max. 100 litres/min.
• Water temperature: max. 80° C
May be used on Foundry - • Max. water pressure on enclosures: 50 kN/
versions only! m 2 (0.5 bar)
High pressure water cleaner • Fan jet nozzle should be used, min. 45°
spread
• Flow: max. 100 litres/min.
Vacuum cleaner - May be used on Standard version
Cloth with mild detergent
Do's and don'ts!

The section below specifies some special considerations when cleaning the manipulator.
Always!
• Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
• Always check that all protective covers are fitted to the robot before cleaning!
Never!
• 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!
3 Maintenance
3.5.1. Oil change, gearbox, axes 5 and 6
3.5 Changing/ replacing activities
Location of oil plugs

The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below.
xx0200000475
A Oil plug, gearbox axis 5

B Oil plug, gearbox, axis 6
Required equipment
Equipment, etc. Art. no. Amount Note

Lubricating oil gearbox 5 3HAC0860-1 350 ml Optimol BM 100
and 6
Oil collecting vessel Capacity: 400 ml.
Standard Toolkit, IRB 140 3HAC020812- The contents are defined in
001 section Standard toolkit in
the Product manual,
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
3 Maintenance
WARNING!
result in burns!
TIP!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
WARNING!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
WARNING!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
• damage seals and gaskets
• completely press out seals and gaskets
• prevent the manipulator from moving freely
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
Draining, axes 5 and 6

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

1. Move the robot to a position where the upper arm is
close to horizontal and axis 4 in the calibration
position.
2. Remove the oil plugs. Shown in the figure Location
The cavity behind the plugs, containing the oil, is of oil plugs on page 73!
common to gearboxes 5 and 6, but during draining,
both must be removed.
3. Move axis 4 90° to a position where the axis 6 oil plug
faces downwards.
4. Drain the oil from the gearbox. Vessel capacity specified in
section Required equipment
on page 73!
5. Move axis 4 another 90°. This allows the remaining oil
to be drained.
6. Refit the oil plug.
3 Maintenance
Refill, axes 5 and 6

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

1. Run the robot to a position where the upper arm
is close to horizontal and axis 4 in the calibration
position.
2. Remove the oil plug, axis 5.. Shown in the figure Location of oil
The cavity behind the plugs, containing the oil, is plugs on page 73!
common to gearboxes 5 and 6, but during
draining, both must be removed.
3. Fill oil in gearbox 5 until the oil level reaches the The figure shows the manipulator
oil plug hole on the side of the wrist. positions for filling and draining
respectively for a standing
manipulator:
xx0300000161
Positions:
• A: Draining position
• B: Filling position
The figure shows the manipulator
positions for filling and draining
respectively for an inverted
manipulator:
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.
3 Maintenance
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.
4 Repair
4.2.1. Replacement of cable harness
4.2 Complete robot
Location of cable harness

The cable harness runs from the base to the motors of axes 3-6.
Required equipment
Equipment, etc. Spare part no. Art. no. Note

Cable harness 3HAC 7370-1 Standard and Foundry
versions
Clean room version
Includes cabling:
• Cable harness,
power axis 1-3
• 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 The contents are defined
in section Standard toolkit
in the Product manual,
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit
diagram in the Product
manual, reference
information.
4 Repair
Removal, cable harness

The procedure below details how to remove the cable harness.
WARNING!
result in burns!
CAUTION!

1. Remove the serial Detailed in section Replacement of serial
measurement board. measurement unit and battery pack on page 122.
2. Disconnect connectors in the
manipulator base.
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
4 Repair

4. Remove the cables from the See figure above!
cable holder by unscrewing the
cable securing screws.
5. Remove the cover, arm Detailed in section Replacement of cover, arm
housing. housing, IRB 140.
6. Remove the lower arm cover. Detailed in section Replacement of lower arm
cover and gasket on page 108.
7. Gently knock out the VK cover. Detailed in section Removing the VK cover on
page 88.
8. Disconnect connectors in the
rear of the upper arm.
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 See figure above!
screws.
10. Cut any cable ties securing the
cabling inside the lower arm.
4 Repair

11. Disconnect the connectors
inside the lower arm.
xx0200000449
• G: Connectors R3.MP3 and R3.FB3

12. Pull the cables out of the upper
arm.
13. Remove the cover, console. Detailed in section Replacement of cover, console
on page 115.
14. Disconnect the connectors Connectors:
inside the console and undo • R3.MP1
the cable holders. • 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.
4 Repair
Refitting, cable harness

The procedure below details how to refit the cable harness.
WARNING!
• Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!

1. Refit in reverse order to what is
detailed above.
Detailed below are some
recommendations on how to
route the cables.
2. Cable distribution in the cable
holder in the manipulator base.
xx0300000093
Cables:
• A: Signal
• B: Signal
• C: Customer signal
• D: Power cable, axes 4-6
• E: Pressurized air supply
• F: Power cable, axes 1-3
4 Repair

3. Cable layout in the lower arm.
xx0200000449
• A: Cable ties
• B: Pressurized air hose
• C: Power cables, axes 4, 5 and 6
• D: Customer cables, signal
• E: Signal cables, axes 4, 5 and 6
• F: Signal cable, axis 3
4 Repair

4. Cable holder in the upper arm.
xx0300000094
Cables:
• A: Customer signal
• B: Signal
• C: Pressurized air supply
• D: Power cables
4 Repair
4.2.2. Replacement of complete upper arm
Location of upper arm

The upper arm is located on top of the manipulator as shown in the figure below.
xx0200000446
A Cover, armhousing
B Attachment screws, cover armhousing, (4 pcs)
C CS-connector
D Pressurized air connector
E VK cover
F Cable guide
G Attachment screws, cable guide
H Attachment screws, upper arm (6 pcs)
J Sealing ring
4 Repair
Required equipment
Equipment Spare part no. Art. no. Note

Upper arm, spare Std/F 3HAC 10466-1 Standard and Foundry
versions
Includes all required
sealings and gaskets.
Upper arm, spare CR 3HAC 10466-3 Clean room versions
sealings and gaskets.
Sealing ring 3HAB 3732-13 To be replaced if
damaged only
Included in the upper arm
assembly
VK cover 3HAC 2166-13
Gasket upper arm cover 3HAC 7867-1 To be replaced if
damaged only
Included in the upper arm
assembly
Special socket - For fitting the CS-
connector
required. See references required.
to these procedures in
the step-by-step
instructions below.
WARNING!
result in burns!
Removal, upper arm

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

1. Run the manipulator arm to a horizontal position.
2. Remove all brackets securing any exterior cabling
to the upper arm by unscrewing their attachment
screws respectively.
4 Repair

3. Remove the rear cover armhousing by unscrewing Shown in the figure Location of
its four attachment screws. upper arm on page 85!
4. DO NOT under any circumstance unscrew the six
screws on top of the lower arm! Doing so will cause
the manipulator to require a complete rebuild!
xx0300000101
• A: DO NOT touch these

screws! (NOTE! Only
two screws shown!)
5. Disconnect all cables to/from motors 4-6. Connectors
• R3.MP4
• R3.MP5
• R3.MP6
• R3.FB4
• R3.FB5
• R3.FB6
6. Disconnect any connector from the CS-connector. Shown in the figure Location of
upper arm on page 85!
7. Use a special socket to remove the CS-connector Shown in the figure Location of
from the housing and pull it into the upper arm upper arm on page 85!
assembly. Art. no. specified in section
Required equipment on page
86!
8. Remove the pressurized air connector from the Shown in the figure Location of
housing and pull it into the upper arm assembly. upper arm on page 85!
Art. no. specified in section
86!
9. Remove the VK-cover from the upper arm/lower Shown in the figure Location of
arm joint. upper arm on page 85!
Detailed in section Removing
the VK cover on page 88.
10. Remove the cable guide by unscrewing its two Shown in the figure Location of
attachment screws. upper arm on page 85!
11. Gently pull all cables and hoses out.
12. Remove the upper arm by unscrewing its six Shown in the figure Location of
13. Lift the upper arm and place it on a secure surface.
4 Repair
Removing the VK cover

The procedure below details how to remove the VK cover from the upper arm.
xx0200000433
A Lower arm
B Lower arm cover gasket
C Cover l. arm, spare (without lamp unit)
D Cover l. arm, spare (with lamp unit)
Step Action Note

1. Remove the lower arm cover by unscrewing its
attachment screws.
2. 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!
3. If the VK cover is damaged, it must be replaced Specified in section Refitting of
on refitting. complete upper arm.
4 Repair
Refitting
The procedure below details how to refit the complete upper arm.
Step Action Note

1. Check the sealing ring to see whether it is Shown in the figure Location of
damaged. upper arm on page 85!
Replace if it is damaged! Art. no. specified in section
Required equipment on page 86!
2. Lift the upper arm into position.
3. Secure the upper arm with its six attachment Shown in the figure Location of
screws. upper arm on page 85!
Tightening torque: 35 Nm ± 3 Nm
4. Gently pull all cables and hoses through the
hole in the upper arm.
5. Reconnect all connectors to motors 4-6. Connectors
• R3.MP4
• R3.MP5
• R3.MP6
• R3.FB4
• R3.FB5
• R3.FB6
6. Refit the cable guide with its two attachment Shown in the figure Location of
screws. upper arm on page 85!
7. 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.
8. Pull the CS-connector through the housing Shown in the figure Location of
and secure it into the fitting in the upper arm upper arm on page 85!
assembly. Art. no. specified in section
Use a special socketto secure it. Required equipment on page 86!
9. Reconnect any connector previously
connected externally to the CS connector.
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 Shown in the figure Location of
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.
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.
4 Repair
4.2.3. Replacement of complete lower arm
Location of lower arm

The lower arm is located between upper arm and frame as shown in the figure below.
xx0200000469
A Lower arm
4 Repair
Required equipment

Lower arm, spare 3HAC 10468-1 Standard and Foundry
versions
bearings, oil and VK cover.
Lower arm, spare 3HAC 10468-4 Clean room versions
bearings, oil and VK cover.
section Standard toolkit in
the Product manual,
Lifting device for lower Lifting capacity xx kg
arm
Special socket - For fitting the CS-
connector
the step-by-step
instructions below.
Removal, lower arm

The procedure below details how to remove the complete lower arm.
WARNING!
result in burns!
4 Repair

1. Remove the console. Detailed in section Replacement of console on
page 118.
2. DO NOT under any
circumstance unscrew the six
screws on top of the lower arm!
Doing so will cause the
manipulator to require a
complete rebuild!
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 Shown in the figure above!
attachment screws.
Also remove the washer.
5. Raise the lifting device to
remove the lower arm.
4 Repair
Refitting, lower arm

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

1. Fit the lifting device and lift the
lower arm into position.
2. Fit the lower arm to gearbox, axis
2, and secure it with its
attachment screws and washers.
xx0300000097
Parts:
• A: Washer
• B: Lower arm attachment screws (10 pcs)
• C: VK cover
3. Fit a new VK cover by gently Shown in the figure above!
tapping it into position.
4. Refit the console. Detailed in section Replacement of console on
page 118.
5. Recalibrate the robot. Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in section
Document references in the Product manual,
4 Repair
4.2.4. Replacement of base, spare
Location of base
The base is located at the bottom of the manipulator as shown in the figure below.
xx0200000423
A Base
B Bottom plate
C Bottom plate attachment screws (26 pcs)
D Gearbox/base attachment screws and washers (20 pcs each)
E Joint, gearbox/base
F Damper, axis 1
G Washer
Required equipment

Base, spare 3HAC 10470-1 Standard and Foundry
versions
Includes Parallel pin 3HAC
3785-2
Base, spare 3HAC 10470-3 Clean room versions
Includes Parallel pin 3HAC
3785-2
Lifting slings - Min. capacity 20 kg
4 Repair

LocTite 574 For sealing the base to the
gearbox 1-2
the Product manual,
references to these
procedures in the
step-by-step
instructions below.
Removal, base
The procedure below details how to remove the base.
WARNING!
result in burns!
Step Action Info

1. Remove motors 1 and 2. Detailed in sections Replacement of
motor, axis 1 on page 130 and
Replacement of motor, axis 2 on page
135 respectively.
2. Remove the cable harness. Detailed in section Replacement of
cable harness on page 78.
3. Remove the serial measurement board. Detailed in section Replacement of
serial measurement unit and battery
pack on page 122.
4. Remove the complete upper arm. Detailed in section Replacement of
complete upper arm on page 85.
5. Remove the complete lower arm. Detailed in section Replacement of
complete lower arm on page 91.
6. Place the remaining base/gearbox axes 1- Shown in the figure Location of base.
2 assembly upside down on a work bench.
Remove the bottom plate.
7. Remove the gearbox/base attachment Shown in the figure Location of base.
screws.
8. Separate the base from the gearbox 1-2.
4 Repair
Refitting
The procedure below details how to refit the complete lower arm.
WARNING!
result in burns!
Step Action Note

1. Place the gearbox 1-2 and the base on a
workbench.
2. 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.
3. Secure the gearbox to the base with the Shown in the figure Location of base.
gearbox/base attachment screws and Tightening torque: 35 Nm ± 3Nm
washers.
4. Refit the bottom plate and secure it with its Shown in the figure Location of base.
attachment screws.
5. Turn the base into standing upright.
6. Refit the complete lower arm. Detailed in section Replacement of
complete lower arm on page 91.
7. Refit the complete upper arm. Detailed in section Replacement of
complete upper arm on page 85.
8. Refit motors 1 and 2. Detailed in sections Replacement of
motor, axis 1 on page 130 and
Replacement of motor, axis 2 on page
135 respectively.
9. Refit the serial measurement board. Detailed in section Replacement of
serial measurement unit and battery
pack on page 122.
10. Refit the cable harness. Detailed in section Replacement of
cable harness on page 78.
Art. no. for the manuals are specified
in section Document references in
the Product manual, reference
information.
DANGER!
it is vital that:
4 Repair
4 Repair
4.3.1. Replacement of wrist unit
4.3 Upper arm
Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm.
xx0200000438
A Wrist unit attachment screws (3 pcs)

B Oil plug (one shown)
C Wrist unit
Required equipment

Wrist unit (Std/F) 3HAC 10475-1 Standard and Foundry
versions
O-ring sealing plate not
included!
Wrist unit (CR) 3HAC 10475-4 Clean room versions
O-ring sealing plate not
included!
O-ring sealing plate 3HAC 7191-1 Must be replaced
Grease 3HAC 3537-1 For lubricating the o-ring
sealing plate
4 Repair

the Product manual,
Arm 3HAC 9037-1 For adjusting the gear play,
motor/pinion
references to these
below.
Removal, wrist unit

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

1.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Drain the oil from the wrist unit. Detailed in section Oil
change, gearbox, axes 5
and 6 on page 73.
3. Remove the wrist unit by unscrewing its three Shown in the figure in
attachment screws. section Location of wrist unit
on page 99.
Refitting, wrist unit

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

1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the robot to a position where the upper
arm is vertical. The axis 5 motion plane
should be horizontal.
3. Lightly lubricate the o-ring sealing plate with Art. no. is specified in section Required
grease. equipment on page 99.

4 Repair
Step Action Note

4. 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.
5. In order to release the brake, connect the Connect to connector R3.MP5 or 6:
24 VDC power supply to motors: • +: pin 7
• -: pin 8
6. Fit the Arm to the rear of the motor. Art. no. is specified in section Required
equipment on page 99.
7. Manually push the motor to adjust the motor
in relation to the gear in the gearbox.
Minimize the gear play as shown in the
figure.
xx0200000445
• A: Wrist unit, axes 5 and 6

gears
• B: Drive shafts from motors,
axes 5 and 6 gears
• C: Adjustment direction
• D: Gear play
8. Tighten the wrist unit attachment screws. Tightening torque: 28 Nm ± 3 Nm
9. Check the gear play by moving axes 5 and The gear play should be xx to pass the
6 by hand. test.
10. Perform a leak-down test. Detailed in section Leak-down test.
11. Refill the wrist unit with oil. Detailed in section Oil change,
gearbox, axes 5 and 6 on page 73.
12. Recalibrate the robot! Calibration is detailed in separate
Art. no. for the manuals are specified in
section Document references in the
information.
DANGER!
it is vital that:

4 Repair
4.3.2. Replacement of damper, axis 3
Location of damper, axis 3

The damper, axis 3, is shown in the figure below!
xx0200000427
A Damper, axis 3
Required equipment

Damper axis 3 3HAC 7881-1
Other tools and These procedures
procedures may be include references to the
required. See references tools required.
the step-by-step
instructions below.

4 Repair
Removal, damper axis 3

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

1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the robot to a position that enables access to Shown in the figure Location of
damper, axis 3. damper, axis 3 on page 102.
3. 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 Action Note

1.
Danger!
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.
3. Refit the damper by gently pressing it onto the cast
tab on the upper arm.
DANGER!
it is vital that:

4 Repair

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

Damper axis 5 3HAC 8964-1
the step-by-step
instructions below.

4 Repair

Step Action Note

1.
Danger!
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.
3. Unhook the end of the damper, and push it into the
recess.
4. Manually move the wrist (robot axis 5) away from the
damper to pull it out.

Step Action Note

1.
Danger!
2. 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!
3. Manually move the wrist (robot axis 5) in order to pull
the damper into position.
4. Fold out the damper hooks to secure it in position.
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
• - special attention is paid to the function of the part previously serviced.

4 Repair
4.3.4. Replacement of cover, arm housing
Location of cover, armhousing

The cover, armhousing is located on the rear of the upper arm as shown in the figure below.
xx0200000464
A Cover, arm housing

B Attachment screws, cover, armhousing
C Gasket, upper arm cover
Required equipment
Equipment, etc. Spare part. no. Art. no. Note

Cover, arm housing 3HAC 10473-1 Standard and Foundry
version
Includes gasket 3HAC
7867-1
Cover, arm housing 3HAC 10473-3 Clean Room versions
7867-1
Gasket, upper arm cover 3HAC 7867-1
Standard toolkit 3HAC020812-001 The contents are
defined in section
Standard toolkit in the
Product manual,
procedures may be include references to
required. See references the tools required.
the step-by-step
instructions below.

4 Repair
Removal
The procedure below details how to remove the cover, armhousing.
WARNING!
result in burns!
Step Action Note

1. Manually, run the robot to a position that enables
access to the rear of the upper arm.
2. Remove the cover, armhousing by unscrewing its Shown in the figure Location
attachment screws. of cover, armhousing on
page 106.
NOTE! Do not damage the
gasket inside the cover!
Refitting
The procedure below details how to refit cover, armhousing.
WARNING!
result in burns!
Step Action Note

1. Manually, run the robot to a position that enables Shown in the figure Location
access to the rear of the upper arm. of cover, armhousing on
page 106.
2. Make sure the gasket inside the cover, arm housing Replace if damaged.
has not been damaged. Shown in the figure Location
of cover, armhousing on
page 106.
3. Secure the cover, arm housing to the upper arm with
its attachment screws.

4 Repair
4.4.1. Replacement of lower arm cover and gasket
4.4 Lower arm
Location of lower arm cover and gasket

The lower arm cover and gasket are located as shown in the figure below.
xx0200000433
A Lower arm
B Gasket lower-arm cover
C Cover l. arm, spare (without lamp unit)
D Cover l. arm, spare (with lamp unit)

4 Repair
Required equipment

Cover l. arm, spare, Std/F 3HAC 10471-1 Standard and Foundry
versions
No lamp unit included
7869-1
Cover l. arm, spare, CR 3HAC 10471-3 Clean room versions
No lamp unit included
7869-1
Gasket lower-arm cover 3HAC 7869-1
Isopropanol 1177 1012-208 For cleaning sealing
surfaces
defined in section
Product manual,
Other tools and procedures These procedures
may be required. See include references to
references to these the tools required.
Removal, lower arm cover and gasket

The procedure below details how to remove the lower arm cover and gasket.
WARNING!
result in burns!
Step Action Note

1. Remove the lower arm cover by unscrewing its Shown in the figure Location
attachment screws. of lower arm cover and
gasket on page 108.
2. If the gasket is to be replaced, proceed below!
Use a knife to gently remove the old gasket from the
cover.
3. Clean the sealing surface with isopropanol, making Art. no. specified in section
sure it is completely clean and free from scratches Required equipment on
and burrs. page 109.

4 Repair
Refitting, lower arm cover and gasket

The procedure below details how to refit the lower arm cover and gasket.
WARNING!
• - Motors and gears are HOT after running the robot! Burns may result from touching
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step Action Note

1. If the Gasket lower-arm cover is to be replaced, Shown in the figure Location
proceed below. If not, see further down! of lower arm cover and
gasket on page 108.
2. Remove the protective backing from the self- Make absolutely sure it is
adhesive gasket and fit it onto the cover sealing correctly located!
surface.
3. Refit the lower arm coverwith its attachment screws. Shown in the figure Location
of lower arm cover and
gasket on page 108.

4 Repair

The damper, axis 2, is located as shown in the figure below!
xx0200000426
A Damper, axis 2
Required equipment

Damper ax. 2 3HAC 7880-1
the Product manual,
references to these
below.

4 Repair

Step Action Note

1.
Danger!
2. Run the robot to a position that enables you to access the
attachment screw of damper, axis 2.
3. Remove the damper by unscrewing the single attachment
screw and washer.

Step Action Note

1.
Danger!
2. Run the robot to a position that enables access to the
attachment screw of the damper, axis 2.
3. Secure the damper with its single attachment screw 1 pc: M6 x 16.
and washer.
DANGER!
it is vital that:

4 Repair
4.4.3. Replacement of indicator lamp
Location of indicator lamp

The indicator lamp is located on the side of the lower arm as shown in the figure below.
xx0200000472
A Indication lamp
B Lower arm cover
Required equipment

Indicator lamp 3HAC 9258-1
information!
references to these
procedures in the
step-by-step
instructions below.

4 Repair
Removal
The procedure below details how to remove the indicator lamp.
WARNING!
result in burns!
Step Action Note

1. Remove the lower arm cover. Detailed in section
Replacement of lower arm
cover and gasket on page
108.
2. Remove the damper by gently prying the plastic semi-
transparent damper from the cast tab.
Refitting
The procedure below details how to refit the indicator lamp.
WARNING!
result in burns!
Step Action Note

1. Run the robot to a position that enables access to
damper, axis 3.
2. Refit the damper by gently pressing it onto the cast
tab on the upper arm.
DANGER!
it is vital that:

4 Repair
4.5.1. Replacement of cover, console
4.5 Frame and base
Location of cover, console

The cover, console is located on top of the console as shown in the figure below.
xx0200000462
A Cover, console
B Attachment screws, cover, console (4 pcs)
C Gasket
D Console
Required equipment

Cover, console, spare 3HAC 10472-1 Standard and Foundry
version
7868-1
Cover, console, spare 3HAC 10472-3 Clean Room versions
7868-1
Gasket, cover console 3HAC 7868-1

4 Repair

in section Standard
toolkit in the Product
manual, reference
information!
required. See tools required.
references to these
below.
Removal
The procedure below details how to remove the cover, console.
WARNING!
result in burns!
Step Action Note

1. 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.
2. Remove the cover, console by unscrewing its NOTE! Do not damage the
attachment screws. gasket inside the cover!
Refitting
The procedure below details how to refit cover, console.
WARNING!
result in burns!
Step Action Note

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.

4 Repair
Step Action Note

2. Make sure the gasket inside the cover, console Replace if damaged.
has not been damaged. Shown in the figure Location of
cover, console on page 115.
3. Secure the cover, console to the console with its
attachment screws.

4 Repair
4.5.2. Replacement of console
Location of console
The console is located on top of gearbox, axes 1-2 as shown in the figure below.
xx0200000462
A Cover, console
B Attachment screws, cover, console (4 pcs)
C Gasket
D Console
Required equipment

Console, spare 3HAC 10478-1 Standard and Foundry
version
Console, spare 3HAC 10478-3 Clean Room versions
defined in section
Product manual,

4 Repair
Removal
The procedure below details how to remove the cover, console.
WARNING!
result in burns!

1. Remove the cable harness. Detailed in section Replacement of cable harness
on page 78.
2. Remove the serial Detailed in section Replacement of serial
measurement board. measurement unit and battery pack on page 122.
3. Remove the complete upper Detailed in section Replacement of complete upper
arm. arm on page 85.
4. DO NOT under any
circumstance unscrew the six
screws on top of the lower
arm! Doing so will cause the
manipulator to require a
complete rebuild!
xx0300000101
Parts:
• A: DO NOT touch these screws! (Note! Only
two screws shown!)
5. Remove the motor of axis 3. Detailed in section Replacement of motor and
timing belt, axis 3 on page 139.
6. Attach the lifting device to the
lower arm.

4 Repair

7. Remove the bearing hub by
screws.
xx0300000096
Parts:
• A: Console
• B: Bearing hub
• C: Bearing hub attachment screws (6 pcs)
• D: Console attachment screws (10 pcs)
• E: Washers (10 pcs)
8. Remove the console by Shown in the figure above!
screws.
Refitting
The procedure below details how to refit cover, console.
WARNING!
result in burns!

4 Repair

1. Refit the console and secure it with
its attachment screws and washers.
xx0300000096
Parts:
• A: Console
• B: Bearing hub
• C: Bearing hub attachment screws (6
pcs)
• D: Console attachment screws (10 pcs)
• E: Washers (10 pcs)
2. Refit the bearing hub and secure it Shown in the figure above!
with its attachment screws. Tightening torque: 15 Nm ± 1 Nm
3. Refit the complete upper arm. Detailed in section Replacement of complete
upper arm on page 85.
4. Refit motor 3 and timing belt. Detailed in section Replacement of motor and
timing belt, axis 3 on page 139.
5. Refit the serial measurement board. Detailed in section Replacement of serial
measurement unit and battery pack on page
122.
6. Refit the cable harness. Detailed in section Replacement of cable
harness on page 78.
7. Recalibrate the robot! Calibration is detailed in separate calibration
manuals.

4 Repair
4.5.3. Replacement of serial measurement unit and battery pack
Location of serial measurement unit and battery pack

The serial measurement unit and battery pack are located inside the manipulator base as
shown in the figure below.
xx0200000432
A Rear cable cover

B Battery pack
C Serial measurement board (SMB)
D SMB attachment screws (4 pcs)
E Manipulator base bottom plate
Required equipment

Serial measurement unit 3HAC 9522-1
Battery pack 4944 026-4 NiCd type
Battery pack 3HAB 9999-1 3 cell, lithium type
Battery pack 3HAB 9999-2 6 cell, lithium type
Cable tie Indoors
Gasket base-cover 3HAC 7870-1 Replace only if required!

4 Repair

Standard Toolkit, IRB 140 3HAC020812-001 The contents are defined
in section Standard
toolkit in the Product
manual, reference
information!
to these procedures in the
step-by-step instructions
below.
manual, reference
information.
Removal
The procedure below details how to remove the serial measurement unit and battery pack.
WARNING!
result in burns!
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!

4 Repair
CAUTION!
Step Action Note

1. Set the robot system to MOTORS OFF state. This will simplify calibration of the
robot after replacement since no
coarse calibration will be required.
2. Remove the rear cable cover from the base of Shown in the figure Location of
the robot by unscrewing its attachment screws. serial measurement unit and
battery pack on page 122!
3. 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.
4. 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
5. Lift the board out.
6. If the battery pack is to be replaced, proceed Shown in the figure Location of
below! serial measurement unit and
Cut the cable tie and disconnect the battery battery pack on page 122!
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.
Refitting
The procedure below details how to refit the serial measurement unit and battery pack.
WARNING!
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to
electrostatic voltages.
• Before handling, make sure you are connected to earth through a special ESD wrist
bracelet or similar.

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!
Step Action Note

1. Connect the new battery pack to the serial
measurement unit and secure it with a cable tie.
2. Reconnect all connectors to the unit. Connectors
• R2.SMB
• R2.FB1-3
• R2.FB4-6
• R2.G
3. Place the serial measurement unit in position 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!
4. Make sure the gasket sealing the rear cable cover Shown in the figure Location of
has not been damaged. serial measurement unit and
Replace the gasket if required. battery pack on page 122!
Art. no. specified in section
122!
5. Making sure all cables are correctly located Shown in the figure Location of
behind the rear cable cover, refit it into position. serial measurement unit and
Make sure no cables or other equipment fitted battery pack on page 122!
behind the cover get pinched by the cover.
6. Secure the rear cable cover to the base of the Shown in the figure Location of
robot with its attachment screws. serial measurement unit and
battery pack on page 122!
7. This is valid if NiCd type batteries are used only!
Lithium batteries do not require charging before
use.
Recharge the battery for at least 36 hrs by leaving
the mains supply switched on for this amount of
time.
8. Recalibrate the robot! Calibration is detailed in
separate calibration manuals.
references in the Product
manual, reference information.

4 Repair
4.5.4. Replacement of control cable
Location of control cable

The control cable is located on the rear of the manipulator base as shown in the figure below.
xx0200000467
A Gasket, base-cover
B Attachment screws and washers (9 pcs each), control cable
C Control cable, spare
Required equipment

Control cable, spare 3HAC 10476-1 3m
Standard and Foundry
versions
Cover gasket included
versions
Control cable, spare 3HAC 11331-1 15 m
versions
versions

4 Repair

versions
Clean Room versions
Clean Room versions
Clean Room versions
Clean Room versions
Clean Room versions
the step-by-step
instructions below.
Removal
The procedure below details how to remove the control cable.
WARNING!
result in burns!

4 Repair

1. Make sure the robot system has been
switched off, and that no power is
supplied to the manipulator.
2. Remove the Control cable, spareby Shown in the figure Location of control cable
unscrewing its attachment screws. 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. Pull the cable out of the manipulator
base.
5. Disconnect the connectors from the
control cabinet.

4 Repair
Refitting
The procedure below details how to refit control cable.
WARNING!
result in burns!

1. Place the control cable on the floor with Shown in the figure Location of control
the manipulator base cover close to the cable on page 126.
manipulator.
2. Connect the connectors inside the
manipulators base.
xx0300000090
Connectors:
• A: R1.MP1-3
• B: R1.CS
• C: Air hose
• D: R1.MP4-6
3. Fit a new gasket when refitting the cover. Included in the spare part
4. Fit the cover onto the manipulator base Shown in the figure Location of control
and secure it with its attachment screws. cable on page 126.

4 Repair
4.6.1. Replacement of motor, axis 1
4.6 Motors
Location of motor axis 1

The motor axis 1 is located on the rear of the manipulator as shown in the figure below:
xx0200000407
A Motor, axis 1
B Cover for connector access
C Motor attachment screws (4 pcs)
D Cable gland attachment screws (4 pcs)
E Console
Required equipment
Equipment, etc. Spare part no. Art no. Note

Rot. ac motor with 3HAC 10469-3 Clean room versions.
pinion 3HAC 021966-001
Rot. ac motor with 3HAC 10469-1 Standard and Foundry
pinion 3HAC 021965-001 versions.
Rot. ac motor w 3HAC 10469-4 High performance version.
pinion TStd/TF
O-ring 2152 2012-426 Must be replaced when
replacing motor!
Included in the spare parts
motor kits
Cable gland gasket 3HAC xx Fitted onto the console
cable gland

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

Grease 3HAB 3537-1 Used to lubricate the o-ring
the Product manual,
motor/pinion
Power supply 24 VDC, max. 1,5 A
For releasing the brakes
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit diagram

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!
result in burns!
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Step Action Note

1. 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.
2. Disconnect the motor 1 connectors inside the Connectors:
console. • R3.MP1
• R3.FB1
3. Cut any cable ties and remove any brackets securing
the cables.
4. 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.
5. In order to release the brakes, connect the 24 VDC Connect to connector
power supply: R3.MP1
• +: pin 7
• -: pin 8
6. Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers. of motor axis 1 on page 130.
7. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
8. Remove the motor by gently lifting it straight up.

4 Repair
Refitting
The procedure below details how to refit motor, axis 1.
WARNING!
NOTE!
used!
Step Action Note

1. Make sure the mating surfaces on the motor
and the gearbox are clean and free from burrs.
2. Make sure the o-ring on the circumference of Art. no. is specified in section
the motor is seated properly. Lightly lubricate Required equipment on page 130.
the o-ring with grease .
3. In order to release the brake, connect the 24 Connect to connector R2.MP1
VDC power supply: • +: pin 7
• -: pin 8
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!
5. Fit the motor with four attachment screws and Tightening torque: approx 2 Nm
plain washers.
6. Fit the Arm to the end of the motor shaft. Art. no. is specified in section
Required equipment on page 130.
7. Adjust the motor in relation to the gear in the There should be a barely noticable
gearbox. gear play.
Use the Arm tool to wiggle the motor shaft
back and forth to feel the play.
8. Tighten the motor attachment screws. Tightening torque: approx 11 Nm ± 1
Nm
9. Disconnect the brake release voltage.
10. Make sure the cable gland gasket has not Art. no. is specified in section
been damaged. Replace, if it has. Required equipment on page 130.
11. Push the cables into the console, and refit the
cable gland with its attachment screws.

4 Repair
Step Action Note

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

4 Repair

The motor axis 2 is located on the front of the manipulator as shown in the figure below.
xx0200000408
A Motor, axis 2
B Cover for connector access
C Motor attachment screws (4 pcs)
D Cable gland attachment screws (4 pcs)
E Console
Required equipment

Rot. ac motor with 3HAC 10469-3 Clean room versions.
pinion, spare 3HAC 021966-001
Rot. ac motor with 3HAC 10469-1 Standard and Foundry
pinion, spare 3HAC 021965-001 versions.
Rot. ac motor with 3HAC 10469-4 High performance version.
pinion, spare,
TStd/TF
O-ring 2152 2012-426 Must be replaced when
replacing motor!
Cable gland gasket 3HAC xx Fitted onto the console cable
gland
Grease 3HAB 3537-1 For lubricating the o-ring.
information!

4 Repair

motor/pinion
Power supply 24 VDC, 1.5 A.
For releasing the brakes.
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit diagram in
the Product manual,
Removal
WARNING!
result in burns!
NOTE!
used!
Step Action Note

1. 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.
2. Disconnect the motor 2 connectors inside the Connectors:
console. • R3.MP2
• R3.FB2
3. Cut any cable ties and remove any brackets securing
the cables.
4. 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.
5. In order to release the brakes, connect the 24 VDC Connect to connector
power supply: R3.MP2
• +: pin 2
• -: pin 5
6. Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers. of motor axis 2 on page 135.
7. Lift the motor to get the pinion away from the gear.

4 Repair
Step Action Note

9. Remove the motor by gently pulling it out.
There is a real danger of oil running out of the motor
attachment hole when removing the motor. Take any
necessary measures to collect the oil.
10. Remove any remaining oil from the gearbox by
siphoning it out.
Refitting
WARNING!
NOTE!
used!
Step Action Note

1. Make sure the mating surfaces on the motor and
the gearbox are clean and free from burrs.
2. Make sure the o-ring on the circumference of the Art no. is specified in section
motor is seated properly. Lightly lubricate the o- Required equipment on page
ring with grease . 135.
3. In order to release the brake, connect the 24 VDC Connect to connector R2.MP2
power supply: • +: pin 7
• -: pin 8
4. Fit the motor, making sure the motor pinion is Make sure the motor is turned
properly mated to gearbox 2. the right way, i.e. connections
rearwards.
Make sure the motor pinion
does not get damaged!
5. Fit the motor with four attachment screws and plain Tightening torque: approx 2
washers. Nm
6. Fit the Arm to the end of the motor shaft. Art no. is specified in section
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.
8. Tighten the motor attachment screws. Tightening torque: approx 11
Nm ± 1 Nm

4 Repair
Step Action Note

10. Make sure the cable gland cover gasket has not Art no. is specified in section
been damaged. Replace if it has. Required equipment on page
135.
11. Push the cables into the console, and refit the cable
gland with its attachment screws.
12. Perform a leak-down test. Detailed in section Leak-down
test.
13. Refill the gearbox with oil.
14. Recalibrate the robot! Calibration is detailed in
separate calibration manuals.
references in the Product
manual, reference information.

4 Repair
4.6.3. Replacement of motor and timing belt, axis 3

The motor axis 3 is located behind the lower arm cover on the right hand side of the
manipulator as shown in the figure below.
xx0200000448
A Lower arm cover

B Attachment screws, lower arm cover (13 pcs)
C Belt shield
D Motor 3
E Attachment screws, belt shield (3 pcs)
F Attachment screws, motor 3 (4 pcs)
G Belt

4 Repair
Required equipment

Rot. ac motor with 3HAC 7866-1 Includes timing belt
pinion 3HAC 021756-001 pulley.
Timing belt 3HAC 6793-1
Grease 3HAB 3537-1 For lubricating the o-
ring.
defined in section
Product manual,
procedures may be include references to
required. See the tools required.
references to these
below.
manual, reference
information.
Removal
WARNING!
result in burns!
NOTE!
used!

1. Remove any equipment hindering Shown in the figure in section Location of
access to the lower arm cover. motor axis 3 on page 139.
2. Remove the lower arm cover by Shown in the figure in section Location of
unscrewing its attachment screws. motor axis 3 on page 139.

4 Repair

3. Cut the cable ties to facilitate
accessing the motor.
xx0200000449
• A: Cable ties
4. Disconnect motor connectors. Connectors:
• R3.MP3
• R3.FB3
• R3.H1 (if Safety lamp is fitted)
• R3.H2 (if Safety lamp is fitted)

4 Repair

5. DO NOT under any circumstance
unscrew the three screws securing the
belt wheel! Doing so will cause the
manipulator to require a complete
rebuild!
xx0300000102
Parts:
• DO NOT touch these screws! (3 pcs)
6. Remove the belt shield by unscrewing Shown in the figure in section Location of
its twoattachment screws. motor axis 3 on page 139.
7. Remove the remaining Shown in the figure in section Location of
motorattachment screws. motor axis 3 on page 139.
8. Remove the belt. Shown in the figure in section Location of
motor axis 3 on page 139.
9. Remove the motor. Shown in the figure in section Location of
Refitting
WARNING!

1. Make sure the mating surfaces on the
motor and the lower arm are clean and
free from burrs.
2. Fit the motor in the lower arm.
3. Fit the belt. Shown in the figure in section Location of
4. Tighten the two motor attachment
screws slightly, but not completely.

4 Repair

5. Adjust the position of the motor in such a Correct belt tension F=35 - 60 N
way that the correct belt tension is
achieved.
6. DO NOT adjust the belt tension using the
intermediate wheel securing screws.
7. Fit the belt shield and secure it with the Tightening torque: 4 Nm ± 0.5 Nm
two remaining screws.
8. Tighten the last motor attachment Tightening torque: 4 Nm ± 0.5 Nm
screws.
9. Refit the cabling as shown.
xx0200000449
• A: Cable ties
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

4 Repair
Location of motor, axis 4

The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0200000455
A Attachment screws, motor 4 (4 pcs)

B Motor, axis 4
C O-ring
Required equipment

Rot. ac motor with 3HAC 7842-1 Standard, Clean Room and
pinion 3HAC 021757-001 Foundry versions
Does not include the o-ring!
O-ring 3HAC 3772-24 Must be replaced when
replacing motor!
Grease 3HAC 3537-1 Used to lubricate the o-ring.
the Product manual,
Power supply 24 VDC, max. 1,5 A.
For releasing the brakes.
Arm 3HAC 9037-1 For adjusting the gear play

4 Repair

references to these
procedures in the
step-by-step
instructions below.
manual, reference
information.
Removal
WARNING!
result in burns!
NOTE!
used!
Step Action Note

1. Remove the motors for axes 5 and 6. Detailed in section
Replacement of motor and
timing belt, axes 5 or 6 on page
147.
2. Manually run the manipulator to a position where This will enable the motor 4 to
the upper arm points straight down. be removed without draining
the oil in the gearbox.
3. Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws. motor, axis 4 on page 144.
4. In order to release the brake, connect the 24 VDC Connect to connector R3.MP4
power supply: • +: pin 7
• -: pin 8
5. Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
6. Remove the motor by gently lifting it straight out. Make sure the motor pinion is
not damaged!

4 Repair
Refitting
WARNING!
NOTE!
used!
Step Action Note

1. 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.
2. 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 .
3. In order to release the brake, connect the 24 Connect to connector R3.MP4
VDC power supply: • +: pin 7
• -: pin 8
4. Fit the motor with the attachment screws. Tightening torque: approx. 2 Nm
5. Fit the Arm to the end of the motor shaft. Art. no. is specified in section
Required equipment on page 144.
6. Adjust the motor in relation to the gear in the There should be a barely noticable
gearbox. gear play.
Use the Arm tool to wiggle the motor shaft
back and forth to feel the play.
7. Tighten the motor attachment screws. Shown in the figure Location of
motor, axis 4 on page 144.
Tightening torque: 6 Nm ± 0.6 Nm
8. Refit motors 5 and 6. Detailed in section Replacement of
motor and timing belt, axes 5 or 6 on
page 147.

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

The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the
figure below.
xx0200000453
A Lower arm cover

B Attachment screws, lower arm cover
C Cover, armhousing
D Attachment screws, cover armhousing (4 pcs)
E VK cover
F Pressurized air hose (on front of upper arm)

4 Repair
G CS connector
H Cable guide
J Attachment screws, cable guide
K Belt shield
L Attachment screws, belt shield
M Motor attachment screws, 4 pcs per motor
N Attachment screws, motor console
P Clamping unit screws
Q Clamping unit
R Timing belt, axis 6
S Pulley, axis 6
T Screws securing the pulley to the axis 5 drive shaft
U Timing belt, axis 5
V Pulley, axis 5
W Motor console, ax. 5-6
X Motor, axis 4
Y Motor, axis 5
Z Motor, axis 6
Required equipment

Rot. ac motor with pinion 3HAC 7842-1 Axis 4
3HAC 021757-001 Standard, Clean room
and Foundry versions.
Rot. ac motor with pinion 3HAC 7841-1 Axes 5 and 6
3HAC 021758-001 Standard, Clean room
and Foundry versions.
Timing belt 3HAC 6779-1 Axes 5 and 6
VK cover 3HAC 2166-13
Clamping unit 3HAC 7939-1
defined in section
Product manual,
Special socket xx 3HAC xx For fitting the CS-
connector
diagram in the
Product manual,

4 Repair
Removal
The procedure below details how to remove motor, axis 5 or 6.
WARNING!
result in burns!
NOTE!
used!
Step Action Note

1. Run the robot to a position where the upper
arm is close to horizontal
2. Remove the lower arm cover by Shown in the figure in section Location
unscrewing its attachment screws. of motor and timing belt, axes 5 or 6 on
page 147!
3. Remove the rear cover armhousing by Shown in the figure in section Location
unscrewing its four attachment screws. of motor and timing belt, axes 5 or 6 on
page 147!
4. Disconnect all cables to/from motors 4-6. Connectors:
• R3.MP4
• R3.MP5
• R3.MP6
• R3.FB4
• R3.FB5
• R3.FB6
5. Disconnect any connector from the CS- Shown in the figure in section Location
connector. of motor and timing belt, axes 5 or 6 on
page 147!
6. Use a special socket to remove the CS- Shown 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
7. 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!
equipment!
8. 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.

4 Repair
Step Action Note

9. 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!
10. Gently pull the cables out of the upper arm.
11. Remove the belt shield by unscrewing its Shown in the figure in section Location
attachment screws. of motor and timing belt, axes 5 or 6 on
page 147!
12. Unscrew the motor attachment screws. Shown in the figure in section Location
of motor and timing belt, axes 5 or 6 on
page 147!
13. Unscrew the clamping unit screws Shown in the figure in section Location
of motor and timing belt, axes 5 or 6 on
page 147!
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, Shown in the figure in section Location
axis 6. of motor and timing belt, axes 5 or 6 on
page 147!
17. Remove the screws securing the pulley to Shown in the figure in section Location
the axis 5 drive shaft. of motor and timing belt, axes 5 or 6 on
page 147!
18. Remove the pulley and belt from motor, Shown in the figure in section Location
axis 5. of motor and timing belt, axes 5 or 6 on
page 147!
19. Remove the motor console, ax. 5-6 by Shown in the figure in section Location
unscrewing its attachment screws. of motor and timing belt, axes 5 or 6 on
page 147!

4 Repair
Refitting
WARNING!
NOTE!
used!
Step Action Note

1. Make sure the mating surfaces on the motor
and the console are clean and free from
burrs.
2. Fit the motors in the motor console without Shown in the figure in section
tightening the attachment screws. 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,
4. Fit pulley, axis 5 and timing belt, axis 5 with Shown in the figure in section
their attachment screws and washers. Location of motor and timing belt,
5. Tighten the motor attachment screws to This will facilitate adjustment of the
enable the motor to be shifted slightly. belt tension.
6. Adjust the belt tension by xx. Correct belt tension F=35 - 60 N
7. Secure the motor with its attachment screws Tightening torque: 4 Nm ± 0.5 Nm
including the ones in the motor console.
8. Fit pulley, axis 6 and timing belt, axis 6 with Shown in the figure in section
their attachment screws and washers. Location of motor and timing belt,
9. Fit the clamping unit and secure it with its Shown in the figure in section
clamping unit attachment screws. Location of motor and timing belt,
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,

4 Repair
Step Action Note

13. Pull the pressurized air connector through Shown in the figure in section
the housing and secure it into fitting in the Location of motor and timing belt,
upper arm assembly. axes 5 or 6 on page 147!
equipment
14. Pull the CS-connector through the housing Shown in the figure in section
and secure it into the fitting in the upper arm Location of motor and timing belt,
assembly. axes 5 or 6 on page 147!
Use a special socketto secure it. Art. no. specified in section Required
equipment
15. Reconnect any connector to the CS- Shown in the figure in section
connector. Location of motor and timing belt,
16. Reconnect all cables to/from motors 4-6. Connectors
• R3.MP4
• R3.MP5
• R3.MP6
• R3.FB4
• R3.FB5
• R3.FB6
17. Refit the cable guide with its two attachment Shown in the figure in section
screws. Location of motor and timing belt,
18. Fit a newVK-cover to the upper arm/lower Shown in the figure in section
arm joint. Location of motor and timing belt,
Gently knock it into position. axes 5 or 6 on page 147!
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,
20. Refit any brackets securing any exterior
cabling to the upper arm with their
attachment screws respectively.
Art. no. for the manuals are specified
in section Document references in the
information.

4 Repair
4.6.6.1. Measuring the gear play, axis 5
4.6.6. Adjustments and measurements
General
After reassembly due to repair work or any other reason, the gear play must be checked to
ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed
below.
Certain measurement tools must be fashioned to enable measuring. The dimensions of these
are specified.
Required equipment
Equipment, etc. Art no. Note

Arm 3HAC 9037-1 For adjusting the gear play, motor/pinion
Measurement dial with Measuring range 0-xx mm, accuracy xx
magnetic base
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
WARNING!
result in burns!

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

1. Manually, turn axis 4 90°.
2. Fit the dial fitting arm and dial
to the manipulator turning disk
as shown in the figure.
Apply the 40 N load as shown.
xx0200000457
3. Remove the load and read

Value 1.
4. Apply 40 N load as shown.
xx0200000458

Value 2.
6. Calculate the gear play value. Gear play value = value 1 - value 2
7. Determine whether or not the OK < 0.18 mm (4.1 arc minutes)
value is OK.

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. Art no. Note

Arm 3HAC 9037-1 For adjusting the gear play, motor/pinion
Measurement dial with Measuring range 0-xx mm, accuracy xx
magnetic base
Other tools and These procedures include references to
procedures may be the tools required.
required. See references
to these procedures in the
step-by-step instructions
below.
WARNING!
result in burns!

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

1. Manually, turn axis 4 90°.
2. Fit the dial fitting arm and dial to
the manipulator turning disk as
shown in the figure.
Apply the 40 N load as shown.
xx0200000460

Value 1.
4. Apply 40 N load as shown.
xx0200000461

Value 2.
6. Calculate the gear play value. Gear play value = value 1 - value 2
7. Determine whether or not the OK < 0.30 mm (10.3 arc minutes)
value is OK.

4 Repair
4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1
4.7 Gearboxes
Location of gearbox axes 1-2

The axes 1-2 gearbox is located as shown in the figure below. Note that both gearboxes, 1 and
2, are a single unit!
The damper, axis 1, is shown in the figure in the procedure!
xx0200000422
A Gearbox, axis 1-2
Required equipment

Gearbox, ax. 1-2 3HAC 10467-1 Standard and Foundry versions
spare, Std/F Includes gearbox 3HAC 6603-1
Includes all required lubricant!
Includes all o-rings and sealing
rings!
Gearbox, ax. 1-2 3HAC 10467-3 Clean room version
spare, CR Includes gearbox 3HAC 6603-1
Includes all required lubricant!
Includes all o-rings and sealing
rings!
Damper, axis 1 3HAC 7527-1
Flange sealing 1234 0011-116 2 ml
LocTite, 574 3HAC xx For sealing gearbox/base
Sealing ring 3HAC 6965-1 Replace only when damaged!

4 Repair

information!
Lifting device, 3HAC xx
gearbox 1-2
procedures may references to the tools required.
be required. See
references to
these procedures
in the step-by-step
instructions below.
Removal, gearbox 1-2

The procedure below details how to remove gearbox, axes 1-2.
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Caution!
The gear box weighs 39 kg! All lifting equipment used must be dimensioned accordingly!

1. Remove motor 1. Detailed in section Replacement of motor, axis 1
on page 130.
2. Remove motor 2. Detailed in section Replacement of motor, axis 2
on page 135.
3. Remove the cable harnesses. Detailed in section Replacement of cable harness
on page 78.
4. Remove the serial measurement 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.
5. Remove the upper arm. Detailed in section Replacement of complete
upper arm on page 85.
6. Remove the lower arm. Detailed in section Removal of complete lower
arm.
7. Drain the oil from gearbox 1.

4 Repair

8. 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.
9. Remove the bottom plate by
unscrewing its 26 attachment
screws.
xx0200000423
• A: Gearbox 1-2
• B: Bottom plate
• C: Bottom plate attachment screws (26
pcs)
• D: Gearbox/base attachment screws (20
pcs)
• E: Joint, gearbox/base
• F: Damper, axis 1
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

Step Action Note

1. Open the base of the robot. Detailed in section Removal,
gearbox 1-2 on page 158.
2. Remove the damper, axis 1.
Refitting of damper, axis 1

Step Action Note

1. Fit the damper, axis 1. Shown in the illustration
Refitting, gearbox 1-2 on
page 160.
2. Proceed with assembling the robot. Detailed in section Refitting,
gearbox 1-2 on page 160.

4 Repair
Refitting, gearbox 1-2

The procedure below details how to refit gearbox, axes 1-2.
WARNING!
NOTE!
used!
CAUTION!
The gearbox weighs 39 kg! All lifting equipment used must be dimensioned accordingly!

1. Place the gearbox 1-2 on a
suitable workbench.
2. Fit a small amount of LocTite
574 onto the Joint, gearbox/
base.
xx0200000423
• A: Gearbox 1-2
• B: Bottom plate
• C: Bottom plate attachment screws (26 pcs)
• D: Gearbox/base attachment screws (20
pcs)
• E: Joint, gearbox/base
• F: Damper, axis 1
• G: Washer
3. 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.
4. Refit the bottom plate and Shown in the figure Location of gearbox axes 1-2 on
secure it with its attachment page 157.
screws.

4 Repair

5. Fit the lifting tool to the base/ Art. no. is specified in section Required equipment
frame and turn it right side up on page 157.
on top of a suitable
workbench.
6. Refit the lower arm. Detailed in section Refitting of complete lower arm.
7. Refit the upper arm. Detailed in section Refitting of complete upper arm.
8. Refit the serial measurement Detailed in section Replacement of serial
board. measurement unit and battery pack on page 122.
9. Refit the cable harnesses. Detailed in section Refitting of cable harness.
10. Refit motors 1 and 2. Detailed in section Refitting of motor 1 and Refitting
of motor 2 respectively.
12. Refill the gear box with oil.
13. Recalibrate the robot. Calibration is detailed in separate calibration
manuals.

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.

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.

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
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, i.e. the axes positions (angles) are (standard method)
set to 0º. or
Standard calibration data is found in the file Levelmeter calibration
calib.cfg, supplied with the robot at delivery. (alternative method)
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.
Absolute Accuracy Based on standard calibration, but besides CalibWare
calibration positioning the robot at home position, the
(optional) 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 absacc-
compensation 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

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.

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

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

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 Action Note

1. Select axis-by-axis motion mode.
2. 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.
3. When all axes are positioned, store the Detailed in sections:
revolution counter settings. Storing the revolution counter setting
with the TPU on page 169
(RobotWare 4.0).
Storing the revolution counter setting
with the FlexPendant on page 170
(RobotWare 5.0).
Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have
any mechanical stops and can therefore be calibrated at the wrong turn.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the exact calibration position will be lost due to
uneven gear ratio. This affects the following robots:
Robot variant Axis 4 Axis 6

IRB 140 Yes Yes

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 Action Note

1. Press the button "Miscellaneous" then ENTER to select the
service window.
xx0100000194
2. Select Calibration from the View menu.

The Calibration window appears.
If there is more than one unit connected to the robot, they will
be listed in the window.
xx0100000201
3. Select the desired unit and choose Rev Counter Update

from the Calib menu.
The Revolution Counter Update window appears.
xx0100000202
4. Select the desired axis and press Incl to include it (it will
be marked with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked
with an x.
CANCEL returns to the Calibration window.

Step Action Note

6. Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.
7. At this point, it is recommended that the revolution counter Not required.
values are saved to a diskette.
8.
Caution!
If a revolution counter is incorrectly updated, it will cause
incorrect robot positioning, which in turn may cause damage or
injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the
calibration position on page 172.
Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).
Step Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
en0400000771

Step Action
3. Tap Update revolution counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
5. A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from
the list of axes.
6.
Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 172.

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 Action Note

1. Crate a new program
2. Use MoveAbsJ
3. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs
, v1000, z50, Tool0
4. Run the program in manual mode
5. Check that the calibration marks for the axes align 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.
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 Action Note

1. On ABB menu tap Program Editor.
2. Create a new program.
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff
s, v1000, z50, Tool0
5. Run the program in manual mode.
How to update the revolution
counters is detailed in section
on page 168.

Using the Jogging window on the TPU, S4Cplus

This section describes how to jog the robot to all axes zero position.
Step Action Illustration/information

1. Open the Jogging window.
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.
Detailed in section Updating
revolution counters on page
168.
Using the Jogging window on the FlexPendant, IRC5

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

1. Tap Jogging in the ABB menu.
2. Tap Motion mode to choose group of axes to jog.
3. Tap axes 1-3 to jog axes 1, 2 or 3.
4. Manually run the robots axes to a position where the
axis position value read on the FlexPendant, is equal
to zero.
How to update the counters
is detailed in section
on page 168.


Index
C
Calibration position 168
calibration position, checking 172
calibration position, jog to 173
Connection of external safety devices 15
D
direction of axes 167
L
Limitation of Liability 16
N
negative directions, axes 167
P
positive directions, axes 167
R
Revolution counters 168
S
Safety, service 15
U
Updating revolution counters 168
V
Validity and responsibility 15

3HAC 023297-001 part 1, Revision A, en

Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592
Product manual (part 2 of 2), reference information
Articulated robot
IRB 140
M2000, M2000A, M2004

Product manual (part 2 of 2), reference information
IRB 140
M2000
M2000A
M2004
Document ID: 3HAC023297-001

Revision: A
The information in this manual is subject to change without notice and
should not be construed as a commitment by ABB. ABB assumes no
responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing
herein shall be construed as any kind of guarantee or warranty by ABB
for losses, damages to persons or property, fitness for a specific purpose
or the like.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABB's written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
© Copyright 2004-2008 ABB All right reserved.

Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Reference information 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Spare part / part list 27

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Spare part / part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Foldouts 33
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Circuit diagram 35
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table of Contents
Overview
Overview
About this manual

This manual contains reference information for all procedures in part 1: Product manual,
procedures.
Usage
This manual should be used during:
• installation
• maintenance work
• repair work.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/ installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Reference information Useful information when performing installation, maintenance
or repair works. Includes lists of necessary tools, additional
documents, safety standards, etc.
Spare part / Part list Complete spare part lists and complete lists of robot
components, shown in the foldouts.
Foldouts Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Circuit diagram for the robot.
Overview
Revisions
Revision Description
- First edition
Replaces previous manuals:
• Installation and commissioning manual
• Maintenance manual
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Section Document references added to the chapter Reference
information.
• Information about the controller removed from the manual.
• Additional spare part numbers for the motors.
A Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
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
• Part list
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.
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
• Part list
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
• How to use the application

• Examples of how to use the application
Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudioOnline
• Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
1 Reference information
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
1.2. Applicable Safety Standards
1.2. Applicable Safety Standards
Standards, general
The robot is designed in accordance with the requirements of:
• EN ISO10218-1 : 2005, Robots for industrial environments - Safety requirements -
Part 1 Robot
• ANSI/RIA 15.06-1999
• ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing
systems - Basic requirements
• DIN 19258 - Interbus-S, International Standard
Standards, safety fence

The following standards are applicable to the safety fence surrounding the robot cell:
• ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing
systems - Basic requirements
• prEN 999:1995
Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:
• IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached
by the upper limbs.
• EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human
body.
• EN 811 Safety of machinery - Safety distance to prevent danger zones being reached
by the lower limbs.
• Pr EN 999 Safety of machinery - The positioning of protective equipment in respect
of approach speeds of the human body.
• EN 1088 Safety of machinery - Interlocking device associated with guards principles
for design and selection.
1.3. Unit conversion
1.3. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal
1.4. Screw joints
1.4. Screw joints
General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After
this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
• Use the correct tightening torque for each type of screw joint.
1.4. Screw joints
• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.
• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil- Class 10.9, oil- Class 12.9, oil-
lubricated lubricated lubricated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34
M10 55 66
M12 96 115
M16 235 280
1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90
1.5. Weight specifications
1.5. Weight specifications
Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for
each manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
1.6. Document references
General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot

The product specification includes generic technical data. The specification listed below is
the English version.
Document name Document ID

Product specification 3HAC 9041-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name Document ID

Product manual, S4Cplus M2000 3HAC 021333-001
Product manual, S4Cplus M2000A 3HAC 021128-001
Product manual, IRC5 M2004 3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name Document ID Note

User’s guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation
of S4Cplus based robot systems.
Operator’s manual (IRC5) 3HAC 16590-1
Calibration manuals

Calibration Pendulum 3HAC 16578-1 Enclosed with the Calibration Pendulum
Instruction Toolkit.
Instructions for Levelmeter 3HAC 022907-001 Enclosed with the Levelmeter 2000.
calibration (alternative
method)
CalibWare 2.0 Users Guide 3HAC 16090-1 Calibration tool for Absolute Accuracy
calibration.
Additional documentation

External axes 3HAC 9299-1
1.7. Standard toolkit
1.7. Standard toolkit
General
All service (repair, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. All special tools, i.e. all tools that are not considered
standard as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents
Standard tool, IRB 140: 3HAC020812-001 contains:
Qty Art. no. Tool

1 - Ring-open-end spanner 8-19mm
1 - Socket head cap 2,5-17mm
1 - Torx socket no:20-60
1 - Torque wrench 10-100Nm
1 - Small screwdriver
1 - Ratchet head for torque wrench 1/2
1 - Socket head cap no:5, socket 1/2"" bit L 20mm
1 - Small cutting plier
1.8. Performing a leak-down test
1.8. Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment

Leakdown tester 3HAC 0207-1
Leak detection spray -
Procedure

1. Finish the refitting procedure of the motor or gear in
question.
2. Remove the topmost oil plug on the gear in question, Art. no. is specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3. Apply compressed air, and raise the pressure with the Recommended value: 0.2 -
knob until the correct value is shown on the 0.25 bar (20 - 25 kPa)
manometer.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is
be detected. significantly colder or
warmer than the gearbox to
be tested, a slight pressure
increase or decrease
respectively may occur. This
is quite normal.
6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection Art. no. is specified above!
spray .
Bubbles indicate a leak.
8. When the leak has been localized: take the
necessary measures to correct the leak.
1.9. Lifting equipment and lifting instructions
1.9. Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in
the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
1.10. Mounting instructions for bearings
1.10. Mounting instructions for bearings
General
This section details how to mount and grease different types of bearings on the manipulator.
Equipment

Grease 3HAB 3537-1 Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Follow the instructions below when mounting a bearing on the manipulator.
1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.
2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and
other contamination. Cast components must be free from foundry sand.
3. Bearing rings, inner rings and roller elements must under no circumstances be subjected
to direct impact. Furthermore, the roller elements must not be exposed to any stresses
during the assembly work.
Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered
bearing on the manipulator.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
Note! The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the
bearing.
Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
• The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available volume.
• Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the split
condition.
1.11. Mounting instructions for seals
General
This sections details how to mount different types of seals to the manipulator.
Equipment

Grease 3HAB 3537-1 Used to lubricate the seals.
Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
Step Action Note

1. Check the seal to ensure that:
• the seal is of the correct type (provided with cutting
edge).
• there is no damage to the sealing edge (feel with a
fingernail).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced, as it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page
to the seal.) 24.
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
Flange seals and static seals

The procedure below details how to fit flange seals and static seals.
Step Action Note

1. Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint
(without sealing compund).
If the flange surfaces are defective, the parts may not be used
beacuse leakage could occur.
2. Clean the surfaces properly and in accordance with ABB
ROBOTICS PRODUCTS recommendations.
3. Distribute the sealing compound evenly over the surface, preferably
with a brush.
4. Tighten the screws evenly when fastening the flange joint.
O-rings
The procedure below details how to fit o-rings.
Step Action Note

1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings
may not be used.
3. Check the o-ring grooves. Defective o-rings
The grooves must be geometrically correct and free from pores may not be used.
and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.
2 Spare part / part list
2.1. Introduction

2.1. Introduction
Definitions
This chapter specifies all spare parts and replacement articles of the robot.
2.2. Spare part / part list
Spare part / part list

The table below details all replacement articles on the robot. The items refer to chapter
Foldouts.
Item Qty Art. no. Name Rem.

1 1 3HAC 10470-1 Base spare
2 1 3HAC 8999-1 Bottom plate
3 26 9ADA 629-44 Torx pan head roll. screw M5x12
4 1 3HAC 6599-1 Gasket bottom plate
5 1 3HAC 9522-1 Serial meas. board ass.
6 1 4944 026-4 Battery pack 7.2V 4Ah NiCd
7 2 2166 2055-6 Cable straps, outdoors 7.6x368
8 28 9ADA 618-46 Torx pan head screw M5x20
9 1 3HAC 9030-1 Cable bracket
10 1 3HAC 9415-1 Clamp
11 1 3HAC 6755-1 Cable holder
13 1 3HAC 10476-1 Control cable spare Std/F L=3m
14 1 3HAC 10477-1 Control cable spare Std/F L=7m
15 1 3HAC 7527-1 Damper axis 1
16 20 3HAB 3402-52 Hex. socket head cap screw M10x35 8.8
Gleitmo 610
17 2 3HAC 7950-1 Washer
18 2 3HAC 9860-1 Protecting plate
19 1 3HAC 8466-1 Protective earth cable
20 2 3HAC 9063-1 Hose clip D = 10
21 1 SK 615 503-2 Membrane
22 1 SK 616 013-F Bracket CBK
23 1 1SFA Actuator black
616100R1006
24 1 3HAC 7870-1 Gasket base-cover
25 10 9ADA 290-1 Hexagon nut with flange M5
26 1 2529 1920-2 Plug R 1/8"
27 2 2522 2101-8 Protective hood D=11.4-13
28 1 3HAC 8806-1 Clamp
29 1 3HAC 7370-1 Cable harness IRB 140
30 1 3HAC 2589-1 Instruction plate Battery
replacement
32 20 ml 1234 0011-116 Flange sealing Lotctite 574
33 1 3HAC 10470-3 Base, spare CR
34 1 3HAC 10476-4 Control cable spare CR L=3m

35 1 3HAC 10477-2 Control cable spare CR L=7m
36 1 3HAC 11331-1 Control cable spare Std/F L = 15 m
37 1 3HAC 11331-2 Control cable spare CR L = 15 m
50 1 3HAC 10467-1 Gearbox axes 1-2, spare Std/F Item 67 incl.
51 2 3HAC 10469-1 Motor with pinion spare Std/F
3HAC 021965-001
52 24 3HAB 3409-25 Hex socket head cap screw M6x20 12.9
Gleitmo 610
53 18 9ADA 312-6 Plain washer 6.4x12x1.6
54 2 2152 2012-426 O-ring 74.5x3
55 1 3HAC 6788-1 Bearing hub
56 1 3HAC 10478-1 Console spare Std/F
57 1 3HAC 10472-1 Cover console spare Std/F Item 58 incl.
58 1 3HAC 7868-1 Gasket console-cover
59 1 3HAC 5894-1 Cable bracket T=1.5
60 1 3HAC 6965-1 Sealing ring 150x189x8.5
61 3 3HAC 3785-6 Parallel pin D = 6 m6 L = 16
62 2 3HAB 3732-19 Sealing ring (V-ring) 85x11
64 2 2166 2018-2 Clamp D = 11
65 1 3HAC 10481-1 Connector bracket
67 3000 ml 1171 2016-604 Lubricating oil
68 1 3HAC 10467-3 Gearbox axes 1-2, spare CR
69 2 3HAC 10469-3 / Motor with pinion, spare CR
3HAC 021966-001
70 1 3HAC 10478-3 Console, spare CR
71 1 3HAC 10472-3 Cover console, spare CR
72 1 3HAC 10645-1 Clamp D = 4.7
100 1 3HAC 10468-1 Lower arm (axis 3), spare Item 67, 107
and 108 incl.
101 1 3HAC 10471-1 Cover, without lamp unit Item 103 incl.
102 1 3HAC 10474-1 Cover, with lamp unit Item 103 incl.
103 1 3HAC 7869-1 Gasket lower-arm cover
104 1 3HAC 7866-1 / Rot. ac motor incl. pinion
3HAC 021756-001
105 1 3HAC 6793-1 Timing belt
106 1 3HAC 6762-1 Belt shield
107 1 3HAB 3643-17 Groove ball bearing 80x100x10
108 2 3HAA 2166-13 VK-Cover D = 100 B = 10
110 1 3HAA 2356-14 Washer SRKB 6.4x18x1.6

Gleitmo 610
112 12 9ADA 312-5 Plain washer 5.3x10x1
113 1 3HAC 9258-1 Indicator lamp
114 1 3HAC 10468-4 Lower arm, spare CR
115 1 3HAC 10471-3 Cover, without lamp unit
116 1 3HAC 10474-3 Cover, with lamp unit
150 1 3HAC 10466-1 Upper arm compl. with wrist Motors incl.
151 1 3HAC 10475-1 Wrist, spare Std/F Item 155, 181
and 182 incl.
152 1 3HAC 7191-1 O-ring sealing plate
Gleitmo 610
154 3 9ADA 312-7 Plain washer 8.4x16x1.6
155 3 2529 1920-2 Plug R 1/8"
156 1 3HAC 10479-1 Axis 4 complete, spare Std/F Item 111, 112,
180, 159, 161,
160 and 182
incl.
Gleitmo 610
158 6 9ADA 334-7 Spring washer, conical 8.4x18x2
159 1 3HAB 3732-13 Sealing ring (V-ring) 99x10.5
160 1 3HAC 7842-1 / Rot. ac motor with pinion
3HAC 021757-001
161 1 3HAB 3772-24 O-ring 29x3
162 2 3HAC 7841-1 / Rot. ac motor with pinion
3HAC 021758-001
Gleitmo 610
164 1 3HAC 6773-1 Motor Console axes 5-6
165 5 9ADA 183-13 Hex. socket head cap screw M5x12
166 3 3HAA 2356-15 Washer SRKB 5.3x15x1.2
167 1 3HAC 7367-1 Cable holder
168 1 3HAC 8572-1 Clamp
169 2 3HAC 6779-1 Timing belt
170 1 3HAC 6777-1 Timing Belt Pulley Z2/5
171 1 3HAC 6778-1 Timing Belt Pulley Z2/6
172 1 3HAC 7939-1 Clamping unit
173 1 3HAC 7391-1 Belt shield
174 1 3HAC 10473-1 Cover armhousing spare Item 175 incl.
175 1 3HAC 7867-1 Gasket upper arm cover
177 1 3HAC 6761-1 Cable guide
178 1 3HAC 7561-3 Dustcap for receptacles 12p

179 2 2125 2052-178 Distance bolt M5X55
180 1 3HAC 6598-1 Hose nipple G 1/4"
181 1 3HAB 8964-1 Damper axis 5
182 550 ml 3HAC 0860-1 Lubricating oil Optimol Opti-
gear BM 100
183 1 3HAC 10466-3 Upper arm, spare CR
184 1 3HAC 10475-4 Wrist, spare CR
185 1 3HAC 10479-3 Axis 4 complete, spare CR
186 1 3HAC 10439-3 Cover armhousing, spare CR
187 1 3HAC 11922-1 Slip strip
3 Foldouts
3.1. Introduction
3 Foldouts
3.1. Introduction
Overview
The foldouts in this chapter refer to the part list.
1 33 15 32 18 27 8 13 34 35 36 37 38 39 3 31 20 19
R1/4
21 22 23 28 3
Inside of cover
4 5 7 16 35 Nm 17 6 11 9 26 29 31
24 8 12
10
Inside of base
2 3 30 25
Base complete
Foldout 1
51 62 56 70 8 57 71 58 52 53 32 65 25 25 72 31
A
62
52 15,5 Nm A (1 : 2)
31 55
52
53
52 54 53 52 51 69
53
54
63
64
68 50 ax.1 1,2 litre

ax.2 1,0 litre
67
61 61 60 63 31 59 31 63 63
Foldout 2
0,4 litre
67 100 114 104 105 64 3 103 101 115 8 113 102 116
Do not loosen
these screws
Do not loosen
these screws
3 110 109 18
66
17 16 35 Nm 108 107 112 111 4,1 Nm 106
Lower arm complete with cables

Lower arm (shown without cables) (shown without cover)
Foldout 3
0,35 litre oil (at oil change).
0,30 litre oil (New wrist)

0,2 litre oil
182 151 184 152 180 182 156 185 176
159
162 162 164 163 4,1 Nm 112
169 170 171 172 3 Nm 173
153 28 Nm
154 181
108 35 Nm 6 Nm
157 158 161 112 111 160
112 4,1 Nm 163

Upper arm (shown without cables)
112 4,1 Nm 111 166 165 6 Nm 4,1 Nm

169 112 163
175 8 174 186 12
Foldout 4
177 179
168
167
150 183 20 165
187
Upper arm with cables

178 (shown without cover)
155
Upper arm complete
Foldout 5
4 Circuit diagram
4.1. Introduction
4 Circuit diagram
4.1. Introduction
Overview
This chapter includes the circuit diagram for the robot.
Circuit Diagram
CONTENTS
Page
Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............................................................101-108
IRB 140
Manipulator Circuit Diagram 3HAC 6816-3
LIST OF CONTENTS
IRB 140 No. of Sheets 8 Sheet no. 101

CONNECTION POINT LOCATIONS

SERIAL MEASUREMENT BOARD

MOTOR AXIS 1 - 3

FEEDBACK AXIS 1 - 3

MOTOR AXIS 4 - 6

FEED-BACK AXIS 4 - 6

CUSTOMER CONNECTIONS

3HAC 023297-001 part 2, Revision A, en

Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

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© Copyright 2004-2008 ABB All right reserved.

2 Installation and commissioning 41

5 Calibration information 163

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

About this manual

Who should read this manual?

Product documentation, M2000/M2000A

Controller hardware option manual

Product documentation, M2004

• How to use the application

How to read the product manual

Reading the procedures

Step Action Note/Illustration

References to required equipment

Step Action Note/Illustration

1.2 General safety information

1.2.2. General information

1.2.2.1. Safety, service

Validity and responsibility

Connection of external safety devices

1.2.2.2. Limitation of Liability

1.2.2.3. Related information

Type of information Detailed in document Section

1.2.3. Safety risks

1.2.3.1. Safety risks during service work on robot

Safety risk Description

Motors and gears are HOT after running the robot!

Take any necessary measures to ensure that the robot

Safety risk Description

The cable packs are sensitive to mechanical damage!

Gearboxes and motors

Safety risk Description

Whenever parting/mating motor and gearbox, the gears

Safety risk Description

Do not under any circumstances, deal with the balancing

1.2.3.2. Safety risks related to gripper

1.2.3.3. Safety risks related to tools/workpieces

1.2.3.4. Safety risks related to pneumatic/hydraulic systems

1.2.3.5. Safety risks during operational disturbances

1.2.3.6. Safety risks during installation and service

General risks during installation and service

Nation/region specific regulations

Non-voltage related risks

To be observed by the supplier of the complete system

1.2.3.7. Risks associated with live electric parts

Voltage related risks, general

Voltage related risks, controller

Voltage related risks, robot

Voltage related risks, tools, material handling devices, etc

1.2.4. Safety actions

1.2.4.1. Safety fence dimensions

1.2.4.2. Fire extinguishing

1.2.4.3. Emergency release of the robot’s arm

1.2.4.4. Brake testing

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

1.2.4.6. Safe use of the Teach Pendant Unit

1.2.4.7. Work inside the manipulator's working range