ABB Robotics

Product manual
IRB 140

Trace back information:

Workspace R12-1 version a7
Checked in 2012-03-27
Skribenta version 896

Product manual
IRB 140 type C
IRB 140T type C
IRB 140-6/0.8 type C
IRB 140T-6/0.8 type C
M2004
Document ID: 3HAC027400-001
Revision: J

Copyright 2004-2012 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

Copyright 2004-2012 ABB. All rights reserved.

ABB AB
Robotics Products
SE-721 68 Vsters
Sweden

Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation, M2004 ....................................................................................................... 12
How to read the product manual ...................................................................................................... 14
1

Safety

15

1.1
1.2

15
16
16
17
17
19
20
21
22
23
24
24
25
26
27
28
29
30
31
31
33
33
35
40
41
42
44
45

1.3

Introduction to safety information .........................................................................

General safety information ..................................................................................
1.2.1 Safety in the manipulator system ...............................................................
1.2.2 Safety risks ............................................................................................
1.2.2.1 Safety risks during installation and service work on manipulators .........
1.2.2.2 CAUTION - Hot parts may cause burns! ...........................................
1.2.2.3 Safety risks related to tools/work pieces ..........................................
1.2.2.4 Safety risks related to pneumatic/hydraulic systems ..........................
1.2.2.5 Safety risks during operational disturbances .....................................
1.2.2.6 Risks associated with live electric parts ...........................................
1.2.3 Safety actions .........................................................................................
1.2.3.1 Safety fence dimensions ...............................................................
1.2.3.2 Fire extinguishing ........................................................................
1.2.3.3 Emergency release of the manipulators arm ....................................
1.2.3.4 Brake testing ..............................................................................
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" ........................
1.2.3.6 Safe use of the FlexPendant ..........................................................
1.2.3.7 Work inside the manipulator's working range ...................................
1.2.4 Safety stops ...........................................................................................
1.2.4.1 What is an emergency stop? ..........................................................
Safety related instructions ..................................................................................
1.3.1 Safety signals in the manual ......................................................................
1.3.2 Safety symbols on manipulator labels .........................................................
1.3.3 DANGER - Moving manipulators are potentially lethal! ...................................
1.3.4 DANGER - First test run may cause injury or damage! ...................................
1.3.5 WARNING - The unit is sensitive to ESD! .....................................................
1.3.6 WARNING - Safety risks during handling of batteries .....................................
1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......

Installation and commissioning

47

2.1
2.2

47
48
48
52
54
55
55
56
57
60
61
63
64
66
68
69
69
70
70

2.3

2.4
2.5

Introduction ......................................................................................................
Unpacking .......................................................................................................
2.2.1 Pre-installation procedure .........................................................................
2.2.2 Working range, IRB 140 ...........................................................................
2.2.3 Risk of tipping/stability .............................................................................
On-site installation ............................................................................................
2.3.1 Lifting the manipulator with lifting slings ......................................................
2.3.2 Lifting and turning the manipulator .............................................................
2.3.3 Manually releasing the brakes ...................................................................
2.3.4 Orienting and securing the manipulator .......................................................
2.3.5 Fitting equipment on manipulator ..............................................................
2.3.6 Loads ....................................................................................................
2.3.7 Setting the system parameters for a suspended robot ....................................
2.3.8 Bolt pattern ............................................................................................
2.3.9 Installation of signal lamp .........................................................................
Restricting the working range ..............................................................................
2.4.1 Restricting the working range ....................................................................
Electrical connections ........................................................................................
2.5.1 Customer connections on manipulator .......................................................

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Table of contents

Maintenance

73

3.1
3.2

73
74
74
75
76
76
78
79
82
82
84
84

3.3

3.4
3.5
4

Repair
4.1
4.2

4.3

4.4

4.5

4.6

4.7

Introduction ......................................................................................................
Maintenance schedules ......................................................................................
3.2.1 Specification of maintenance intervals ........................................................
3.2.2 Maintenance schedule .............................................................................
Inspection activities ...........................................................................................
3.3.1 Inspection, damper axes 2, 3 and 5 .............................................................
3.3.2 Inspection, robot cabling ..........................................................................
3.3.3 Inspection, timing belts ............................................................................
Cleaning activities .............................................................................................
3.4.1 Cleaning, robot ......................................................................................
Changing/ replacing activities ..............................................................................
3.5.1 Changing the oil in axes 5 and 6 gearboxes .................................................

87

Introduction ......................................................................................................
Complete robot .................................................................................................
4.2.1 Replacement of cable harness ...................................................................
4.2.2 Replacing parts on Clean Room robots .......................................................
4.2.3 Replacement of complete upper arm ..........................................................
4.2.4 Replacement of complete lower arm ...........................................................
4.2.5 Replacement of base ...............................................................................
Upper arm .......................................................................................................
4.3.1 Replacement of wrist unit .........................................................................
4.3.2 Replacing the damper, axis 3 .....................................................................
4.3.3 Replacement of damper, axis 5 ..................................................................
4.3.4 Replacement of cover, arm housing ............................................................
Lower arm .......................................................................................................
4.4.1 Replacement of lower arm cover and gasket ................................................
4.4.2 Replacing the damper, axis 2 .....................................................................
4.4.3 Replacement of indicator lamp ...................................................................
Frame and base ................................................................................................
4.5.1 Replacement of cover, console ..................................................................
4.5.2 Replacement of console ...........................................................................
4.5.3 Replacement of serial measurement unit and battery pack ..............................
4.5.4 Replacement of control cable ....................................................................
Motors ............................................................................................................
4.6.1 Replacement of motor, axis 1 ...................................................................
4.6.2 Replacement of motor, axis 2 ....................................................................
4.6.3 Replacement of motor and timing belt, axis 3 ...............................................
4.6.4 Replacement of motor, axis 4 ....................................................................
4.6.5 Replacement of motor and timing belt, axes 5 or 6 ........................................
4.6.6 Adjustments and measurements ................................................................
4.6.6.1 Measuring the gear play, axis 5 ......................................................
4.6.6.2 Measuring the gear play, axis 6 ......................................................
Gearboxes .......................................................................................................
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 ...................................
4.7.2 Service work on gearbox, axis 4 .................................................................
4.7.3 Amount of oil .........................................................................................

87
88
88
96
98
104
108
112
112
116
118
120
122
122
125
127
130
130
133
137
142
146
146
150
154
160
163
169
169
171
173
173
178
179

Calibration information

181

5.1
5.2
5.3
5.4
5.5
5.6

181
182
184
185
186
188

Introduction .....................................................................................................
Calibration methods ...........................................................................................
Calibration scale and correct axis position .............................................................
Calibration movement directions for all axes ..........................................................
Updating revolution counters ...............................................................................
Checking the calibration position ..........................................................................

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Table of contents

Decommissioning
6.1

Environmental information .................................................................................. 189

Robot description
7.1

189

191

Type C of IRB 140 ............................................................................................. 191

Reference information

193

8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11

193
194
196
197
200
201
202
203
204
205
207

Introduction ......................................................................................................
Applicable safety standards ................................................................................
Unit conversion .................................................................................................
Screw joints ....................................................................................................
Weight specifications .........................................................................................
Standard tools ..................................................................................................
Special tools ....................................................................................................
Performing a leak-down test ...............................................................................
Lifting accessories and lifting instructions ..............................................................
Mounting instructions for bearings .......................................................................
Mounting instructions for seals ............................................................................

Spare part lists

9.1
9.2

209

Introduction ...................................................................................................... 209

Spare parts - robot IRB 140 ................................................................................. 210

10 Circuit diagram

219

10.1 About circuit diagrams ....................................................................................... 219

Index

221

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This page is intentionally left blank

Overview of this manual

Overview of this manual

About this manual
This manual contains instructions for:

mechanical and electrical installation of the robot

maintenance of the robot

mechanical and electrical repair of the robot.

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 com-misioning

Required information about lifting and installation of the robot.

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.

Reference information

Useful information when performing installation, maintenance

or repair work. Includes lists of necessary tools, additional
documents, safety standards, etc.

Continues on next page

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Overview of this manual

Continued

Chapter

Contents

Spare parts and exploded Complete spare part list and complete list of robot components,
views
shown in exploded views.
Circuit diagram

References to the circuit diagrams for the robot.

References
Reference

Document ID

Circuit diagram - IRB 140 type C

3HAC6816-3

Product manual - IRC5

3HAC021313-001

Product specification - IRB 140

3HAC041346-001

Operating manual - IRC5 with FlexPendant

3HAC16590-1

Operating manual - Calibration Pendulum

3HAC16578-1

Operating manual - Service Information System

3HAC025709-001

Technical reference manual - RAPID Instructions, Functions and 3HAC16581-1

Data types
Application manual - CalibWare Field 5.0

3HAC030421-001

Revisions
Revision

Description

First edition, see also Type C of IRB 140 on page 191.

IRB 140-6/0.8 and IRB 140T-6/0.8 added.

Clean room added.

Changes made in:
Prerequisites in section Overview
Oil change in section Maintenance

Content updated in section:

Making robot ready for operation, Cleanroom , Additional installation procedure.

Content updated in section:

Repair, exchange of parts on Clean room robots
Maintenance, Cleaning of robot
Maintenance schedule: Interval for replacement of battery pack
changed.
Section What is an emergency stop? added to chapter Safety.

Content updated in sections:

Article numbers added or replaced in sections Replacement of
complete upper arm on page 98, Replacement of complete lower
arm on page 104, Replacement of gearbox, axes 1-2 and damper,
axis 1 on page 173, and Type C of IRB 140 on page 191.

Continues on next page

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Overview of this manual

Continued

Revision

Description

Content updated in sections:

Required equipment updated in Replacement of motor and timing
belt, axis 3 on page 154.
Spare part list updated regarding Foundry Plus cable guard and
new wrist.
Circuit diagrams are not included in this document but delivered
as separate files. See Circuit diagram on page 219.
List of standards updated, see Applicable safety standards on
page 194.
Sealing compound updated in Replacing parts on Clean Room
robots on page 96.
Decommissioning chapter added.
The chapter Safety updated with:
Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 33.
New safety labels on the manipulators, see Safety symbols on
manipulator labels on page 35.
Revised terminology: robot replaced with manipulator.

This revision includes the following additions:

New section, Restricting the working range on page 69.
Lifting and turning the manipulator on page 56.
This revision includes the following updates:
Corrected amount of oil in axes 3, 5, and 6, see Amount of oil on
page 179.
Updates in chapter Calibration.

This revision includes the following updates:

Corrected article number for VK cover, see Replacement of complete upper arm on page 98 and Replacement of motor and timing
belt, axes 5 or 6 on page 163.

This revision includes the following updates:

A new block, about general illustrations, added in section How to
read the product manual on page 14.
The option Foundry Plus Cable Guard is removed.
Some general tightening torques have been changed/added, see
updated values in Screw joints on page 197.
The figure of the base is updated in concerned sections.
Added WARNING - Safety risks during handling of batteries on
page 44.

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Product documentation, M2004

Product documentation, M2004

Categories for manipulator documentation
The manipulator documentation is divided into a number of categories. This listing
is based on the type of information in the documents, regardless of whether the
products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for M2004 manipulator systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:

Safety information.

Installation and commissioning (descriptions of mechanical installation or

electrical connections).

Maintenance (descriptions of all required preventive maintenance procedures

including intervals and expected life time of parts).

Repair (descriptions of all recommended repair procedures including spare

parts).

Calibration.

Decommissioning.

Reference information (safety standards, unit conversions, screw joints, lists

of tools ).

Spare parts list with exploded views (or references to separate spare parts
lists).

Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe the manipulator software in general and
contain relevant reference information.

RAPID Overview: An overview of the RAPID programming language.

RAPID Instructions, Functions and Data types: Description and syntax for
all RAPID instructions, functions, and data types.

RAPID Kernel: A formal description of the RAPID programming language.

System parameters: Description of system parameters and configuration

workflows.

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:

The purpose of the application (what it does and when it is useful).

Continues on next page

12

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Product documentation, M2004

Continued

What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).

How to install included or required hardware.

How to use the application.

Examples of how to use the application.

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):

Emergency safety information

General safety information

Getting started, IRC5 and RobotStudio

Introduction to RAPID

IRC5 with FlexPendant

RobotStudio

Trouble shooting, for the controller and manipulator.

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How to read the product manual

How to read the product manual

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

8.

Action

Note/Illustration

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, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.

3.

Action

Note/Illustration

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 the chapter Safety on page 15.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise certain work methods or general information, that is valid for several robot
models, can be illustrated with pictures that show a different robot model that the
one described in the current manual.

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1 Safety
1.1 Introduction to safety information

1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into two categories:

General safety aspects, important to attend to before performing any service

work on the robot. These are applicable for all service work and are found
in General safety information on page 16.

Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 33.

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1 Safety
1.2.1 Safety in the manipulator system

1.2 General safety information

1.2.1 Safety in the manipulator system
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire 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 manipulator is installed.
The users of ABB industrial manipulators 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 manipulator
system are designed and installed correctly. Personnel working with manipulators
must be familiar with the operation and handling of the industrial manipulator as
described in the applicable documents, for example:

Operating manual - IRC5 with FlexPendant

Product manual

Connection of external safety devices

Apart from the built-in safety functions, the manipulator is also supplied with an
interface for the connection of external safety devices. An external safety function
can interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the manipulator.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial manipulator will not cause injury or damage
even if all safety instructions are complied with.
Related information
Type of information

Detailed in document

Section

Installation of safety devices Product manual for the manipulator

Changing operating modes

Installation and
commissioning

Operating manual - IRC5 with FlexPend- Operating modes

ant

Restricting the working space Product manual for the manipulator

16

Installation and
commissioning

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1 Safety
1.2.2.1 Safety risks during installation and service work on manipulators

1.2.2 Safety risks

1.2.2.1 Safety risks during installation and service work on manipulators
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the manipulator.
General risks during installation and service
The instructions in the product manual in the chapter Installation and
commissioning must always be followed.

Emergency stop buttons must be positioned in easily accessible places so

that the manipulator 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 manipulator must have the appropriate training for the
equipment in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damages during the installation of the manipulator, the
regulations applicable in the country concerned and the instructions of ABB
Robotics must be complied with.
Non-voltage related risks
Safety zones, which must be crossed before admittance, must be set up in
front of the manipulator'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
manipulator'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 manipulator parts, there is a risk
of being crushed by the parallel arm (if there is one).

Energy stored in the manipulator for the purpose of counterbalancing certain

axes may be released if the manipulator, or parts thereof, are dismantled.

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

Be aware of stored heat energy in the controller.

Never use the manipulator as a ladder, which means, do not climb on the
manipulator motors or other parts during service work. There is a serious
risk of slipping because of the high temperature of the motors and oil spills
that can occur on the manipulator.

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.
Continues on next page
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1 Safety
1.2.2.1 Safety risks during installation and service work on manipulators
Continued

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.

Complete manipulator
Safety risk
Hot components!

Description
CAUTION
Motors and gears are HOT after running the
manipulator! Touching motors and gears may
result in burns!
With a higher environment temperature, more
surfaces on the manipulator will get HOT and
may also result in burns.

Removed parts may result in collapse of

manipulator!

WARNING
Take any necessary measures to ensure that
the manipulator does not collapse as parts
are removed, e.g. secure the lower arm according to repair instruction if removing motor, axis 2.

Removed cables to the measurement system

WARNING
If the internal cables for the measurement
system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.

Cabling
Safety risk
Cable packs are sensitive to mechanical
damage!

Description
CAUTION
The cable packs are sensitive to mechanical
damage! They must be handled with care,
especially the connectors, in order to avoid
damaging them!

Gearboxes and motors

Safety risk
Gears may be damaged if excessive force
is used!

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

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1 Safety
1.2.2.2 CAUTION - Hot parts may cause burns!

1.2.2.2 CAUTION - Hot parts may cause burns!

Description
During normal operation, many manipulator parts become hot, especially the drive
motors and gears. Sometimes areas around these parts also become hot. Touching
these may cause burns of various severity.
Because of a higher environment temperature, more surfaces on the manipulator
get hot and may result in burns.
Elimination
The instructions below detail how to avoid the dangers specified above:
Action
1

Always use your hand, at some distance, to

feel if heat is radiating from the potentially
hot component before actually touching it.

Wait until the potentially hot component has

cooled if it is to be removed or handled in any
other way.

Info

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1 Safety
1.2.2.3 Safety risks related to tools/work pieces

1.2.2.3 Safety risks related to tools/work pieces

Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. 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 work pieces in the
event of a power failure or a disturbance to the controller.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.

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1 Safety
1.2.2.4 Safety risks related to pneumatic/hydraulic systems

1.2.2.4 Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy

Residual energy can be present in these systems. After shutdown, particular

care must be taken.

The pressure in pneumatic and hydraulic systems must be released before

starting to repair them.

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

Dump valves should be used in case of emergency.

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

Safe design

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1 Safety
1.2.2.5 Safety risks during operational disturbances

1.2.2.5 Safety risks during operational disturbances

General

The industrial manipulator is a flexible tool that 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
Corrective maintenance 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.

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1 Safety
1.2.2.6 Risks associated with live electric parts

1.2.2.6 Risks associated with live electric parts

Voltage related risks, general
Although troubleshooting may, on occasion, need 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 from outside the robots working space.

Voltage related risks, IRC5 controller

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

Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in

the controller.

Units such as I/O modules, can be supplied with power from an external
source.

The mains supply/mains switch

The transformers

The power unit

The control power supply (230 VAC)

The drive system power supply (230 VAC)

The service outlets (115/230 VAC)

The customer power supply (230 VAC)

The power supply unit for additional tools, or special power supply units for
the machining process.

The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.

Additional connections.

Voltage related risks, manipulator

A danger of high voltage is associated with the manipulator 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 the chapter Installation and commissioning on page 47).

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.

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1 Safety
1.2.3.1 Safety fence dimensions

1.2.3 Safety actions

1.2.3.1 Safety fence dimensions
General
Install a safety cell around the manipulator to ensure safe manipulator installation
and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the
load being handled by the manipulator is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the manipulator
axes and from the position at which the manipulator is working in the work cell
(see the section Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the manipulator.

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1 Safety
1.2.3.2 Fire extinguishing

1.2.3.2 Fire extinguishing

Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator system (manipulator or controller)!

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1 Safety
1.2.3.3 Emergency release of the manipulators arm

1.2.3.3 Emergency release of the manipulators arm

Description
In an emergency situation, any of the manipulator's axes may be released manually
by pushing the brake release buttons on the manipulator.
How to release the brakes is detailed in the section:

Manually releasing the brakes on page 57.

The manipulator arm may be moved manually on smaller manipulator models, but
larger models may require using an overhead crane or similar equipment.
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!

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1 Safety
1.2.3.4 Brake testing

1.2.3.4 Brake testing

When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be checked as described
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.

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1 Safety
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s"

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

Note
Do not change Transm gear ratio or other kinematic system parameters from
the FlexPendant or a PC. This will affect the safety function "Reduced speed 250
mm/s".

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1 Safety
1.2.3.6 Safe use of the FlexPendant

1.2.3.6 Safe use of the FlexPendant

Enabling device
The enabling device is a manually operated, constant pressure push-button which,
when continuously activated in one position only, allows potentially hazardous
functions but does not initiate them. In any other position, hazardous functions are
stopped safely.
The enabling device is of a specific type where you must press the push-button
only half-way to activate it. In the fully in and fully out positions, manipulator
operation is impossible.
Note
The enabling device is a push-button located on the side of the FlexPendant
which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:

The enabling device must never be rendered inoperational in any way.

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

soon as there is no need for the manipulator to move.

The programmer must always bring the FlexPendant with him/her when
entering the manipulator's working space. This is to prevent anyone else
from taking control of the manipulator without the programmers knowledge.

Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function is described in Operating manual - IRC5
with FlexPendant.

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1 Safety
1.2.3.7 Work inside the manipulator's working range

1.2.3.7 Work inside the manipulator's working range

WARNING
If work must be carried out within the manipulators work area, 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 operational and to block operation
from a computer link or remote control panel.

The manipulators speed is limited to max. 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space. The position
Manual mode with full speed (100%) may only be used by trained personnel
who are aware of the risks that this entails. Manual mode with full speed
(100%) is not available in USA or Canada.

Pay attention to the rotating axes of the manipulator. Keep away from axes
to not 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 the section Brake testing
on page 27.
WARNING

NEVER, under any circumstances, stay beneath any of the manipulators axes!
There is always a risk that the manipulator will move unexpectedly when
manipulator axes are moved using the enabling device or during other work
inside the manipulators working range.

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1 Safety
1.2.4.1 What is an emergency stop?

1.2.4 Safety stops

1.2.4.1 What is an emergency stop?
Definition of emergency stop
An emergency stop is a state that overrides any other manipulator control,
disconnects drive power from the manipulator motors, stops all moving parts, and
disconnects power from any potentially dangerous functions controlled by the
manipulator system.
An emergency stop state means that all power is disconnected from the manipulator
except for the manual brake release circuits. You must perform a recovery
procedure, i.e, resetting the emergency stop button and pressing the Motors On
button, in order to return to normal operation.
The manipulator system can be configured so that the emergency stop results in
either:

An uncontrolled stop, immediately stopping the manipulator actions by

disconnecting power from the motors.

A controlled stop, stopping the manipulator actions with power available to

the motors so that the manipulator path can be maintained. When completed,
power is disconnected from the motors.

The default setting is an uncontrolled stop. However, controlled stops are preferred
since they minimize extra, unnecessary wear on the manipulator and the actions
needed to return the manipulator system back to production. Please consult your
plant or cell documentation to see how your manipulator system is configured.
Note
The emergency stop function may only be used for the purpose and under the
conditions for which it is intended.
Note
The emergency stop function is intended for immediately stopping equipment
in the event of an emergency.
Note
Emergency stop should not be used for normal program stops as this causes
extra, unnecessary wear on the manipulator. For how to perform normal program
stops, see in the section Stopping programs in Operating manual - IRC5 with
FlexPendant.

Continues on next page

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1 Safety
1.2.4.1 What is an emergency stop?
Continued
Classification of stops
The safety standards that regulate automation and manipulator equipment define
categories in which each type of stop applies:
If the stop is...

... then it is classified as...

uncontrolled

category 0 (zero)

controlled

category 1

Emergency stop devices

In a manipulator system there are several emergency stop devices that can be
operated in order to achieve an emergency stop. There are emergency stop buttons
available on the FlexPendant and on the controller cabinet (on the Control Module
on a Dual Cabinet Controller). There can also be other types of emergency stops
on your manipulator. Consult your plant or cell documentation to see how your
manipulator system is configured.

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1 Safety
1.3.1 Safety signals in the manual

1.3 Safety related instructions

1.3.1 Safety signals in the manual
Introduction to safety signals
This section specifies all dangers that can arise when doing the work described
in this manual. Each danger consists 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 do

not eliminate the danger.

Instruction about how to eliminate danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol

Designation

Significance

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,
impact, fall from height, and so on.

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 crushing, impact, fall from height, etc.

ELECTRICAL
SHOCK

Warns for electrical hazards which could result in

severe personal injury or death.

CAUTION

Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.

xx0200000022

xx0100000002

xx0200000024

xx0100000003

ELECTROSTATIC Warns for electrostatic hazards which could result

DISCHARGE (ESD) in severe damage to the product.

xx0200000023

Continues on next page

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1 Safety
1.3.1 Safety signals in the manual
Continued
Symbol

Designation

Significance

NOTE

Describes important facts and conditions.

TIP

Describes where to find additional information or

how to do an operation in an easier way.

xx0100000004

xx0100000098

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1 Safety
1.3.2 Safety symbols on manipulator labels

1.3.2 Safety symbols on manipulator labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the manipulator system, for example
during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 35.
The information labels can contain information in text (English, German, and
French).
Symbols on safety labels
Symbol

Description

xx0900000812

xx0900000811

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
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.

xx0900000839

See user documentation

Read user documentation for details.
Which manual to read is defined by the symbol:
No text: Product manual.
EPS: Application manual - Electronic Position Switches.
xx0900000813

Continues on next page

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1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol

Description
Before dismantling see product manual

xx0900000816

Do not dismantle
Dismantling this part can cause injury.

xx0900000815

Extended rotation
This axis has extended rotation (working area) compared to
standard.

xx0900000814

Brake release
Pressing this button will release the brakes. This means that
the manipulator arm can fall down.
xx0900000808

Tip risk when loosening bolts

The manipulator can tip over if the bolts are not securely
fastened.

xx0900000810

Crush
Risk of crush injuries.

xx0900000817

Continues on next page

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1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol

Description
Heat
Risk of heat that can cause burns.

xx0900000818

Moving robot
The robot can move unexpectedly.

xx0900000819

xx1000001141

Brake release buttons

xx0900000820

xx1000001140

Lifting bolt

xx0900000821

Chain sling with shortener

xx1000001242

Continues on next page

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1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol

Description
Lifting of robot

xx0900000822

Oil
Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop

xx0900000824

No mechanical stop

xx1000001144

Stored energy
Warns that this part contains stored energy.
Used in combination with Do not dismantle symbol.

xx0900000825

Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.

xx0900000826

Continues on next page

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1 Safety
1.3.2 Safety symbols on manipulator labels
Continued
Symbol

Description
Shut off with handle
Use the power switch on the controller.

xx0900000827

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1 Safety
1.3.3 DANGER - Moving manipulators are potentially lethal!

1.3.3 DANGER - Moving manipulators are potentially lethal!

Description
Any moving manipulator is a potentially lethal machine.
When running, the manipulator may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the manipulator.
Elimination
Action

Note

Before attempting to run the manipulator, Emergency stop equipment such as gates,
make sure all emergency stop equipment tread mats, light curtains, etc.
is correctly installed and connected.

Usually the hold-to-run function is active

only in manual full speed mode. To increase safety it is also possible to activate
hold-to-run for manual reduced speed with
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.

Make sure no personnel are present within

the working range of the manipulator before pressing the start button.

How to use the hold-to-run function is described in section How to use the hold-torun function in the Operating manual - IRC5
with FlexPendant.

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1 Safety
1.3.4 DANGER - First test run may cause injury or damage!

1.3.4 DANGER - First test run may cause injury or damage!

Description
Since performing a service activity often requires disassembly of the robot, there
are several safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service
activity, such as repair, installation, or maintenance.
Action
1

Remove all service tools and foreign objects from the robot and its working area

Check that the fixture and workpiece are well secured, if applicable

Install all safety equipment properly

Make sure all personnel are standing at a safe distance from the robot, that is out of
its reach behind safety fences, and so on

Pay special attention to the function of the part previously serviced

Collision risks
CAUTION
When programming the movements of the manipulator always check potential
collision risks before the first test run.

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1 Safety
1.3.5 WARNING - The unit is sensitive to ESD!

1.3.5 WARNING - The unit is sensitive to ESD!

Description
ESD (electrostatic 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 grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Elimination
Action

Note

Use a wrist strap

Wrist straps must be tested frequently to ensure

that they are not damaged and are operating correctly.

Use an ESD protective floor mat.

The mat must be grounded through a current-limiting resistor.

Use a dissipative table mat.

The mat should provide a controlled discharge of

static voltages and must be grounded.

Location of wrist strap button

The location of the wrist strap button is shown in the following illustration.
IRC5
The wrist strap button is located in the top right corner.

xx0500002171

Wrist strap button

Continues on next page

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1 Safety
1.3.5 WARNING - The unit is sensitive to ESD!
Continued
Panel Mounted Controller

xx0600003249

Panel Mounted Control Module

Panel Mounted Drive Module

Wrist strap button NOTE! When not used, the wrist strap must always be attached
to the wrist strap button.

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1 Safety
1.3.6 WARNING - Safety risks during handling of batteries

1.3.6 WARNING - Safety risks during handling of batteries

Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.
Elimination
Action

Note

Do not short circuit, recharge, puncture, incinerate, crush, immerse, Operating

force discharge or expose to temperatures above the declared oper- temperatures
ating temperature range of the product. Risk of fire or explosion.
are listed in
Pre-installation procedure on
page 48.

Use safety glasses when handling the batteries.

In the event of leakage, wear gloves and chemical apron.

In the event of fire, use self-contained breathing apparatus.

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1 Safety
1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease)
Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.
Warnings and elimination
Warning

xx0100000002

Description

Elimination/Action

Changing and draining gearbox Make sure that protective gear

oil or grease may require hand- like goggles and gloves are alling hot lubricant heated up to ways worn during this activity.
90 C.

Hot oil or grease

When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are alreaction.
ways worn.
xx0100000002

Allergic reaction

xx0100000002

When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure
away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.

Possible pressure
build-up in gearbox

xx0100000002

Do not overfill

xx0100000002

Overfilling of gearbox lubricant

can lead to internal over-pressure inside the gearbox which in
turn may:
damage seals and gaskets
completely press out
seals and gaskets
prevent the robot from
moving freely.

Make sure not to overfill the

gearbox when filling it with oil or
grease!
After filling, check the correct
level.

Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Always use the type of oil specified
by the manufacturer!

Do not mix types of oil

Warm oil drains quicker than
cold oil.

When changing gearbox oil, first

run the robot for a time to heat
up the oil.

xx0100000098

Heat up the oil

Continues on next page

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1 Safety
1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease)
Continued
Warning

xx0100000004

Specified amount depends on drained

volume

Description

Elimination/Action

The specified amount of oil or After refilling, check the lubricant

grease is based on the total
level.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
on how much has previously
been drained from the gearbox.

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2 Installation and commissioning

2.1 Introduction

2 Installation and commissioning

2.1 Introduction
General
This chapter contains information for installing the IRB 140 type C at the working
site.
More detailed technical data can be found in the Product specification for the IRB
140 type C, such as:

Load diagram

Permitted extra loads (equipment)

Location of extra loads (equipment).

Safety information
Before any installation 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 describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 15 before performing any installation
work.
Note
If the IRB 140 type C is connected to power, always make sure that the robot is
connected to protective earth before starting any installation work!
For more information see:

Product manual - IRC5

Product manual - IRC5 Panel Mounted Controller

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2 Installation and commissioning

2.2.1 Pre-installation procedure

2.2 Unpacking
2.2.1 Pre-installation procedure
Introduction
This section is 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
Installation craftsmen working with an ABB robot must:

be trained by ABB and have the required knowledge of mechanical and

electrical installation/maintenance/repair work

conform to all national and local codes.

Action

Visually inspect the robot to make sure that it is not damaged.

Make sure that the lifting device used is suitable to handle the weight of the robot as
specified in:
Weight, robot on page 48

If the robot is not installed directly, it must be stored as described in:

Storage conditions, robot on page 50

Make sure that the expected operating environment of the robot conforms to the
specifications as described in:
Operating conditions, robot on page 51

Before taking the robot to its installation site, make sure that the site conforms to:
Loads on foundation, robot on page 49
Protection classes, robot on page 51
Requirements, foundation on page 50

Before moving the robot, please observe the stability of the robot:
Risk of tipping/stability on page 54

When these prerequisites are met, the robot can be taken to its installation site as
described in section:
On-site installation on page 55

Install required equipment, if any.

Installation of signal lamp on page 68

Weight, robot
The table shows the weight of the robot.
Robot model

Weight

IRB 140 type C

100 kg

Note
The weight does not include tools and other equipment fitted on the robot!

Continues on next page

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2 Installation and commissioning

2.2.1 Pre-installation procedure
Continued
Loads on foundation, robot
The illustration shows the directions of the robots stress forces. The directions are
valid for all floor mounted and suspended robots.

Txy

Fz
Fxy

Tz

xx1100000521

Fxy

Force in any direction in the XY plane

Fz

Force in the Z plane

Txy

Bending torque in any direction in the XY plane

Tz

Bending torque in the Z plane

The table shows the various forces and torques working on the robot 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 at the same time!

Continues on next page

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2 Installation and commissioning

2.2.1 Pre-installation procedure
Continued
Floor Mounted
Force

Endurance load (in operation)

Max. load (emergency stop)

Force xy

1020 N

2000 N

Force z

- 1000 620 N

- 1000 1250 N

Torque xy

700 Nm

1500 Nm

Torque z

250 Nm

470 Nm

Wall Mounted
Force

Endurance load (in operation)

Max. load (emergency stop)

Force xy

1750 N

2800 N

Force z

850 N

1600 N

Torque xy

1020 Nm

1710 Nm

Torque z

250 Nm

485 Nm

Force

Endurance load (in operation)

Max. load (emergency stop)

Force xy

1020 N

2000 N

Force z

+ 1000 620 N

+ 1000 1250 N

Torque xy

700 Nm

1500 Nm

Torque z

250 Nm

470 Nm

Suspended

Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement

Value

Note

Maximum levelness

0.5 mm

Flat foundations give better repeatability of the

resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver calibration is changed this will influence the absolute accuracy.

Maximum tilt

The limit for the maximum payload on the robot

is reduced if the robot is tilted from 0.
Contact ABB for further information about acceptable loads.

Minimum resonance
frequency

22 Hz

Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter

Value

Minimum ambient temperature

-25 C

Continues on next page

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2 Installation and commissioning

2.2.1 Pre-installation procedure
Continued
Parameter

Value

Maximum ambient temperature

+55 C

Maximum ambient temperature (less than 24 hrs)

+70 C

Maximum ambient humidity

95% at constant temperature

(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter

Value

Minimum ambient temperature

+45 C

Maximum ambient temperature

+5 C

Maximum ambient humidity

95% at constant temperature

Protection classes, robot

The table shows the protection class of the robot:
Equipment

Protection class

Manipulator

IP 67

Manipulator, Foundry Plus version

IP 67

Manipulator, Clean Room version

IP 67

Manipulator, Wash version

IP 67

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2 Installation and commissioning

2.2.2 Working range, IRB 140

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)

Axis 2

Axis 3

450

712

70

1092

-90

314

421

+50

765

99

+110

-90

255

-119

+110

+4

-480

23

-90

-150

596

-90

+50

218

558

+110

-230

-670

352

-90

-90

Continues on next page

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2.2.2 Working range, IRB 140
Continued
Working range axis 1
The illustrations below shows the unrestricted working range of axis 1.

xx0200000061

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2.2.3 Risk of tipping/stability

2.2.3 Risk of tipping/stability

Risk of tipping
If the robot is not fastened to the foundation and standing still, the robot is not
stable in the whole working area. Moving the arms will displace the center of gravity,
which may cause the robot to tip over.
The shipping position is the most stable position.
Do not change the robot position before securing it to the foundation!
WARNING
The robot is likely to be mechanically unstable if not secured to the foundation!

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2 Installation and commissioning

2.3.1 Lifting the manipulator with lifting slings

2.3 On-site installation

2.3.1 Lifting the manipulator with lifting slings
Introduction
This section details how to lift the manipulator using lifting slings.
Equipment

Note

Sling line for manipulator

Length: 2 m. Load: 500 kg.

Sling line for control cable

Illustration

xx0200000084

Sling line for manipulator

Sling line for manipulator

Sling line for control cable

How to lift the manipulator

1 Adjust the manipulator to lifting position according to the illustration.
2 Put one sling line around each leg on the lower arm (positions 1 and 2).
3 Use another sling line to secure the lifting of the control cable (position 3).

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2.3.2 Lifting and turning the manipulator

2.3.2 Lifting and turning the manipulator

Recommendation
Use lifting slings to lift the manipulator. See Lifting the manipulator with lifting
slings on page 55.
For more information contact ABB.

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2 Installation and commissioning

2.3.3 Manually releasing the brakes

2.3.3 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 brake release unit when the robot is connected to the controller.

using the brake release unit when the robot is disconnected from the
controller, but connected to an external power supply at the connector R1.MP.

using an external voltage supply directly on the motor connector.

Using the brake release unit when the robot is connected to the controller
Use this procedure to release the holding brakes with the internal brake release
unit.
Action
1

Note

The brake release button (A) is located at the base of

the robot.

xx0200000069

2
DANGER
When releasing the holding brakes, the robot axes
may move very quickly and sometimes in unexpected
ways!
Make sure no personnel is near or beneath the robot
arm!
3

Release the holding brakes by pushing the brake release button.

The brake will function again as soon as the button is
released.

Continues on next page

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2.3.3 Manually releasing the brakes
Continued
Using the brake release unit with an external power supply
This section details how to release the holding brakes with the internal brake
release unit using an external voltage supply. This is done if the robot is not
connected to the controller.
Action

Note

1
DANGER
Incorrect connections, such as supplying
power to the wrong pin, may cause all brakes
to be released simultaneously!
2

Also, be careful not to interchange the

24V and 0V pins. If they are mixed up,
damage can be caused to a resistor diode and to the system board.

Connect an external power supply to connector XP1.

xx0200000071

Supply:
A: B16 24V DC
B: B14 0V
3

Push the brake release button to release the

holding brakes, according to the previous
procedure.

Continues on next page

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2 Installation and commissioning

2.3.3 Manually releasing the brakes
Continued
Using external power supply
This section details how to release the holding brakes using an external voltage
supply. If the positions of the robot 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 robot.
Action
1

Note/Illustration

Remove the screws and dismount the cover

on the back of the robot base.

xx0200000072

Locate the R1.MP4-6 connector and disconnect.

Connect an external power supply to release the holding brake on all axis.

A: 13 0V
B: 15 24V DC

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2.3.4 Orienting and securing the manipulator

2.3.4 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, robot on page 49.
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 robot 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 66.
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

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2.3.5 Fitting equipment on manipulator

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 - IRB 140.
Illustration, holes on upper arm
The illustration below shows the stock holes available for fitting extra equipment
on the upper arm.

xx0600003263

Continues on next page

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2.3.5 Fitting equipment on manipulator
Continued
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 turning disk, use only screws with quality 12.9. When
fitting equipment on other places, standard screws with quality 8.8 can be used.

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2.3.6 Loads

2.3.6 Loads
Introduction
Any loads mounted on the manipulator must be defined correctly and carefully
(with regard to the position of the center of gravity and inertia factor) to avoid jolting
movements and overloading the motors. If this is not done correctly operation
stops can occur.
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 Operating manual - IRC5 with FlexPendant.
Brake performance
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB.

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2.3.7 Setting the system parameters for a suspended robot

2.3.7 Setting the system parameters for a suspended robot

General
Initially the system is configured for mounting on the floor, without leaning. The
method for mounting the robot in a suspended position is basically the same as
for floor mounting.
Note
With suspended installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.
System parameters
If the robot is mounted at any other angle, the system parameter Gravity Beta must
be updated. Gravity Beta specifies the robots mounting angle expressed in radians.
Note
Gravity Beta must be configured correctly so that the robot system can control
the movements in the best possible way. An incorrect definition of the mounting
angle (Gravity Beta) will result in:

Overloading the mechanical structure.

Lower path performance and path accuracy.

Some functions will not work properly, for example Load Identification and
Collision detection.

Mounting angles and values

The parameter Gravity Beta specifies the robots mounting angle in radians. It is
calculated in the following way.
Gravity Beta = A x 3.141593/180 = B radians, where A is the mounting angle in
degrees and B is the mounting angle in radians.
Example of position

Mounting angle (A)

Gravity Beta

Floor (A)

0.000000 (Default)

Wall (C)

90

1.570796

Suspended (D)

180

3.141593

Continues on next page

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2.3.7 Setting the system parameters for a suspended robot
Continued

xx0200000066

Defining the parameter in the software

The value of the system parameter Gravity Beta must be redefined when changing
the mounting angle of the robot. The parameter belongs to the type Robot, in the
topic Motion. How to calculate a new value is detailed in Mounting angles and
values on page 64.
The parameter is described in Technical reference manual - System parameters.
The parameter can be edited either with the FlexPendant or in RobotStudio. See
Operating manual - IRC5 with FlexPendant or Operating manual - RobotStudio.
Article numbers for the manuals are specified in References on page 10.

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2 Installation and commissioning

2.3.8 Bolt pattern

2.3.8 Bolt pattern

Hole configuration
The illustration below shows the hole configuration used when securing the
manipulator:
184,5
20 20
39

13
0,5 ABC

140

A
A-A

155

3,2

22

22

17
0

80

40

D
D

12

32

180

180

xx0200000085

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2.3.8 Bolt pattern
Continued
Cross section, guide sleeve hole
The illustration below shows the cross section of the guide sleeve holes:

xx0200000086

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2.3.9 Installation of signal lamp

2.3.9 Installation of signal lamp

Note
Do not use the signal lamp in a Clean Room environment.
Signal lamp
See the mounting/assembly instruction delivered with the signal lamp option.

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2.4.1 Restricting the working range

2.4 Restricting the working range

2.4.1 Restricting the working range
Introduction
When installing the manipulator, make sure that it can move freely within its entire
working space. If there is a risk that it can collide with other objects, its working
space should be limited.
WARNING
The working space can only be limited using software, for this reason the limited
area cannot be classified as a safe zone. All work within this zone is prohibited.
System parameters
The system parameters that must be changed (Upper joint bound and Lower joint
bound) are described in Technical reference manual - System parameters.
Limiting devices
Examples of limiting devices are listed below.
1 Light curtains.
2 Tread mats.
3 Other similar devices.
4 Software.

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2.5.1 Customer connections on manipulator

2.5 Electrical connections

2.5.1 Customer connections on manipulator
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

For air on base / upper arm

R1/4" Max. 8 bar/hose inner diameter: 6.5 mm

Signal connector on upper arm

FCI UT 071412SH44N connector

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

Continues on next page

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2.5.1 Customer connections on manipulator
Continued
Recommended parts
To connect power and signal conductors to the upper arm connector, the following
parts are recommended

xx0200000132

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

Multipole connector 12 pin

Adapter Tin plated 12 pin

Pins for cable area 0.25-0.5 mm 2

Pins for cable area 0.5-1.5 mm 2

Shrinking hose, bootled shaped

Shrinking hose angled

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

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3 Maintenance
3.1 Introduction

3 Maintenance
3.1 Introduction
Structure of this chapter
This chapter describes all the maintenance activities recommended for the IRB
140 type C.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided up according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work!
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 15 before performing any service
work!
Note
If the IRB 140 type C is connected to power, always make sure that the IRB 140
type C is connected to protective earth before starting any maintenance work!
For more information see:

Product manual - IRC5

Product manual - IRC5 Panel Mounted Controller

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3 Maintenance
3.2.1 Specification of maintenance intervals

3.2 Maintenance schedules

3.2.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 140 type C:

Calendar time: specified in months regardless of whether the system is

running or not.

Operating time: specified in operating hours. More frequent running means

more frequent maintenance activities.

SIS: specified by the robot's SIS (Service Information System). A typical

value is given for a typical work cycle, but the value will differ depending on
how hard each part is run. The SIS used in M2004 is further described in the
Operating manual - Service Information System.

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3 Maintenance
3.2.2 Maintenance schedule

3.2.2 Maintenance schedule

General
The robot, consisting of robot and controller cabinet, must be maintained regularly
to ensure its function. The maintenance activities and their respective intervals are
specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!
The inspection intervals do not specify the life of each component.
Activities and intervals, standard equipment
The sections referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
activity

Equipment

Interval

Reference

Inspection

Robot

Regularly i
For Clean Room robots:
Daily

Check for abnormal wear

or contamination

Inspection

Damper, axes 2-3 Regularly i

Inspection, damper axes

2, 3 and 5 on page 76

Inspection

Cable harnesses Regularly i

Inspection, robot cabling

on page 78

Inspection

Timing belts

36 mths

Inspection, timing belts on

page 79

Changing

Gearbox 5, oil

36 mths

Changing the oil in axes

5 and 6 gearboxes on
page 84

Changing

Gearbox 6, oil

36 mths

Changing the oil in axes

5 and 6 gearboxes on
page 84

Replacement

Battery pack,
Measurement
system

Battery low alert ii

Replacement of serial
measurement unit and
battery pack on page 137

Cleaning

Complete robot

Regularly i

Cleaning, robot on
page 82

ii

"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.
Battery low alert (38213 Battery charge low) is displayed when remaining backup capacity (robot
powered off) is less than 2 months. Typical lifetime of a new battery is 36 months if the robot is
powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be
extended (approx. 3 times) for longer production breaks by a battery shutdown service routine.
See Operating manual - IRC5 with FlexPendant for instructions.

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3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5

3.3 Inspection activities

3.3.1 Inspection, damper axes 2, 3 and 5
Location of dampers
The figure below shows the location of all the dampers to be inspected.

xx0200000426

Damper, axis 2

xx0200000427

Damper, axis 3

Continues on next page

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3 Maintenance
3.3.1 Inspection, damper axes 2, 3 and 5
Continued
Required equipment
Equipment

Art. no.

Note

Standard toolkit

Content is defined in section Standard tools on

page 201.

Inspection, dampers
The procedure below details how to inspect the dampers.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2

Check all dampers for damage, such as cracks Shown in the figure Location of
or existing impressions that are larger than 1 mm. dampers on page 76.

Check attachment screws for deformation.

If any damage is detected, the damper must be

replaced with a new one!

Replacement is detailed in sections:

Replacing the damper, axis
2 on page 125
Replacing the damper, axis
3 on page 116
Replacement of damper,
axis 5 on page 118.

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3 Maintenance
3.3.2 Inspection, robot cabling

3.3.2 Inspection, robot cabling

Introduction
CAUTION
Always read the specific instructions for Clean Room robots before doing any
repair work, see Replacing parts on Clean Room robots on page 96
Location, robot cabling
The robot cabling comprises the cabling between the robot and controller cabinet
as well as the externally visible cabling around motors 1 and 2.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.
Required equipment
Equipment

Note

Standard toolkit

Content is defined in section on page ?.

Other tools and procedures may be re- These procedures include references to the tools
quired. See references to these proced- required.
ures in the step-by-step instructions
below.
Circuit diagram

See chapter Circuit diagram on page 219.

Inspection, robot cabling

Use this procedure to inspect the robot cabling.
Action

Note

1
DANGER
Turn off all:
electric power supply to the robot
hydraulic pressure supply to the robot
air pressure supply to the robot
Before entering the robot working area.
2

Visually inspect:
the control cabling between the robot and
control cabinet
the cabling to motors 1 and 2.
Look for abrasions, cuts or crush damages.

Replace the cabling if wear or damage is detected. This is detailed in section Replacement of cable harness on page 88.

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3 Maintenance
3.3.3 Inspection, timing belts

3.3.3 Inspection, timing belts

Location of timing belts
Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the
figures below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000448

Timing belt, axis 3

Continues on next page

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3 Maintenance
3.3.3 Inspection, timing belts
Continued

xx0600003261

Timing belt, axis 6

Timing belt, axis 5

Required equipment
Equipment, etc.

Art. no.

Note

Standard toolkit

3HAC020812-001

Content is defined in section Standard

tools on page 201.

Other tools and procedures

may be required. See references to these procedures
in the step-by-step instructions below.

These procedures include references to

the tools required.

Continues on next page

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3 Maintenance
3.3.3 Inspection, timing belts
Continued
Inspection
The procedure below details how to inspect the timing belts.
WARNING
Please observe the following before commencing any repair work on the
manipulator:

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

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

When replacing motors/reducers, make sure that those parts of the robot
which could move unexpectedly are mechanically blocked as specified in
the individual procedures.
Action

Note

Gain access to each belt by remov- These procedures are detailed in sections
ing covers, etc.
Replacement of motor and timing belt, axis 3
on page 154 and Replacement of motor and
timing belt, axes 5 or 6 on page 163.

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 154 and Replacement of motor and timing belt, axes 5 or
6 on page 163.

Check each belt for tension.

If the belt tension is not correct, it
should be adjusted.

The belt tension should be:

Axis 3: F = 35-60 N
Axis 5: F = 35-60 N
Axis 6: F = 35-60 N

xx0200000474

Belt tension adjustment is detailed in sections

Replacement of motor and timing belt, axis 3
on page 154 and Replacement of motor and
timing belt, axes 5 or 6 on page 163.

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3 Maintenance
3.4.1 Cleaning, robot

3.4 Cleaning activities

3.4.1 Cleaning, robot

WARNING
Turn off all electrical power supplies to the manipulator before entering its work
space.
General
To secure high uptime it is important that the robot is cleaned regularly. The
frequency of cleaning depends on the environment in which the robot works.
Different cleaning methods are allowed depending on the protection class of the
robot.
Note
Always check the serial number label for verification of the robot protection class.
Cleaning activities
These instructions specify allowed cleaning methods for each protection class.
Protection
class

Cleaning method
Vacuum
cleaner

Wipe with cloth Rinse with water

Standard

Yes

Yes. With light Yes. It is highly re- No

cleaning deter- commended that
gent.
water contain a
rust-prevention
solution and that
the robot be dried
afterwards.

High pressure water or

steam

Foundry Plus Yes

Yes. With light Yes. It is highly recleaning deter- commended that

gent or spirit. water contain a
rust-prevention
solution.

Yes i . It is highly recommended that water and

steam contains rust preventive, without cleaning
detergents.

Wash

Yes

Yes. With light Yes. It is highly recleaning deter- commended that

gent or spirit. water contain a
rust-prevention
solution.

Yes ii . It is highly recommended that water and

steam contains rust preventive, without cleaning
detergents.

Clean room

Yes

Yes. With light No

cleaning detergent, spirit or
isopropyl alcohol.

No

i
ii

Perform according to section Cleaning with water and steam on page 83.
Perform according to section Cleaning with water and steam on page 83.

Continues on next page

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3 Maintenance
3.4.1 Cleaning, robot
Continued
Cleaning with water and steam
Cleaning methods that can be used for ABB robots with protection Standard,
Foundry Plus, Wash and Foundry Prime.
Equipment, etc.

Note

Vacuum cleaner
Cloth with mild detergent
Water cleaner

Steam cleaner

Max. water pressure at the nozzle: 700 kN/m2 (7

bar) i
Fan jet nozzle should be used, min. 45 spread
Distance from nozzle to encapsulation: min. 0.4
m
Flow: max. 20 liters/min i.
Water pressure at nozzle: max. 2,500 kN/m2 (25
bar)
Type of nozzle: fan jet, min. 45 spread
Distance from nozzle to encapsulation: min. 0.4
m
Water temperature: max. 80 C

Typical tap water pressure and flow

Cables
Movable cables need to be able to move freely:

Remove waste material, such as sand, dust and chips, if it prevents cable
movement.

Clean the cables if they have a crusty surface, for example from dry release
agents.

Dos and don'ts!

The section below specifies some special considerations when cleaning the robot.
Always!

Always use cleaning equipment as specified above! Any other cleaning

equipment may shorten the life of the robot.

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

Never!

Never point the water jet at connectors, joints, sealings or gaskets!

Never use compressed air to clean the robot!

Never use solvents that are not approved by ABB to clean the robot!

Never spray from a distance closer then 0.4m!

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

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3 Maintenance
3.5.1 Changing the oil in axes 5 and 6 gearboxes

3.5 Changing/ replacing activities

3.5.1 Changing the oil in axes 5 and 6 gearboxes
Location of oil plugs
The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure
below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0600002846

Oil plug, draining and filling

Oil plug, vent hole

Required equipment
Equipment, etc.

Art. no.

Amount

Note

Lubricating oil

3HAC0860-1

Total amount: 350 Optimol BM 100

ml (new wrist)
Amount at oil
change: 300 ml

Oil collecting vessel

Capacity: 400 ml.

Standard toolkit

Content is defined in section

Standard tools on page 201.

Other tools and procedures may be required.

See references to
these procedures in
the step-by-step instructions below.

These procedures include references to the tools required.

Continues on next page

84

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3 Maintenance
3.5.1 Changing the oil in axes 5 and 6 gearboxes
Continued
Draining, wrist unit
The procedure below details how to drain oil from the gearboxes in the wrist unit.
Action

Note/Illustration

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
WARNING
Handling gearbox oil involves several safety
risks. Before proceeding, please read the safety
information in the section WARNING - Safety
risks during work with gearbox lubricants (oil
or grease) on page 45.
3

Position the robot as shown in the figure to the Vessel capacity is specified in section
right:
Required equipment on page 84!
upper arm: upwards for a standing robot
axis 4: 180, to a position where the oil
plug (A), faces downwards.
Note! The total amount of oil will not be drained.
There will remain approximately 50 ml in the
wrist unit.

xx0500001434

A Oil plug, draining and filling

The position for an inverted robot is
the opposite!
4

Remove the both oil plugs.

Shown in the figure Location of oil
Both oil plugs must be removed in order to drain plugs on page 84.
the wrist unit properly.

Refit the oil plug, vent hole.

Continues on next page

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3 Maintenance
3.5.1 Changing the oil in axes 5 and 6 gearboxes
Continued
Filling oil, wrist unit
The procedure below details how to fill oil in the gearboxes in the wrist unit.
Action

Note/Illustration

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2
WARNING
Handling gearbox oil involves several safety
risks. Before proceeding, please read the
safety information in the section WARNING Safety risks during work with gearbox lubricants (oil or grease) on page 45.
3

Remove the oil plug, draining and filling.

Shown in the figure Location of oil

plugs on page 84!

Position the robot as shown in the figure to the The oil quality and amount is specified
right:
in section Required equipment on
upper arm: downwards for a standing page 84!
robot
axis 4: 90, to a position where the oil
plug (A), faces upwards.
Fill oil in the wrist unit through the oil plug.

xx0500001435

A: Oil plug, draining and filling

The position for an inverted robot is
the opposite.
5

Refit the oil plug.

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4 Repair
4.1 Introduction

4 Repair
4.1 Introduction
Structure of this chapter
This chapter describes all repair activities recommended for the IRB 140 type C
and any external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for
example spare parts numbers, required special tools, and materials.
The procedures are gathered in sections, divided according to the component
location on the IRB 140 type C.
Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information on page 193.
Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 15
before commencing any service work.
Note
If the IRB 140 type C is connected to power, always make sure that the IRB 140
type C is connected to earth before starting any repair work.
For more information see:

Product manual - IRC5

Product manual - Panel Mounted Controller.

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4 Repair
4.2.1 Replacement of cable harness

4.2 Complete robot

4.2.1 Replacement of cable harness
Location of cable harness
The cable harness runs from the base to the motors of axes 3-6.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.
Required equipment
Equipment, etc.

Spare part no.

Cable harness

3HAC 7370-1

Standard toolkit

Art. no.

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
3HAC020812-001

Other tools and procedures may be required.

See references to
these procedures in
the step-by-step instructions below.
Circuit Diagram

Note

Content is defined in section Standard tools on

page 201.
These procedures include
references to the tools required.

3HAC 6816-3

See chapter Circuit diagram on page 219.

Continues on next page

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4 Repair
4.2.1 Replacement of cable harness
Continued
Removal, cable harness
The procedure below details how to remove the cable harness.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
CAUTION

The cable packs are sensitive to mechanical damage! They must be handled
with care, especially the connectors, in order to avoid damaging them!
Action

Note/Illustration

Remove the serial measurement

board.

Detailed in section Replacement of serial measurement unit and battery pack on page 137.

Disconnect connectors in the manipulator base.

xx0300000090

Connectors:
A: R1.MP1-3
B: R1.CS
C: Air hose
D: R1.MP4-6

Continues on next page

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4 Repair
4.2.1 Replacement of cable harness
Continued
Action
3

Note/Illustration

Remove the cable holder by unscrewing its attachment screws.

xx0300000091

A: Cable holder
B: Attachment screws
C: Cable securing screws

Remove the cables from the cable See figure above!

holder by unscrewing the cable
securing screws.

Remove the cover, arm housing.

Detailed in section Replacement of cover, arm

housing on page 120.

Remove the lower arm cover.

Detailed in section Replacement of lower arm

cover and gasket on page 122.

Gently knock out the VK cover.

Detailed in section Removing the VK cover on

page 101.

Continues on next page

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4 Repair
4.2.1 Replacement of cable harness
Continued
Action
8

Note/Illustration

Disconnect connectors in the rear

of the upper arm.

xx0300000092

Connectors:
A: R2.CS
B: Pressurized air connection
C: R3.FB4
D: R3.FB5
E: R3.FB6
F: R3.MP5
G: R3.MP4
H: R3.MP6
Parts:
J: Shield
9

Remove the shield by unscrewing See figure above!

its attachment screws.

10 Cut any cable ties securing the

cabling inside the lower arm.

Continues on next page

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4 Repair
4.2.1 Replacement of cable harness
Continued
Action

Note/Illustration

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 130.

14 Disconnect the connectors inside Connectors:

the console and undo the cable
R3.MP1
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.

Continues on next page

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4 Repair
4.2.1 Replacement of cable harness
Continued
Refitting, cable harness
The procedure below details how to refit the cable harness.
WARNING
Please observe the following before commencing any repair work on the
manipulator:

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

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

- Take any necessary measures to ensure that the manipulator does not
collapse as parts are removed, e.g. to secure the lower arm with fixtures if
removing motor, axis 2.
CAUTION

The cable packs are sensitive to mechanical damage! They must be handled
with care, especially the connectors, in order to avoid damaging them!
Action
1

Refit in reverse order to what is detailed above.

Detailed below are some recommendations on how to route the
cables.

Cable distribution in the cable

holder in the manipulator base.

Note/Illustration

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

Continues on next page

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4 Repair
4.2.1 Replacement of cable harness
Continued
Action
3

Note/Illustration

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
G: Connectors R3.MP3 and R3.FB3

Continues on next page

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4 Repair
4.2.1 Replacement of cable harness
Continued
Action
4

Note/Illustration

Cable holder in the upper arm.

xx0300000094

Cables:
A: Customer signal
B: Signal
C: Pressurized air supply
D: Power cables

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4 Repair
4.2.2 Replacing parts on Clean Room robots

4.2.2 Replacing parts on Clean Room robots

General
When replacing parts on a Clean Room robot, it is important to make sure that
after the replacement, no particles will be emitted from the joint between the
structure and the new part, and that the easy cleaned surface is retained.
Required equipment Clean Room
Equipment

Spare parts

Note

Sealing compound

Sikaflex 521 FC. Color white.

Tooling pin

Width 6-9 mm, made of wood.

Spirit

Etanol

Knife
Lint free cloth
Touch up paint Clean Room,
White

3HAC036639-001

Removing
Use this procedure when removing a part for replacement on a Clean Room robot.
Action
1

Description

Cut the paint with a knife in the joint between

the part that will be removed and the structure, to avoid that the paint cracks.

xx0900000121

Carefully grind the paint edge that is left on

the structure to a smooth surface.

Refitting
Action

Description

Before the parts are refitted, clean the joint Use etanol on a lint free cloth.
so that it is free from oil and grease.

Place the tooling pin in hot water.

Continues on next page

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4 Repair
4.2.2 Replacing parts on Clean Room robots
Continued
Action
3

Description

Seal all refitted joints with Sikaflex 521FC.

xx0900000122

Use the tooling pin to even out the surface

of the Sikaflex seal.

xx0900000125

Wait 15 minutes.

Sikaflex 521FC skin dry time (15 minutes).

Use Touch up paint Clean Room, white to

paint the joint.

3HAC036639-001.

Note
Always read the instruction with Product Data
Sheet in the Paint Repair Kit Clean Room

Note
After all repair work, wipe the robot free from particles with spirit on a lint free
cloth.

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4 Repair
4.2.3 Replacement of complete upper arm

4.2.3 Replacement of complete upper arm

Location of upper arm
The upper arm is located on top of the manipulator as shown in the figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000446

Cover, armhousing

Attachment screws, cover armhousing, (4 pcs)

CS-connector

Pressurized air connector

VK cover

Cable guide

Attachment screws, cable guide

Attachment screws, upper arm (6 pcs)

Sealing ring

Continues on next page

98

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4 Repair
4.2.3 Replacement of complete upper arm
Continued
Required equipment
Equipment

Spare part no.

Art. no.

Note

Upper arm, spare Std/F 3HAC026581-001

Standard and Foundry

versions.
Includes all required sealings and gaskets.

Upper arm, spare CR

Clean room versions.

Includes all required sealings and gaskets.

3HAC026581-003

Sealing ring

3HAB3732-13

To be replaced if damaged
only.
Included in the upper arm
assembly.

VK cover

3HAA2166-13

Gasket upper arm cover

3HAC7867-1

Standard toolkit

3HAC020812-001 Content is defined in section Standard tools on

page 201.

Special socket

For fitting the CS-connector.

Other tools and procedures may be required.

See references to
these procedures in the
step-by-step instructions below.

These procedures include

references to the tools required.

WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.

Removal, upper arm

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

Note

Run the manipulator arm to a horizontal position.

Remove all brackets securing any exterior cabling

to the upper arm by unscrewing their attachment
screws respectively.

Remove the rear cover armhousing by unscrewing Shown in the figure Location of
its four attachment screws.
upper arm on page 98!

Continues on next page

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4 Repair
4.2.3 Replacement of complete upper arm
Continued
Action
4

Note

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!)

Disconnect all cables to/from motors 4-6.

Connectors
R3.MP4
R3.MP5
R3.MP6
R3.FB4
R3.FB5
R3.FB6

Disconnect any connector from the CS-connector. Shown in the figure Location of
upper arm on page 98!

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 as- upper arm on page 98!
sembly.
Art. no. specified in section Required equipment on page 99!

Remove the pressurized air connector from the

housing and pull it into the upper arm assembly.

Shown in the figure Location of

upper arm on page 98!
Art. no. specified in section Required equipment on page 99!

Remove the VK-cover from the upper arm/lower

arm joint.

Shown in the figure Location of

upper arm on page 98!
Detailed in section Removing the
VK cover on page 101.

10 Remove the cable guide by unscrewing its two at- Shown in the figure Location of
tachment screws.
upper arm on page 98!
11 Gently pull all cables and hoses out.
12 Remove the upper arm by unscrewing its six attach- Shown in the figure Location of
ment screws.
upper arm on page 98!
13 Lift the upper arm and place it on a secure surface.

Continues on next page

100

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4 Repair
4.2.3 Replacement of complete upper arm
Continued
Removing the VK cover
The procedure below details how to remove the VK cover from the upper arm.

xx0200000433

Lower arm

Lower arm cover gasket

Cover l. arm, spare (without lamp unit)

Cover l. arm, spare (with lamp unit)

Action

Note

Remove the lower arm cover by unscrewing its

attachment screws.

Tap the VK cover with a long blunt edged bar Make sure to press the circumference
through the hole in the lower arm to press it out. of the VK cover evenly to avoid damaging it.
Shown in the figure in section Location
of upper arm on page 98!

If the VK cover is damaged, it must be replaced Specified in section Replacement of

on refitting.
complete upper arm on page 98.

Continues on next page

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4 Repair
4.2.3 Replacement of complete upper arm
Continued
Refitting
The procedure below details how to refit the complete upper arm.
Action

Note

Check the sealing ring to see whether it is

damaged.
Replace if it is damaged!

Shown in the figure Location of upper

arm on page 98!
Art. no. specified in section Required
equipment on page 99!

Lift the upper arm into position.

Secure the upper arm with its six attachment Shown in the figure Location of upper
screws.
arm on page 98!
Tightening torque: 35 Nm 3 Nm

Gently pull all cables and hoses through the

hole in the upper arm.

Reconnect all connectors to motors 4-6.

Refit the cable guide with its two attachment Shown in the figure Location of upper
screws.
arm on page 98!

Pull the pressurized air connector through the Shown in the figure Location of upper
housing and secure it into fitting in the upper arm on page 98!
arm assembly.

Pull the CS-connector through the housing

and secure it into the fitting in the upper arm
assembly.
Use a special socketto secure it.

Reconnect any connector previously connected externally to the CS connector.

Connectors
R3.MP4
R3.MP5
R3.MP6
R3.FB4
R3.FB5
R3.FB6

Shown in the figure Location of upper

arm on page 98!
Art. no. specified in section Required
equipment on page 99!

10 Fit a newVK-cover to the upper arm/lower arm Shown in the figure Location of upper
joint.
arm on page 98!
Gently knock it into position.
Art. no. specified in section Required
equipment on page 99!
Use a plastic mallet or similar.
11 Refit the rear cover armhousing with its four Shown in the figure Location of upper
attachment screws.
arm on page 98!
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 a separate

calibration manual enclosed with the
calibration tools.
General calibration information is included in section

Continues on next page

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4 Repair
4.2.3 Replacement of complete upper arm
Continued

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. FlexPendant enabling

device.

all personnel are standing at a safe distance from the manipulator, i.e. out
of its reach behind safety fences, etc.

special attention is paid to the function of the part that has been serviced.

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4 Repair
4.2.4 Replacement of complete lower arm

4.2.4 Replacement of complete lower arm

Location of lower arm
The lower arm is located between upper arm and frame as shown in the figure
below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000469

Lower arm

Required equipment
Equipment

Spare part no.

Lower arm, spare

3HAC034935-001

Art. no.

Note
Standard and Foundry
versions
Includes all required
bearings, oil and VK cover.

Continues on next page

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4 Repair
4.2.4 Replacement of complete lower arm
Continued
Equipment

Spare part no.

Lower arm, spare

3HAC034937-001

Standard toolkit

Art. no.

Note
Clean room versions
Includes all required
bearings, oil and VK cover.

3HAC020812-001 Content is defined in section Standard tools on

page 201.

Lifting device for lower

arm

Lifting capacity >16 kg

Special socket

Other tools and procedures may be required.

See references to these
procedures in the stepby-step instructions below.

For fitting the CS-connector

These procedures include
references to the tools required.

Removal, lower arm

The procedure below details how to remove the complete lower arm.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Info

Remove the console.

Detailed in section Replacement of console on

page 133.

Continues on next page

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4 Repair
4.2.4 Replacement of complete lower arm
Continued
Action
2

Info

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 attachment Shown in the figure above!

screws.
Also remove the washer.

Raise the lifting device to remove

the lower arm.

Refitting, lower arm

The procedure below details how to refit the complete lower arm.
Action
1

Note

Fit the lifting device and lift the

lower arm into position.

Continues on next page

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4 Repair
4.2.4 Replacement of complete lower arm
Continued
Action
2

Note

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
Tightening torque: 35 Nm 3 Nm
3

Fit a new VK cover by gently tapping it into position.

Shown in the figure above!

Refit the console.

Detailed in section Replacement of console on

page 133.

Recalibrate the robot.

Calibration is detailed in a separate calibration

manual enclosed with the calibration tools.
General Calibration information is included in
section, Calibration information on page 181

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4 Repair
4.2.5 Replacement of base

4.2.5 Replacement of base

Location of base
The base is located at the bottom of the robot as shown in the figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000423

Base

Bottom plate

Attachment screws, bottom plate (26 pcs)

Attachment screws and washers, gearbox/base (10 pcs each)

Damper, axis 1

Washer

Required equipment
Equipment

Spare part no.

Base, spare

3HAC10470-1

Standard and Foundry

versions.
Includes parallel pin 3HAC
3785-2.

Base, spare

3HAC10470-3

Clean room versions.

Includes parallel pin 3HAC
3785-2.

Lifting slings

Art. no.

Note

Continues on next page

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4 Repair
4.2.5 Replacement of base
Continued
Equipment

Spare part no.

Art. no.

Note

Locking liquid

Grease

Loctite 574
For sealing the base to the
gearbox 1-2.
3HAB3537-1

Isopropanol

For lubricating the V-ring.

For cleaning the mating
surfaces.

Standard toolkit

Content is defined in section Standard tools on

page 201.

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

These procedures include

references to the tools required.

Removal, base
The procedure below details how to remove the base from the robot.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2

Remove the axis 1 and 2 motors.

Detailed in sections:
Replacement of motor, axis 1
on page 146
Replacement of motor, axis 2
on page 150

Remove the cable harness.

Detailed in section Replacement of

cable harness on page 88.

Remove the serial measurement unit.

Detailed in section Replacement of

serial measurement unit and battery
pack on page 137.

Remove the complete upper arm.

Detailed in section Replacement of

complete upper arm on page 98.

Remove the complete lower arm.

Detailed in section Replacement of

complete lower arm on page 104.

Unfasten the base from the installation site by

removing the attachment bolts from the foundation.

Fit the lifting slings to the robot, lift it and place

it with the side of the lower arm downwards on
a work bench.

Continues on next page

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4 Repair
4.2.5 Replacement of base
Continued
Action

Note

Remove the bottom plate.

Shown in the figure Location of base

on page 108.

10

Secure the weight of the base and remove the Shown in the figure Location of base
gearbox/base attachment screws and washer. on page 108.

11

Separate the base from the gearbox unit.

Refitting, base
The procedure below details how to refit the base to the robot.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working
area.
2

Place the robot with the side of the lower arm

downwards on a workbench.

Clean the mating surfaces between the base

and the gearbox unit with isopropanol.

Lubricate the mating surface on the base with

Loctite 574.

Lift the base to mounting position.

Secure the base to the gearbox unit with the Shown in the figure Location of base
gearbox/base attachment screws and washer. on page 108.
Tightening torque: 35 Nm 3Nm

Refit the bottom plate and secure it with its at- Shown in the figure Location of base
tachment screws.
on page 108.

Turn the robot to stand upright.

Secure the base to the foundation.

Attachment bolt and tightening torque

are specified in section Attachment
screws on page 60

10

Refit the complete lower arm.

Detailed in section Replacement of

complete lower arm on page 104.

11

Refit the complete upper arm.

Detailed in section Replacement of

complete upper arm on page 98.

12

Refit motors 1 and 2.

Detailed in sections Replacement of

motor, axis 1 on page 146 and Replacement of motor, axis 2 on page 150 respectively.

13

Refit the serial measurement unit.

Detailed in section Replacement of

serial measurement unit and battery
pack on page 137.

14

Refit the cable harness.

Detailed in section Replacement of

cable harness on page 88.

Continues on next page

110

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4 Repair
4.2.5 Replacement of base
Continued

15

Action

Note

Recalibrate the robot.

Calibration is detailed in a separate

calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 181.

16
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 41.

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4 Repair
4.3.1 Replacement of wrist unit

4.3 Upper arm

4.3.1 Replacement of wrist unit
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0600002847

Attachment screws, wrist unit (3 pcs)

Oil plug (only one shown)

Wrist unit

Required equipment
Equipment, etc.

Spare part no.

Art. no.

Wrist Standard/Foundry

Wrist unit (CR)

Note
Standard and Foundry versions.
O-ring sealing plate not included!
Note! The wrist, standard/Foundry is not interchangeable with art. no. 3HAC 10475-1!

3HAC 026569-003

Clean room versions

O-ring sealing plate not included!

Continues on next page

112

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4 Repair
4.3.1 Replacement of wrist unit
Continued
Equipment, etc.

Spare part no.

Art. no.

O-ring sealing plate

Note
Must be replaced.
Note! The o-ring sealing plate is
not interchangeable with art.no.
3HAC 7191-1!

Grease

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

plate.

Standard toolkit

Arm

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

Content is defined in section

Standard tools on page 201.

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions
below.

These procedures include references to the tools required.

Removal, wrist unit

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

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
2

Drain the oil from the wrist unit.

Detailed in section Changing the oil in

axes 5 and 6 gearboxes on page 84.

Remove the wrist unit by unscrewing its

three attachment screws.

Shown in the figure in section Location

of wrist unit on page 112.

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
Action
1

Note

Move the robot to a position where the

upper arm is vertical.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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4 Repair
4.3.1 Replacement of wrist unit
Continued
Action

Note

Lightly lubricate the o-ring sealingplate Art. no. is specified in section Required
with grease.
equipment on page 112.

In order to release the brake, connect

the 24 VDC power supply to motors:

Fit the o-ring sealingplate and the wrist Do not tighten its attachment screws!
unit to the upper arm with the attachment Use a new o-ring! Spare part no. is specified
screws, but do not tighten them.
in Required equipment on page 112.

Fit the arm to the rear of the motor.

Manually push the wrist to adjust the

wrist in relation to the gear in the gearbox.
The gear play must be checked according to subsections Measuring the gear
play, axis 5 on page 169 and Measuring
the gear play, axis 6 on page 171

Connect to connector R3.MP5 or 6:

+: pin 7
-: pin 8

Art. no. is specified in section Required

equipment on page 112.

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.

Check the gear play by moving axes 5

and 6 by hand.

The gear play should be as decribed in subsection Measuring the gear play, axis 5 on
page 169 and Measuring the gear play, axis
6 on page 171 to pass the test.

10

Perform a leak-down test.

Detailed in section Performing a leak-down

test on page 203.

11

Refill the wrist unit with oil.

Detailed in section Changing the oil in axes

5 and 6 gearboxes on page 84.

12

Recalibrate the robot!

Calibration is detailed in a separate calibration manual enclosed with the calibration

tools.
General calibration information is included
in section Calibration information on
page 181.

Continues on next page

114

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4 Repair
4.3.1 Replacement of wrist unit
Continued
Action

Note

13
DANGER
Make sure all safety requirements are
met when performing the first test run.
These are further detailed in the section
DANGER - First test run may cause injury or damage! on page 41.

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4 Repair
4.3.2 Replacing the damper, axis 3

4.3.2 Replacing the damper, axis 3

Location of damper, axis 3
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000427

Damper, axis 3

Required equipment
Equipment, etc.

Art. no.

Damper, axis 3

3HAC 7881-1

Note

Standard toolkit

Content is defined in section

Standard tools on page 201.

Removing the damper axis 3

Use this procedure to remove the damper.

Action

Note

Run the robot to a position where it is best

to enable access to the access 3 damper.

Shown in the figure Location of damper,

axis 3 on page 116.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.

Continues on next page

116

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4 Repair
4.3.2 Replacing the damper, axis 3
Continued
Action
3

Note

Remove the damper by gently prying it from

the cast tab.

Refitting the damper axis 3

Use this procedure to refit the damper.

Action

Note

Run the robot to a position where it is best

to enable access to the location where the
axis 3 damper is fitted.

Shown in the figure Location of damper,

axis 3 on page 116.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3

Refit the damper by gently pressing it onto

the cast tab on the upper arm.

4
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 41.

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4 Repair
4.3.3 Replacement of damper, axis 5

4.3.3 Replacement of damper, axis 5

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

xx0600002806

Damper, axis 5

Recess

Required equipment
Equipment, etc.

Spare part no.

Damper, axis 5

3HAB 8964-1

Standard toolkit

Note

Content is defined in section Standard

tools on page 201.

Removal, damper axis 5

The procedure below details how to remove the damper, axis 5.
Action
1

Note

Run the robot to a position that enables the end of Shown in the figure Location of
the damper to be pushed into the recess in the wrist damper, axis 5 on page 118.
unit.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3

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

recess.

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

damper to pull it out.

Continues on next page

118

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4 Repair
4.3.3 Replacement of damper, axis 5
Continued
Refitting, damper axis 5
The procedure below details how to refit the damper, axis 5.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2

Push the end of the damper into the gap between the
wrist unit and upper arm.

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

the damper into position.

Fold out the damper hooks to secure it in position.

Make sure the damper is

turned the correct way!

5
DANGER
Make sure all safety requirements are met when performing the first test run. These are further detailed in the
section DANGER - First test run may cause injury or
damage! on page 41.

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4 Repair
4.3.4 Replacement of cover, arm housing

4.3.4 Replacement of cover, arm housing

Location of cover, armhousing
The cover, armhousing is located on the rear of the upper arm as shown in the
figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000464

Cover, arm housing

Attachment screws, cover, armhousing

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

Includes gasket 3HAC
7867-1

Gasket, upper arm cover

3HAC 7867-1

Standard toolkit

3HAC020812-001

Other tools and procedures may be required.

See references to these
procedures in the stepby-step instructions below.

Content is defined in
section Standard tools
on page 201.
These procedures include references to the
tools required.

Continues on next page

120

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4 Repair
4.3.4 Replacement of cover, arm housing
Continued
Removal
The procedure below details how to remove the cover, armhousing.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Manually, run the robot to a position that enables

access to the rear of the upper arm.

Remove the cover, armhousing by unscrewing its

attachment screws.

Note

Shown in the figure Location of

cover, armhousing on page 120.
NOTE! Do not damage the gasket inside the cover!

Refitting
The procedure below details how to refit cover, armhousing.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note

Manually, run the robot to a position that enables

access to the rear of the upper arm.

Shown in the figure Location of

cover, armhousing on page 120.

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 120.

Secure the cover, arm housing to the upper arm with

its attachment screws.

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4 Repair
4.4.1 Replacement of lower arm cover and gasket

4.4 Lower arm

4.4.1 Replacement of lower arm cover and gasket
Location of lower arm cover and gasket
The lower arm cover and gasket are located as shown in the figure below.
A more detailed view of the components and its position may be found in section
Spare part lists on page 209.

xx0200000433

Lower arm

Gasket lower-arm cover

Continues on next page

122

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4 Repair
4.4.1 Replacement of lower arm cover and gasket
Continued
C

Cover l. arm, spare (without lamp unit)

Cover l. arm, spare (with lamp unit)

Required equipment
Equipment, etc.

Spare part no.

Lower arm

For spare part

number, see:
Spare part
lists on
page 209.

Cover, lover arm, spare,

Std/F

3HAC 10471-1

Standard and Foundry

versions
No lamp unit included
Includes gasket 3HAC
7869-1

Cover, lower arm, spare, CR 3HAC 10471-3

Clean room versions

No lamp unit included
Includes gasket 3HAC
7869-1

Gasket lower-arm cover

Art. no.

Note

3HAC 7869-1

Isopropanol

1177 1012-208

For cleaning sealing

surfaces

Standard toolkit

3HAC020812-001

Content is defined in
section Standard tools
on page 201.

Other tools and procedures

may be required. See references to these procedures
in the step-by-step instructions below.

These procedures include references to

the tools required.

Removal, lower arm cover and gasket

The procedure below details how to remove the lower arm cover and gasket.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note

Remove the lower arm cover by unscrewing its attach- Shown in the figure Location of
ment screws.
lower arm cover and gasket on
page 122.

Continues on next page

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4 Repair
4.4.1 Replacement of lower arm cover and gasket
Continued
Action

Note

If the gasket is to be replaced, proceed below!

Use a knife to gently remove the old gasket from the
cover.

Clean the sealing surface with isopropanol, making Art. no. specified in section Resure it is completely clean and free from scratches quired equipment on page 123.
and burrs.

Refitting, lower arm cover and gasket

The procedure below details how to refit the lower arm cover and gasket.
WARNING
Please observe the following before commencing any repair work on the
manipulator:

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

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

- Take any necessary measures to ensure that the manipulator does not
collapse as parts are removed, e.g. to secure the lower arm with fixtures if
removing motor, axis 2.
Action

Note

If the Gasket lower-arm cover is to be replaced, pro- Shown in the figure Location of
ceed below. If not, see further down!
lower arm cover and gasket on
page 122.

Remove the protective backing from the self-adhesive Make absolutely sure it is corgasket and fit it onto the cover sealing surface.
rectly located!

Refit the lower arm coverwith its attachment screws. Shown in the figure Location of
lower arm cover and gasket on
page 122.

124

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4 Repair
4.4.2 Replacing the damper, axis 2

4.4.2 Replacing the damper, axis 2

Location of damper, axis 2
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000426

Damper, axis 2

Required equipment
Equipment, etc.

Art. no.

Damper, axis 2

3HAC 7880-1

Standard toolkit

Note

Content is defined in section

Standard tools on page 201.

Other tools and procedures

may be required. See references to these procedures in
the step-by-step instructions
below.

These procedures include

references to the tools required.

Removing the damper

Use this procedure to remove the damper.
Action
1

Note

Run the robot to a position where it is best

to enable access to the attachment screw of
the damper.

Continues on next page

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4 Repair
4.4.2 Replacing the damper, axis 2
Continued
Action

Note

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3

Remove the damper by unscrewing the attachment screw and washer.

Refitting the damper

Use this procedure to refit the damper.
Action
1

Note

Run the robot to a position where it is best

to enable access to the attachment screw of
the damper.

2
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
3

Secure the damper with the attachment screw 1 pc: M6 x 16.

and washer.

4
DANGER
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 41.

126

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4 Repair
4.4.3 Replacement of indicator lamp

4.4.3 Replacement of indicator lamp

Location of indicator lamp
The indicator lamp is located on the side of the lower arm as shown in the figure
below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000472

Indication lamp

Lower arm cover

Required equipment
Equipment, etc.

Spare part no.

Indicator lamp

3HAC 9258-1

Standard toolkit

Art. no.

Note

3HAC020812-001

Content is defined in section

Standard tools on page 201.

Other tools and

procedures may be
required. See references to these procedures in the
step-by-step instructions below.

These procedures include references to the tools required.

Continues on next page

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4 Repair
4.4.3 Replacement of indicator lamp
Continued
Removal
The procedure below details how to remove the indicator lamp.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note

Remove the lower arm cover.

Detailed in section Replacement of lower arm cover and

gasket on page 122.

Remove the damper by gently prying the plastic semitransparent damper from the cast tab.

Refitting
The procedure below details how to refit the indicator lamp.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Run the robot to a position that enables access to

damper, axis 3.

Refit the damper by gently pressing it onto the cast tab

on the upper arm.

Note

Continues on next page

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4 Repair
4.4.3 Replacement of indicator lamp
Continued

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.

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4 Repair
4.5.1 Replacement of cover, console

4.5 Frame and base

4.5.1 Replacement of cover, console
Location of cover, console
The cover, console is located on top of the console as shown in the figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000462

Cover, console

Attachment screws, cover, console (4 pcs)

Gasket

Console

Required equipment
Equipment, etc.

Spare part. no.

Cover, console, spare

3HAC 10472-1

Standard and Foundry

version
Includes gasket 3HAC
7868-1

Cover, console, spare

3HAC 10472-3

Clean Room versions

Includes gasket 3HAC
7868-1

Gasket, cover console

Art. no.

Note

3HAC 7868-1

Continues on next page

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4 Repair
4.5.1 Replacement of cover, console
Continued
Equipment, etc.
Standard toolkit

Spare part. no.

Art. no.

Note

3HAC020812-001 Content is defined in

section Standard tools
on page 201.

Other tools and procedures may be required.

See references to these
procedures in the stepby-step instructions below.

These procedures include references to the

tools required.

Removal
The procedure below details how to remove the cover, console.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note

Manually, run the robot to a position that enables

access to the top of the console.

Shown in the figure Location of

cover, console on page 130.

Remove the cover, console by unscrewing its attach- NOTE! Do not damage the gasment screws.
ket inside the cover!

Refitting
The procedure below details how to refit cover, console.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note

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 130.

Continues on next page

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4 Repair
4.5.1 Replacement of cover, console
Continued
Action

Note

Make sure the gasket inside the cover, console has Replace if damaged.
not been damaged.
Shown in the figure Location of
cover, console on page 130.

Secure the cover, console to the console with its attachment screws.

132

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4 Repair
4.5.2 Replacement of console

4.5.2 Replacement of console

Location of console
The console is located on top of gearbox, axes 1-2 as shown in the figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000462

Cover, console

Attachment screws, cover, console (4 pcs)

Gasket

Console

Required equipment
Equipment, etc.

Spare part. no.

Console, spare

3HAC 10478-1

Standard and Foundry

version

Console, spare

3HAC 10478-3

Clean Room versions

Standard toolkit

Art. no.

Note

3HAC020812-001 Content is defined in

section Standard tools
on page 201.

Other tools and procedures

may be required. See references to these procedures
in the step-by-step instructions below.

These procedures include references to the

tools required.

Continues on next page

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4 Repair
4.5.2 Replacement of console
Continued
Removal
The procedure below details how to remove the cover, console.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note/Illustration

Remove the cable harness.

Detailed in section Replacement of cable harness on

page 88.

Remove the serial measurement board.

Detailed in section Replacement of serial measurement

unit and battery pack on page 137.

Remove the complete upper

arm.

Detailed in section Replacement of complete upper arm

on page 98.

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.

Attach the lifting device to the

lower arm.

Detailed in section Replacement of motor and timing

belt, axis 3 on page 154.

Continues on next page

134

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4 Repair
4.5.2 Replacement of console
Continued
Action
7

Note/Illustration

Remove the bearing hub by

unscrewing its attachment
screws.

xx0300000096

Parts:
A: Console
B: Bearing hub
C: Bearing hub attachment screws (6 pcs)
D: Console attachment screws (10 pcs)
E: Washers (10 pcs)
8

Remove the console by unscrewing its attachment

screws.

Shown in the figure above!

Refitting
The procedure below details how to refit cover, console.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.

Continues on next page

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4 Repair
4.5.2 Replacement of console
Continued
Action
1

Note/Illustration

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)
Tightening torque: 11 Nm 1 Nm
2

Refit the bearing hub and secure it Shown in the figure above!
with its attachment screws.
Tightening torque: 15 Nm 1 Nm

Refit the complete upper arm.

Detailed in section Replacement of complete upper arm on page 98.

Refit motor 3 and timing belt.

Detailed in section Replacement of motor and

timing belt, axis 3 on page 154.

Refit the serial measurement board. Detailed in section Replacement of serial measurement unit and battery pack on page 137.

Refit the cable harness.

Detailed in section Replacement of cable harness

on page 88.

Recalibrate the robot!

Calibration is detailed in a separate calibration

manual enclosed with the calibration tools.
General calibration information is included in
section Calibration information on page 181.

136

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4 Repair
4.5.3 Replacement of serial measurement unit and battery pack

4.5.3 Replacement of serial measurement unit and battery pack

Note
The lifetime of the SMB lithium battery can be extended significantly during a
production break by activating sleep mode with a service routine. See Operating
manual - IRC5 with FlexPendant, section Battery shutdown service routine.
WARNING
See instructions for batteries, WARNING - Safety risks during handling of batteries
on page 44.
Location of serial measurement unit and battery pack
The serial measurement unit and battery pack are located inside the manipulator
base as shown in the figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000432

Rear cable cover

Battery pack

Serial measurement board (SMB)

SMB attachment screws (4 pcs)

Manipulator base bottom plate

Continues on next page

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4 Repair
4.5.3 Replacement of serial measurement unit and battery pack
Continued
Required equipment
Equipment, etc.

Spare part. no.

Art. no.

Note

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

Standard Toolkit, IRB 140

3HAC020812-001 Content is defined in

section Standard tools
on page 201.

Other tools and procedures may be required. See

references to these procedures in the step-bystep instructions below.

These procedures include references to the

tools required.

Circuit Diagram

3HAC 6816-3

Replace only if required!

See chapter Circuit diagram on page 219.

Removal
The procedure below details how to remove the serial measurement unit and battery
pack.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
DANGER

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

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

subjected to electrostatic voltages.

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

Continues on next page

138

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4 Repair
4.5.3 Replacement of serial measurement unit and battery pack
Continued

CAUTION
This component is classified as Hazardous waste and must be disposed of
accordingly!
If in doubt of the correct disposal procedure, please contact your local
environmental authority!
CAUTION
The cable packs are sensitive to mechanical damage! They must be handled
with care, especially the connectors, in order to avoid damaging them!
Action

Note

Set the robot system to MOTORS OFF state. This will simplify calibration of the
robot after replacement since no
coarse calibration will be required.

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 137!

Remove the serial measurement unit by un- Shown in the figure Location of
screwing its attachment screws.
serial measurement unit and batThe removal is simplified by pushing the unit tery pack on page 137!
to the side and then pulling it backwards.

If only the battery is to be replaced, disconnect Connectors

the cables to the battery only!
R2.SMB
R2.FB1-3
Disconnect all connectors from the serial
measurement unit.
R2.FB4-6
R2.G

Lift the board out.

If the battery pack is to be replaced, proceed Shown in the figure Location of

below!
serial measurement unit and batCut the cable tie and disconnect the battery tery pack on page 137!
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.

Continues on next page

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4 Repair
4.5.3 Replacement of serial measurement unit and battery pack
Continued
Refitting
The procedure below details how to refit the serial measurement unit and battery
pack.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
DANGER

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

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

subjected to electrostatic voltages.

Before handling, make sure you are grounded through a special ESD wrist
bracelet or similar.
CAUTION

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

accordingly!
If in doubt of the correct disposal procedure, please contact your local
environmental authority!
CAUTION
The cable packs are sensitive to mechanical damage! They must be handled
with care, especially the connectors, in order to avoid damaging them!
Action

Note

Connect the new battery pack to the serial

measurement unit and secure it with a cable tie.

Reconnect all connectors to the unit.

Place the serial measurement unit in position in- Shown in the figure Location of
side the manipulator base and secure it with its serial measurement unit and
four attachment screws.
battery pack on page 137!

Connectors
R2.SMB
R2.FB1-3
R2.FB4-6
R2.G

Continues on next page

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4 Repair
4.5.3 Replacement of serial measurement unit and battery pack
Continued
Action

Note

Make sure the gasket sealing the rear cable cover Shown in the figure Location of
has not been damaged.
serial measurement unit and
battery pack on page 137!
Replace the gasket if required.
Art. no. specified in section Required equipment on page 138!

Making sure all cables are correctly located be- Shown in the figure Location of
hind the rear cable cover, refit it into position.
serial measurement unit and
Make sure no cables or other equipment fitted battery pack on page 137!
behind the cover get pinched by the cover.

Secure the rear cable cover to the base of the

robot with its attachment screws.

This is valid if NiCd type batteries are used only!

Lithium batteries do not require charging before
use.
Recharge the battery for at least 36 hrs by leaving
the mains supply switched on for this amount of
time.

Recalibrate the robot!

3HAC027400-001 Revision: J

Shown in the figure Location of

serial measurement unit and
battery pack on page 137!

Calibration is detailed in a separate calibration manual enclosed

with the calibration tools.
General calibration information
is included in section Calibration
information on page 181.

141
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4 Repair
4.5.4 Replacement of control cable

4.5.4 Replacement of control cable

Location of control cable
The control cable is located on the rear of the manipulator base as shown in the
figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000467

Gasket, base-cover

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

Control cable, spare

Required equipment
Equipment, etc.

Spare part. no.

Art. no.

Note

Control cable, spare

3HAC 10476-1

3m
Standard and Foundry
versions
Cover gasket included

Control cable, spare

3HAC 10477-1

7m
Standard and Foundry
versions
Cover gasket included

Control cable, spare

3HAC 11331-1

15 m
Standard and Foundry
versions
Cover gasket included

Control cable, spare

3HAC 13090-1

22 m
Standard and Foundry
versions
Cover gasket included

Continues on next page

142

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4 Repair
4.5.4 Replacement of control cable
Continued
Equipment, etc.

Spare part. no.

Control cable, spare

3HAC 13089-1

30 m
Standard and Foundry
versions
Cover gasket included

Control cable, spare

3HAC 10476-4

3m
Clean Room versions
Cover gasket included

Control cable, spare

3HAC 10477-2

7m
Clean Room versions
Cover gasket included

Control cable, spare

3HAC 11331-2

15 m
Clean Room versions
Cover gasket included

Control cable, spare

3HAC 13090-2

22 m
Clean Room versions
Cover gasket included

Control cable, spare

3HAC 13089-2

30 m
Clean Room versions
Cover gasket included

Standard toolkit

Art. no.

Note

3HAC020812-001 Content is defined in section Standard tools on

page 201.

Other tools and procedures may be required.

See references to these
procedures in the stepby-step instructions below.

These procedures include

references to the tools required.

Removal
The procedure below details how to remove the control cable.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note

Make sure the robot system has been

switched off, and that no power is
supplied to the manipulator.

Continues on next page

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4 Repair
4.5.4 Replacement of control cable
Continued
Action

Note

Remove the Control cable, spare by Shown in the figure Location of control cable
unscrewing its attachment screws. on page 142.
Make sure the gasket does not get damaged!

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.

Disconnect the connectors from the

control cabinet.

Refitting
The procedure below details how to refit control cable.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Note

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 142.
manipulator.

Continues on next page

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4 Repair
4.5.4 Replacement of control cable
Continued
Action
2

Note

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

Fit the cover onto the manipulator base Shown in the figure Location of control
and secure it with its attachment screws. cable on page 142.

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4 Repair
4.6.1 Replacement of motor, axis 1

4.6 Motors
4.6.1 Replacement of motor, axis 1
Location of motor axis 1
The motor axis 1 is located on the rear of the manipulator as shown in the figure
below:
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000407

Motor, axis 1

Cover for connector access

Motor attachment screws (4 pcs)

Cable gland attachment screws (4 pcs)

Console

Required equipment
Equipment, etc.

Art no.

Note

Rot. ac motor with pinion

For spare part number,

see:
Spare part lists
on page 209.

O-ring

2152 2012-426

Must be replaced when replacing

motor!
Included in the spare parts motor kits

Grease

3HAB 3537-1

Used to lubricate the o-ring

Standard toolkit

3HAC020812-001

Content is defined in section Standard tools on page 201.

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Continues on next page

146

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4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Equipment, etc.

Art no.

Note

Power supply

24 VDC, max. 1,5 A

For releasing the brakes

Other tools and procedures

may be required. See references to these procedures
in the step-by-step instructions below.

These procedures include references

to the tools required.

Circuit Diagram

See chapter Circuit diagram on

page 219.

Removal
The procedure below details how to remove motor, axis 1.
CAUTION
If the manipulator normally works in an inverted position, it must be removed
from this position and placed on the floor before the work detailed in this
instruction may be carried out!
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Note

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

excessive force is used!
Action

Note

Remove the cover for connector access on top of the Shown in the figure Location of
motor by unscrewing its four attachment screws.
motor axis 1 on page 146.
Detailed in section Replacement
of cover, console on page 130.

Disconnect the motor 1 connectors inside the console.

Cut any cable ties and remove any brackets securing

the cables.

Remove the cable gland by removing its attachment Shown in the figure Location of
screws, and pull the cables out from the console.
motor axis 1 on page 146.

Connectors:
R3.MP1
R3.FB1

Continues on next page

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4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Action

Note

In order to release the brakes, connect the 24 VDC Connect to connector R3.MP1
power supply:
+: pin 7
-: pin 8

Remove the motor by unscrewing its four attachment Shown in the figure Location of
screws and plain washers.
motor axis 1 on page 146.

Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.

Remove the motor by gently lifting it straight up.

Refitting
The procedure below details how to refit motor, axis 1.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Note

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

excessive force is used!
Action

Note

Make sure the mating surfaces on the motor and

the gearbox are clean and free from burrs.

Make sure the o-ring on the circumference of the Art. no. is specified in section Remotor is seated properly. Lightly lubricate the o- quired equipment on page 146.
ring with grease.

In order to release the brake, connect the 24 VDC Connect to connector R2.MP1
power supply:
+: pin 7
-: pin 8

Fit the motor, making sure the motor pinion is

properly mated to gearbox 1.

Make sure the motor is turned the

right way, i.e. connections rearwards.
Make sure the motor pinion does
not get damaged!

Fit the motor with four attachment screws and

plain washers.

Tightening torque: approx 2 Nm

Fit the Arm to the end of the motor shaft.

Art. no. is specified in section Required equipment on page 146.

Continues on next page

148

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4 Repair
4.6.1 Replacement of motor, axis 1
Continued
Action

Note

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.

Tighten the motor attachment screws.

Disconnect the brake release voltage.

10

Make sure the cable gland gasket has not been Art. no. is specified in section Redamaged. Replace, if it has.
quired equipment on page 146.

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 Performing a

leak-down test on page 203.

13

Recalibrate the robot!

Calibration is detailed in a separate

calibration manual enclosed with
the calibration tools.
General calibration information is
included in section Calibration information on page 181.

Tightening torque: approx 11 Nm

1 Nm

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4 Repair
4.6.2 Replacement of motor, axis 2

4.6.2 Replacement of motor, axis 2

Location of motor axis 2
The motor axis 2 is located on the front of the robot as shown in the figure.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000408

Motor, axis 2

Cover for connector access

Motor attachment screws (4 pcs)

Cable gland attachment screws (4 pcs)

Console

Required equipment
Equipment, etc.

Spare part no.

Art. no.

Note

Rot. ac motor with

pinion

For spare part

number, see:
Spare
part lists
on
page 209

O-ring

2152 2012-426 Must be replaced when replacing motor.

Grease

3HAB 3537-1

For lubricating the o-ring.

Isopropanol

For cleaning mating surfaces.

Standard toolkit

Content is defined in section

Standard tools on page 201.

Rotation tool, motor

3HAC 9037-1

For adjusting the gear play,

motor/pinion

Power supply

24 VDC, 1.5 A.
For releasing the brakes.

Continues on next page

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4 Repair
4.6.2 Replacement of motor, axis 2
Continued
Equipment, etc.

Spare part no.

Art. no.

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions
below.
Circuit Diagram

Note
These procedures include references to the tools required.

See chapter Circuit diagram on

page 219.

Removal, motor axis 2

The procedure below details how to remove the axis 2 motor.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2

Remove the cover for connector access on top of the Shown in the figure Location
motor by unscrewing its four attachment screws.
of motor axis 2 on page 150.

Disconnect the motor connectors inside the console. Connectors:

R3.MP2
R3.FB2

Cut any cable ties and remove any brackets or clamps

securing the cables.

Remove the cable gland by removing its attachment

screws, and pull the cables out from the console.

Shown in the figure Location

of motor axis 2 on page 150.

6
DANGER
Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2!
When releasing the holding brakes of the motor, the
lower arm will be movable and may fall down!
7

In order to release the brakes, connect the 24 VDC

power supply to the motor.

Connect to connector R3.MP2

+: pin 7
-: pin 8

8
WARNING
Oil will be running out of the motor attachment hole
when removing the motor! It may also be hot! Take any
necessary measures to collect the oil.
9

Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers.
of motor axis 2 on page 150.

Continues on next page

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4 Repair
4.6.2 Replacement of motor, axis 2
Continued
Action

Note

10

Remove the motor by gently pulling it out, making sure

the motor pinion does not get damaged while moving
it away from the gear.

11

Disconnect the brake release voltage.

12

Remove any remaining oil from the gearbox by siphoning it off.

Refitting, motor axis 2

The procedure below details how to refit the axis 2 motor.
Action

Note

Make sure the mating surfaces on the motor and

the gearbox are clean and free from burrs.
If necessary, clean the surfaces with isopropanol.

Make sure the o-ring on the circumference of the Art. no. is specified in section Remotor is seated properly.
quired equipment on page 150.
Lightly lubricate the o-ring with grease.

In order to release the brakes, connect the 24

VDC power supply to the motor.

Remove the motor cover from top of the motor. Shown in the figure Location of motor axis 2 on page 150.

Fit the rotation tool to the end of the motor shaft. Art. no. is specified in section Required equipment on page 150.

Fit the motor, making sure the motor pinion is

properly mated to gearbox 2.
Use the rotation tool to rotate the motor pinion,
when mating it to the gear.

Make sure the motor is turned the

right way, i.e. connections rearwards.
Make sure the motor pinion does
not get damaged!

Secure the motor with four attachment screws

and plain washers, but do not tighten yet.

Tightening torque: approx 2 Nm.

Adjust the motor in relation to the gear in the

There should be a barely noticable
gearbox.
gear play.
Use the rotation tool to wiggle the motor shaft
back and forth to feel the play. Tap with a plastic
mallet.

Refit the motor cover to the top of the motor.

Be careful not to damage the cables!

10

Tighten the motor attachment screws.

11

Disconnect the brake release voltage.

12

Make sure the cable gland cover gasket has not Art no. is specified in section Rebeen damaged. Replace if it has.
quired equipment on page 150.

13

Push the cables into the console, and refit the

cable gland with its attachment screws.

14

Refit all cable ties and brackets.

15

Perform a leak-down test.

Connect to connector R3.MP2:

+: pin 7
-: pin 8

Tightening torque: approx 11 Nm

1 Nm

Detailed in section Performing a

leak-down test on page 203.

Continues on next page

152

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4 Repair
4.6.2 Replacement of motor, axis 2
Continued
Action

Note

16

Refill the gearbox with oil.

Oil: Mobilgear 600 XP 320

Art.no: 11712016-604
Volume: 1000 ml

17

Recalibrate the robot!

Calibration is detailed in a separate

calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration information on page 181.

18
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 41.

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

4.6.3 Replacement of motor and timing belt, axis 3

Location of motor axis 3
The motor axis 3 is located behind the lower arm cover on the right hand side of
the manipulator as shown in the figure below.
For a more detailed view of the components and its position, see Spare part lists
on page 209.

xx0200000448

Lower arm cover

Attachment screws, lower arm cover (13 pcs)

Belt shield

Motor 3

Attachment screws, belt shield (3 pcs)

Attachment screws, motor 3 (4 pcs)

Belt

Continues on next page

154

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4 Repair
4.6.3 Replacement of motor and timing belt, axis 3
Continued
Required equipment
Equipment, etc.

Spare part no.

Art. no.

Note

Rotating AC motor with 3HAC7866-1

pinion
3HAC021756-001
Timing belt

3HAC6793-1

Standard toolkit

3HAC020812-001

Content is defined in
section Standard tools
on page 201.

Other tools and procedures may be required.

See references to these
procedures in the stepby-step instructions below.

These procedures include references to the

tools required.

Circuit Diagram

See chapter Circuit diagram on page 219.

Removing the motor, axis 3

Use this procedure to remove the motor, axis 3.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Note

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

excessive force is used!
Action

Note

Remove any equipment hindering ac- Shown in the figure in section Location of motor
cess to the lower arm cover.
axis 3 on page 154.

Remove the lower arm cover by unscrewing its attachment screws.

Shown in the figure in section Location of motor

axis 3 on page 154.

Continues on next page

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

Note

Cut the cable ties to simplify accessing

the motor.

xx0200000449

Disconnect motor connectors.

A: Cable ties
B: Pressurized air hose
C: Power cables, axes 4, 5 and 6
D: Customer cables, signal
E: Signal cables, axes 4, 5 and 6
F: Signal cable, axis 3
G: Connectors R3.MP3 and R3.FB3

Connectors:
R3.MP3
R3.FB3
R3.H1 (if Safety lamp is fitted)
R3.H2 (if Safety lamp is fitted)

Continues on next page

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4 Repair
4.6.3 Replacement of motor and timing belt, axis 3
Continued
Action
5

Note

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 motor
its two attachment screws.
axis 3 on page 154.

Remove the remaining motor attach- Shown in the figure in section Location of motor
ment screws.
axis 3 on page 154.

Remove the belt.

Shown in the figure in section Location of motor

axis 3 on page 154.

Remove the motor.

Shown in the figure in section Location of motor

axis 3 on page 154.

Refitting the motor, axis 3

Use this procedure to refit the motor, axis 3.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Action

Make sure the mating surfaces on the

motor and the lower arm are clean and
free from burrs.

Fit the motor in the lower arm.

Fit the belt.

Note

Shown in the figure in section Location of

motor axis 3 on page 154.

Continues on next page

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

Note

Tighten the two motor attachment screws

slightly, but not completely.

Adjust the position of the motor in such Correct belt tension F=35 - 60 N
a way that the correct belt tension is
achieved.

DO NOT adjust the belt tension using the

intermediate wheel securing screws.

Fit the belt shield and secure it with the Tightening torque: 4 Nm 0.5 Nm
two remaining screws.

Tighten the last motor attachment

screws.

Refit the cabling as shown.

Tightening torque: 4 Nm 0.5 Nm

xx0200000449

A: Cable ties
B: Pressurized air hose
C: Power cables, axes 4, 5 and 6
D: Customer cables, signal
E: Signal cables, axes 4, 5 and 6
F: Signal cable, axis 3
G: Connectors R3.MP3 and R3.FB3

Continues on next page

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4 Repair
4.6.3 Replacement of motor and timing belt, axis 3
Continued
Action
10 Recalibrate the robot!

Note
Calibration is detailed in a separate calibration manual enclosed with the calibration
tools.
General calibration information is included
in section Calibration information on page 181.

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4 Repair
4.6.4 Replacement of motor, axis 4

4.6.4 Replacement of motor, axis 4

Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the
figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0600003262

Attachment screws, motor 4 (3 pcs)

Motor, axis 4

O-ring

Required equipment
Equipment, etc.

Spare part no.

Art. no.

Rot. ac motor with pinion For spare part

number, see:
Spare part
lists on
page 209
O-ring

Note
Does not include the o-ring!

3HAC 3772-24 Must be replaced when replacing motor!

Replace if damaged.

Grease

3HAB 3537-1

Used for lubricating the oring.

Standard toolkit

3HAC020812001

Content is defined in section

Standard tools on page 201.

Power supply

24 VDC, max. 1,5 A.

For releasing the brakes.

Rotation tool, motor

3HAC 9037-1

For adjusting the gear play.

Continues on next page

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4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Equipment, etc.

Spare part no.

Art. no.

Note

Other tools and procedures may be required.

See references to these
procedures in the stepby-step instructions below.
Circuit Diagram

These procedures include

references to the tools required.

3HAC 6816-3

See chapter Circuit diagram

on page 219.

Removal, motor axis 4

The procedure below details how to remove the motor, axis 4.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot working area.
2

Manually move the robot to a position where the

upper arm points straight down.

This will enable the motor 4 to be

removed without draining the oil
in the gearbox.

Remove the motors for axes 5 and 6.

Detailed in section Replacement

of motor and timing belt, axes 5 or
6 on page 163.

In order to release the brakes, connect the 24 VDC Connect to connector R3.MP4
power supply to the motor.
+: pin 7
-: pin 8

Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws.
motor on page 160.

Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.

Remove the motor by gently lifting it out.

Make sure the motor pinion is not

damaged!

Refitting, motor axis 4

The procedure below details how to refit the motor, axis 4.
Action

Note

Clean the mating surfaces on the motor and

the gearbox.

Shown in the figure Location of motor

on page 160.

Make sure the o-ring on the circumference of Art. no. is specified in section Rethe motor is seated properly. Lightly lubricate quired equipment on page 160.
the o-ring with grease .

In order to release the brakes, connect the 24 Connect to connector R3.MP4

VDC power supply to the motor.
+: pin 7
-: pin 8

Continues on next page

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4 Repair
4.6.4 Replacement of motor, axis 4
Continued
Action

Note

Fit the motor with the attachment screws and Shown in the figure Location of motor
washers.
on page 160.
Until the motor shaft is adjusted to the gear, as Tightening torque: approx. 2 Nm.
described in following steps, only tighten the
screws lightly.

Fit the rotational tool to the end of the motor

shaft.

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.

Tighten the motor attachment screws.

Shown in the figure Location of motor

on page 160.
Tightening torque: 6 Nm 0.6 Nm.

Refit motors 5 and 6.

Detailed in section Replacement of

motor and timing belt, axes 5 or 6 on
page 163.

Perform a leak-down test.

Detailed in section Performing a leakdown test on page 203.

10

Recalibrate the robot!

Calibration is detailed in a separate

calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 181.

Art. no. is specified in section Required equipment on page 160.

11
DANGER
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 41.

162

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

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

Location of motor and timing belt, axes 5 or 6
The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as
shown in the figure below.
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0600003261

Lower arm cover

Attachment screws, lower arm cover

Cover, armhousing

Attachment screws, cover armhousing (4 pcs)

VK cover

Pressurized air hose (on front of upper arm)

CS connector

Cable guide

Attachment screws, cable guide

Continues on next page

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4 Repair
4.6.5 Replacement of motor and timing belt, axes 5 or 6
Continued
K

Belt shield

Attachment screws, belt shield

Motor attachment screws, 4 pcs per motor

Attachment screws, motor console

Timing belt, axis 6

Pulley, axis 6

Timing belt, axis 5

Pulley, axis 5

Motor console, ax. 5-6

Motor, axis 4

Motor, axis 5

Motor, axis 6

Required equipment
Equipment, etc.

Spare part no.

Art. no.

Note

Rot. ac motor with pinion 3HAC021757-001

Axis 4
Standard, Clean room
and Foundry versions

Rot. ac motor with pinion 3HAC021758-001

Axes 5 and 6
Standard, Clean room
and Foundry versions

Timing belt

Axes 5 and 6

3HAC6779-1

VK cover

3HAA2166-13

Standard toolkit

3HAC020812-001 Content is defined in

section Standard tools
on page 201.

Special socket 30 mm

For fitting the CS-connector

Other tools and procedures may be required. See

references to these procedures in the step-by-step
instructions below.

These procedures include references to the

tools required.

Circuit Diagram

3HAC6816-3

Sonic Tension Meter

See chapter Circuit diagram on page 219.

Model 505C

Continues on next page

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4 Repair
4.6.5 Replacement of motor and timing belt, axes 5 or 6
Continued
Removal
The procedure below details how to remove motor, axis 5 or 6.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Note

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

excessive force is used!
Action

Note

Run the robot to a position where the upper

arm is close to horizontal

Remove the lower arm cover by unscrewing Shown in the figure in section Location
its attachment screws.
of motor and timing belt, axes 5 or 6 on
page 163!

Remove the rear cover armhousing by un- Shown in the figure in section Location
screwing its four attachment screws.
of motor and timing belt, axes 5 or 6 on
page 163!

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

R3.MP4
R3.MP5
R3.MP6
R3.FB4
R3.FB5
R3.FB6

Disconnect any connector from the CSconnector.

Use a special socket to remove the CSShown in the figure in section Location
connector from the housing and pull it into of motor and timing belt, axes 5 or 6 on
the upper arm assembly.
page 163!
Art. no. specified in section Required
equipment on page 164

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 163!
Art. no. specified in section Required
equipment on page 164!

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!

Continues on next page

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4 Repair
4.6.5 Replacement of motor and timing belt, axes 5 or 6
Continued
Action

Note

Remove the VK-cover from the upper

arm/lower arm joint.

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!
Detailed in section Removing the VK
cover on page 101.

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 163!

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 163!

12

Loosen the motor attachment screws.

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!

13

Remove the pulley and belt from motor,

axis 6.

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!

14

Remove the pulley and belt from motor,

axis 5.

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!

15

Remove the motor console, ax. 5-6 by un- Shown in the figure in section Location
screwing its attachment screws.
of motor and timing belt, axes 5 or 6 on
page 163!

Refitting
The procedure below details how to refit motor, axis 5.
WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.
Note

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

excessive force is used!
Action
1

Note

Make sure the mating surfaces on the motor

and the console are clean and free from
burrs.

Continues on next page

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4 Repair
4.6.5 Replacement of motor and timing belt, axes 5 or 6
Continued
Action

Note

Fit the motors in the motor console without Shown in the figure in section Location
tightening the attachment screws.
of motor and timing belt, axes 5 or 6 on
page 163!

Fit the motor console in the upper arm

Shown in the figure in section Location
housing. Secure with its attachment screws. of motor and timing belt, axes 5 or 6 on
page 163!
Tightening torque: 4 Nm 0.5 Nm

Fit timingbelt, axis 5.

Tighten the motor attachment screws to en- This will facilitate adjustment of the belt
able the motor to be shifted slightly.
tension.

Adjust the belt tension axis 5.

Secure the motor with its attachment screws Tightening torque: 4 Nm 0.5 Nm
including the ones in the motor console.

Fit timing belt, axis 6.

Repeat the belt adjustment procedure de- Correct belt tension F=20 - 40 N
tailed above for the remaining motor axis 6.

10

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

11

Fit the belt shield with its attachment screws. Shown in the figure in section Location
of motor and timing belt, axes 5 or 6 on
page 163!
Tightening torque: 4 Nm 0.5 Nm

12

Pull the pressurized air connector through

the housing and secure it into fitting in the
upper arm assembly.

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!
Art. no. specified in section Required
equipment on page 164

13

Pull the CS-connector through the housing

and secure it into the fitting in the upper arm
assembly.
Use a special socketto secure it.

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!
Art. no. specified in section Required
equipment on page 164

14

Reconnect any connector to the CS-connect- Shown in the figure in section Location
or.
of motor and timing belt, axes 5 or 6 on
page 163!

15

Reconnect all cables to/from motors 4-6.

16

Refit the cable guide with its two attachment Shown in the figure in section Location
screws.
of motor and timing belt, axes 5 or 6 on
page 163!

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!

Correct belt tension F=25 - 50 N

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!

Connectors
R3.MP4
R3.MP5
R3.MP6
R3.FB4
R3.FB5
R3.FB6

Continues on next page

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4 Repair
4.6.5 Replacement of motor and timing belt, axes 5 or 6
Continued
Action

Note

17

Fit a newVK-cover to the upper arm/lower

arm joint.
Gently knock it into position.

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 163!
Art. no. specified in section Required
equipment on page 164
Use a plastic mallet or similar.

18

Refit the rear cover armhousing with its four Shown in the figure in section Location
attachment screws.
of motor and timing belt, axes 5 or 6 on
page 163!

19

Refit any brackets securing any exterior

cabling to the upper arm with their attachment screws respectively.

20

Recalibrate the robot.

Calibration is detailed in a separate

calibration manual enclosed with the
calibration tools.
General calibration information is included in section Calibration information on page 181.

168

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4 Repair
4.6.6.1 Measuring the gear play, axis 5

4.6.6 Adjustments and measurements

4.6.6.1 Measuring the gear play, axis 5
General
After reassembly due to repair work or any other reason, the gear play must be
checked to ensure the repetition accuracy of the robot positioning. The procedure
for axis 5 is detailed below.
Certain measurement tools must be fashioned to enable measuring. The dimensions
of these are specified.
Required equipment
Equipment, etc.

Art no.

Note

Standard toolkit

3HAC020812-001

Content is defined in section Standard

tools on page 201.

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Measurement dial with

magnetic base

Measuring accuracy 0.01mm

Power supply

24 VDC, max. 1.5 A

For releasing the brakes

Other tools and procedures

may be required. See references to these procedures
in the step-by-step instructions below.

These procedures include references to

the tools required.

WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.

Measurement
The procedure below details how to measure the gear play for axis 5.
Action
1

Note

Manually, turn axis 4 90.

Continues on next page

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4 Repair
4.6.6.1 Measuring the gear play, axis 5
Continued
Action
2

Note

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

Remove the load and read

Value 1.

Apply 40 N load as shown.

xx0200000458

Remove the load and read

Value 2.

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

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

value is OK.

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4 Repair
4.6.6.2 Measuring the gear play, axis 6

4.6.6.2 Measuring the gear play, axis 6

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

Standard toolkit

3HAC020812-001

Content is defined in section Standard

tools on page 201.

Arm

3HAC 9037-1

For adjusting the gear play, motor/pinion

Measurement dial with

magnetic base

Measuring accuracy 0.01 mm

Power supply

24 VDC, max. 1.5 A

For releasing the brakes

Other tools and procedures may be required. See

references to these procedures in the step-by-step instructions below.

These procedures include references to

the tools required.

WARNING
Please observe the following before doing 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, for example secure the lower arm with fixtures
if removing motor, axis 2.

Measurement
The procedure below details how to measure the gear play for axis 6.
Action
1

Note

Manually, turn axis 4 90.

Continues on next page

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4 Repair
4.6.6.2 Measuring the gear play, axis 6
Continued
Action
2

Note

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

Remove the load and read

Value 1.

Apply 40 N load as shown.

xx0200000461

Remove the load and read

Value 2.

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

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

value is OK.

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

4.7 Gearboxes
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1
Location of gearbox unit, axes 1-2
The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that
both gearboxes, 1 and 2, are a single unit!
The damper, axis 1, is shown in the figure in the procedure!
A more detailed view of the components and its position may be found in chapter
Spare part lists on page 209.

xx0200000422

Gearbox unit, axes 1-2

Required equipment
Equipment

Art. no.

Gearbox, axis 1 and 2

For spare part num- Includes:

ber, see:
gearbox
Spare part lists
all required lubricant
on page 209.
all o-rings and sealing rings.

Damper, axis 1

3HAC7527-1

Isopropanol

For cleaning the mating surfaces before

fitting.

Flange sealing

1234 0011-116

2 ml

Locking liquid

Loctite 574

Sealing ring

3HAC6965-1

Replace only when damaged!

Lifting slings

Standard toolkit

Note

Content is defined in section Standard

tools on page 201.

Continues on next page

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4 Repair
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1
Continued
Equipment
Other tools and procedures may be required. See
references to these procedures in the step-bystep instructions below.

Art. no.

Note
These procedures include references to
the tools required.

Illustration, base

xx0200000423

Base

Bottom plate

Attachment screws, bottom plate (26 pcs)

Attachment screws and washers, gearbox/base (10 pcs each)

Damper, axis 1

Washer

Continues on next page

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4 Repair
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1
Continued
Removal, gearbox unit axes 1-2
The procedure below details how to remove the complete gearbox unit, axes 1-2.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the
robot working area.
2

Remove the oil plug and drain all

oil from gearbox axis 1 using a
drain pump.

Remove the oil plug and drain all

oil from gearbox axis 2 using a
drain pump.

Remove the motor, axis 2.

Detailed in section Replacement of motor, axis 2

on page 150.

Remove the motor, axis 1.

Detailed in section Replacement of motor, axis 1

on page 146.

Remove the cable harness.

Detailed in section Replacement of cable harness

on page 88.

Remove the serial measurement

board.

Detailed in section Replacement of serial measurement unit and battery pack on page 137.

Remove the upper arm.

Detailed in section Replacement of complete upper

arm on page 98.

Remove the lower arm.

Detailed in section Replacement of complete lower

arm on page 104.

10

Unfasten the base from the installation site by removing the attachment bolts from the foundation.

11

CAUTION
The gearbox unit weighs 30 kg.
All lifting accessories used must
be sized accordingly!

12

Fit the lifting slings to the

base/gearbox unit and place it with
the lower arm side downwards, on
top of a suitable workbench.

13

Remove the bottom plate by un- Shown in the figure Illustration, base on page 174.
screwing its 26 attachment screws.

14

Secure the weight of the base with

lifting slings.

15

Remove the gearbox/base attach- Shown in the figure Illustration, base on page 174.
ment screws and washer.

16

Separate the base from the gearbox unit.

Continues on next page

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4 Repair
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1
Continued
Removal of damper, axis 1
The procedure below details how to remove the damper, axis 1.
Action

Note

Open the base of the robot.

Detailed in section Removal, gearbox unit axes 12 on page 175.

Remove the damper, axis 1.

Refitting of damper, axis 1

The procedure below details how to refit the damper, axis 1.
Action

Note

Fit the damper, axis 1.

Shown in the figure Refitting, gearbox unit

axes 1-2 on page 176.

Proceed with assembling the robot.

Detailed in section Refitting, gearbox unit

axes 1-2 on page 176.

Refitting, gearbox unit axes 1-2

The procedure below details how to refit the complete gearbox unit, axes 1-2.
Action

Note

1
DANGER
Turn off all:
electric power supply
hydraulic pressure supply
air pressure supply
to the robot, before entering the robot
working area.
2

CAUTION
The gearbox unit weighs 30 kg.
All lifting accessories used must be sized
accordingly!

Place the gearbox unit with the lower arm

side downwards on a suitable workbench.

Clean the mating surfaces of the base and

of the gearbox unit with isopropanol.

Fit a small amount of Loctite 574 on the

mating surface in the gearbox unit.

Fit the base to the gearbox unit and secure Shown in the figure Illustration, base on
it with the attachment screws and the
page 174.
washer.
20 pcs, tightening torque: 35 Nm 3 Nm.

Refit the bottom plate and secure it with its Shown in the figure Location of gearbox
attachment screws.
unit, axes 1-2 on page 173.

Fit the lifting slings to the base/gearbox unit,

turn it right side up and move it to the installation site.

Shown in the figure Illustration, base on

page 174.

Continues on next page

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4 Repair
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1
Continued
Action

Note

Secure the base to the foundation

Attachment bolts and the tightening

torque are specified in section Attachment
screws on page 60

10

Refit the lower arm.

Detailed in section Replacement of complete lower arm on page 104.

11

Refit the upper arm.

Detailed in section Replacement of complete upper arm on page 98.

12

Refit the serial measurement board.

Detailed in section Replacement of serial

measurement unit and battery pack on
page 137.

13

Refit the cable harness.

Detailed in section Replacement of cable

harness on page 88.

14

Refit the motors, axes 1 and 2.

Detailed in sections:
Replacement of motor, axis 1 on
page 146
Refitting, motor axis 2 on page 152.

15

Perform a leak-down test.

Detailed in section Performing a leakdown test on page 203.

16

Fill the two gearboxes with oil.

Axis 1 gearbox:
Oil: Mobilgear 600 XP 320
Art.no: 11712016-604
Volume: 1200 ml
Axis 2 gearbox:
Oil: Mobilgear 600 XP 320
Art.no: 11712016-604
Volume: 1000 ml

17

Recalibrate the robot.

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.
General calibration information is included
in section Calibration information on
page 181.

18
DANGER
Make sure all safety requirements are met
when performing the first test run. These
are further detailed in the section DANGER
- First test run may cause injury or damage!
on page 41.

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4 Repair
4.7.2 Service work on gearbox, axis 4

4.7.2 Service work on gearbox, axis 4

General
The gearbox, axis 4, is intended to run without requiring any repairs or maintenance
work. This implies that it must under no circumstances be opened or serviced.
If it requires replacement, the complete upper arm is to be replaced. This procedure
is detailed in section Replacement of complete upper arm on page 98.

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4 Repair
4.7.3 Amount of oil

4.7.3 Amount of oil

Overview
When a part is replaced or repaired it is offen nessecary to add oil into the
gearboxes.
Type and amount of oil in gearboxes axis 1- 2
Gearbox

Type of oil

Art. no.

Amount

Axis 1

Mobilgear 600 XP 320

11712016-604

1200 ml

Axis 2

Mobilgear 600 XP 320

11712016-604

1000 ml

Type and amount of oil in gearboxes 3- 6

Gearbox

Type of oil

Art. no.

Amount

Axis 3

Mobilgear 600 XP 320

11712016-604

300 ml

Axis 4

Mobilgear 600 XP 320

11712016-604

200 ml

Axis 5-6

Optimol BM 100

3HAC0860-1

300 ml

Axis 5-6

Optimol BM 100

3HAC0860-1

300 ml (new wrist)

At oil change, refill the
same volume as is
drained.

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5 Calibration information
5.1 Introduction

5 Calibration information
5.1 Introduction
General
This chapter includes general information about the different calibration methods
and also the detailed procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to the
documentation enclosed with the calibration tools.
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration.
The different methods are briefly described in the section Calibration methods on
page 182 , and further detailed in separate calibration manuals.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost
If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 186. 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 is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, 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.

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5 Calibration information
5.2 Calibration methods

5.2 Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of
calibration

Description

Calibration method

Standard calibration The calibrated robot is positioned at home

position, that is when the positions of the axes
(angles) are set to 0.
Standard calibration data is found on the SMB
(serial measurement board) in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.

Calibration Pendulum
(standard method)
or
Levelmeter calibration
(alternative method)

Absolute accuracy Based on standard calibration, and besides CalibWare

calibration (option- positioning the robot at home position, the
al)
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 calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy 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

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5 Calibration information
5.2 Calibration methods
Continued
Calibration methods
Each calibration method is detailed in a separate manual. Following 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.
Two different routines are available for the Calibration Pendulum method:

Calibration Pendulum II

Reference calibration

The calibration equipment for Calibration Pendulum is delivered as a complete

toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
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 does not have as
good of 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 (Levelmeter 2000) for levelmeter calibration is ordered
as separate parts for each robot, and includes the Operating manual - Levelmeter
Calibration, which describes the method and the different routines further.
CalibWare - Absolute Accuracy calibration
To achieve a good positioning in the Cartesian coordinate system, Absolute
Accuracy calibration is used as a TCP calibration. The CalibWare tool guides
through the calibration process and calculates new compensation parameters.
This is further detailed in the Application manual - CalibWare Field 5.0.
If a service operation is done to a robot with the option 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.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 202.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

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5 Calibration information
5.3 Calibration scale and correct axis position

5.3 Calibration scale 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

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5 Calibration information
5.4 Calibration movement directions for all axes

5.4 Calibration movement directions for all axes

Overview
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
and so on. Positive directions are shown in the graphic below.
This is normally handled by the robot calibration software.
Calibration movement directions, 6 axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!

xx0200000089

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5 Calibration information
5.5 Updating revolution counters

5.5 Updating revolution counters

Introduction
This section describes how to do a rough calibration of each manipulator axis,
which is updating the revolution counter value for each axis using the FlexPendant.
Step 1 - Manually running the manipulator to the calibration position
Use this procedure to manually run the manipulator to the calibration position.
Action

Note

Select axis-by-axis motion mode.

Jog the manipulator to place the calibration See Calibration scale and correct axis pomarks within the tolerance zones.
sition on page 184.
IRB 140, 1400, 2400, 4400, 6600ID/6650ID,
6640ID: Axes 5 and 6 must be positioned
together!

When all axes are positioned, store the re- Step 2 - Storing the revolution counter
volution counter settings.
setting with the FlexPendant on page 186.

Correct calibration position of axis 4 and 6

When running the manipulator to calibration position, it is extremely important to
make sure that axes 4 and 6 of the following mentioned manipulators are positioned
correctly. The axes can be calibrated at the wrong turn, resulting in an incorrectly
calibrated manipulator.
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, underneath the flange plate on the base or on the
frame.
At delivery the manipulator 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 following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to uneven gear ratio. This affects the following manipulators:
Manipulator variant

Axis 4

Axis 6

IRB 140

Yes

Yes

If the calibration marks seem to be wrong (even if the motor calibration data is
correct), try to rotate the axis one turn, update the revolution counter and check
the calibration marks again (try both directions, if needed).
Step 2 - Storing the revolution counter setting with the FlexPendant
Use this procedure to store the revolution counter setting with the FlexPendant
(IRC5).
Action
1

On the ABB menu, tap Calibration.

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

Continues on next page

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5 Calibration information
5.5 Updating revolution counters
Continued
Action
2

Tap the mechanical unit in question.

A screen is displayed, tap Rev. Counters.

en0400000771

Tap Update Revolution Counters....

A dialog box is displayed warning that updating the revolution counters may change
programmed manipulator positions:
Tap Yes to update the revolution counters.
Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.

Select the axis to have its revolution counter updated by:

Ticking in the box to the left
Tapping Select all to update all axes.
Then tap Update.

A dialog box is displayed warning that the updating operation cannot be undone:
Tap Update to proceed with updating the revolution counters.
Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.

CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!
Check the calibration position very carefully after each update. See Checking the
calibration position on page 188.

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5 Calibration information
5.6 Checking the calibration position

5.6 Checking the calibration position

Introduction
Check the calibration position before beginning any programming of the robot
system. This may be done:

Using a MoveAbsJ instruction with argument zero on all axes.

Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their zero
position.
Action

Note

On ABB menu tap Program editor.

Create a new program.

Use MoveAbsJ in the Motion&Proc menu.

Create the following program:

MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, z50, Tool0

Run the program in manual mode.

Check that the calibration marks for the axes align See Calibration scale and correct
correctly. If they do not, update the revolution
axis position on page 184, and Updatcounters.
ing revolution counters on page 186.

Using the jogging window

Use this procedure to jog the robot to the zero position of all axes.
Action

Note

On the ABB menu, tap Jogging.

Tap Motion mode to select group of axes

to jog.

Tap to select the axis to jog, axis 1, 2, or

3.

Manually run the robots axes to a position

where the axis position value read on the
FlexPendant, is equal to zero.

Check that the calibration marks for the See Calibration scale and correct axis posaxes align correctly. If they do not, update ition on page 184, and Updating revolution
the revolution counters!
counters on page 186.

188

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6 Decommissioning
6.1 Environmental information

6 Decommissioning
6.1 Environmental information
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly to prevent health or environmental hazards.
Material

Example application

Batteries, NiCad or Lithium

Serial measurement board

Copper

Cables, motors

Cast iron/nodular iron

Base, lower arm, upper arm

Steel

Gears, screws, base frame, and so on.

Neodymium

Brakes, motors

Plastic/rubber

Cables, connectors, drive belts, and so on.

Oil, grease

Gearboxes

Aluminium

Covers, synchronization brackets

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:

Spills can form a film on water surfaces causing damage to organisms.

Oxygen transfer could also be impaired.

Spillage can penetrate the soil causing ground water contamination.

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7 Robot description
7.1 Type C of IRB 140

7 Robot description
7.1 Type C of IRB 140
Type C new upper arm and wrist
Type C of IRB 140 has a new upper arm, complete and a new wrist unit. As a result
of this, the following parts differ from earlier versions:

Upper arm, complete

Wrist unit

O-ring sealing plate

How to know which type the robot is?

The robots using RobotWare version 5.07.01 or newer have the new upper arm.
Use this procedure to check which RobotWare version is installed:
1 On the FlexPendant ABB menu, tap System Info.
2 Tap System properties. The RobotWare version is displayed on the right
side.
Contact ABB if you are unsure of the type.
Which parts are interchangeable and which are not?
The following parts are interchangeable

The upper arm, complete with spare part no. 3HAC026581-001 is

interchangeable with spare part no. 3HAC023630-001. Note! Software version
5.07.01 is needed!

The following parts are not interchangeable:

The wrist unit with spare part no. 3HAC026569-001 is not interchangeable
with spare part no. 3HAC10475-1.

The o-ring sealing plate with spare part no. 3HAC025420-001 is not
interchangeable with spare part no. 3HAC 7191-1.

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8 Reference information
8.1 Introduction

8 Reference information
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

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8 Reference information
8.2 Applicable safety standards

8.2 Applicable safety standards

Standards, EN ISO
The manipulator system is designed in accordance with the requirements of:
Standard

Description

EN ISO 12100 -1

Safety of machinery - Basic concepts, general principles for

design - Part 1: Basic terminology, methodology

EN ISO 12100 -2

Safety of machinery - Basic concepts, general principles for

design - Part 2: Technical principles

EN ISO 13849-1

Safety of machinery, safety related parts of control systems Part 1: General principles for design

EN ISO 13850

Safety of machinery - Emergency stop - Principles for design

EN ISO 10218-1 i

Robots for industrial environments - Safety requirements -Part

1 Robot

EN ISO 9787

Manipulating industrial robots, coordinate systems, and motion

nomenclatures

EN ISO 9283

Manipulating industrial robots, performance criteria, and related

test methods

EN ISO 14644-1 ii

Classification of air cleanliness

EN ISO 13732-1

Ergonomics of the thermal environment - Part 1

EN IEC 61000-6-4
(option 129-1)

EMC, Generic emission

EN IEC 61000-6-2

EMC, Generic immunity

EN IEC 60974-1 iii

Arc welding equipment - Part 1: Welding power sources

EN IEC 60974-10iii

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1

Safety of machinery - Electrical equipment of machines - Part

1 General requirements

IEC 60529

Degrees of protection provided by enclosures (IP code)

i
ii
iii

There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are
documented.
Only robots with protection clean room.
Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards
Standard

Description

EN 614-1

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

EN 574

Safety of machinery - Two-hand control devices - Functional

aspects - Principles for design

EN 953

Safety of machinery - General requirements for the design and

construction of fixed and movable guards

Standard

Description

ANSI/RIA R15.06

Safety requirements for industrial robots and robot systems

Other standards

Continues on next page

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8 Reference information
8.2 Applicable safety standards
Continued
Standard

Description

ANSI/UL 1740
(option 429-1)

Safety standard for robots and robotic equipment

CAN/CSA Z 434-03
(option 429-1)

Industrial robots and robot Systems - General safety requirements

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8 Reference information
8.3 Unit conversion

8.3 Unit conversion

Converter table
Use the following table to convert units used in this manual.
Quantity

Units

Length

1m

3.28 ft.

Weight

1 kg

2.21 lb.

Weight

1g

0.035 ounces

Pressure

1 bar

100 kPa

Force

1N

0.225 lbf

Moment

1 Nm

0.738 lbf-ft

Volume

1L

0.264 US gal

196

39.37 in

14.5 psi

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8 Reference information
8.4 Screw joints

8.4 Screw joints

General
This section describes how to tighten the various types of screw joints on the IRB
140 type C.
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 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)

11712016-618

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 following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!

Use the correct tightening torque for each type of screw joint.

Only use correctly calibrated torque keys.

Continues on next page

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8 Reference information
8.4 Screw joints
Continued

Always tighten the joint by hand, and never use pneumatic tools.

Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.

Maximum allowed total deviation from the specified value is 10%!

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Dimension

Tightening torque (Nm)

Class 4.8, oil-lubricated

M2.5

0.25

M3

0.5

M4

1.2

M5

2.5

M6

5.0

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with allen head screws.
Dimension

Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)

Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubricated
ated

M5

M6

10

M8

24

34

40

M10

47

67

80

M12

82

115

140

M16

200

290

340

M20

400

560

670

M24

680

960

1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Dimension

Tightening torque (Nm)

Class 10.9, lubricated i

Tightening torque (Nm)

Class 12.9, lubricated i

M8

28

35

M10

55

70

M12

96

120

M16

235

280

M20

460

550

Continues on next page

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8 Reference information
8.4 Screw joints
Continued
Dimension

Tightening torque (Nm)

Class 10.9, lubricated i

Tightening torque (Nm)

Class 12.9, lubricated i

M24

790

950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for
water and air connectors when one or both connectors are made of brass.
Dimension

Tightening torque Nm - Tightening torque Nm - Tightening torque Nm Nominal

Min.
Max.

1/8

12

15

1/4

15

10

20

3/8

20

15

25

1/2

40

30

50

3/4

70

55

90

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8 Reference information
8.5 Weight specifications

8.5 Weight specifications

Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
Following is an example of a weight specification in a procedure:
Action

Note
CAUTION

The robot weighs 100 kg.

All lifting accessories used must be sized accordingly!

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8 Reference information
8.6 Standard tools

8.6 Standard tools

General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty

Tool

Ring-open-end spanner 8-19 mm

Socket head cap 2.5-17 mm

Torx socket no: 20-60

Torque wrench 10-100 Nm

Small screwdriver

Plastic mallet

Ratchet head for torque wrench 1/2"

Socket head cap no: 5, socket 1/2" bit L 20 mm

Socket head cap no: 6, socket 1/2" bit L 20 mm

Socket head cap no: 8, socket 1/2" bit L 20 mm

Small cutting plier

T-handle with ball head

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8 Reference information
8.7 Special tools

8.7 Special tools

General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 201, and of special tools, listed directly in the instructions
and also gathered in this section.
Calibration equipment, Levelmeter (alternative method)
The following table specifies the calibration equipment required when calibrating
the robot with the alternative method, Levelmeter Calibration.
Description

Art. no.

Angle bracket

68080011-LP

Calibration bracket

3HAC13908-9

Calibration tool ax1

3HAC13908-4

Levelmeter 2000 kit

6369901-347

Measuring pin

3HAC13908-5

Sensor fixture

68080011-GM

Sensor plate

3HAC0392-1

Sync. adapter

3HAC13908-1

Turn disk fixture

3HAC68080011-GU

Note

Includes one sensor.

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
Description

Art. no.

Calibration Pendulum toolkit 3HAC15716-1

Note
Complete kit that also includes operating
manual.

202

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8 Reference information
8.8 Performing a leak-down test

8.8 Performing a leak-down test

General
After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.

Art. no.

Leakdown tester

3HAC0207-1

Leak detection spray

Note

Procedure
Action

Note

Finish the refitting procedure of the motor or gear in

question.

Remove the topmost oil plug on the gear in question Art. no. is specified in Required
and replace it with the leakdown tester.
equipment on page 203.
Adapters, which are included in the leakdown tester
kit, may be required.

Apply compressed air and raise the pressure with

the knob until the correct value is shown on the
manometer.

Disconnect the compressed air supply.

Wait for approx. 8-10 minutes. No pressure loss may If the compressed air is significbe detected.
antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.

Was any pressure drop evident?

Localize the leak as detailed below.
Remove the leakdown tester and refit the oil plug.
The test is complete.

Spray suspected leak areas with leak detection spray.

Bubbles indicate a leak.

When the leak has been localized, take the necessary

measures to correct the leak.

Correct value:
0.2 - 0.25 bar (20 - 25 kPa)

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8 Reference information
8.9 Lifting accessories and lifting instructions

8.9 Lifting accessories and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction delivered with each piece of lifting accessories.
This implies that the instructions delivered with the lifting accessories should be
stored for later reference.

204

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8 Reference information
8.10 Mounting instructions for bearings

8.10 Mounting instructions for bearings

General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Equipment, etc.

Art. no.

Note

Grease

3HAB3537-1

Used to grease the bearings, if not

specified otherwise.

Assembly of all bearings

Follow the following instructions while mounting a bearing on the robot.
Action

Note

To avoid contamination, let a new bearing remain in its wrapping

until it is time for fitting.

Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.

Bearing rings, inner rings, and roller elements must not be subjected to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action
1

Note

Tension the bearing gradually until the recommended pre-tension is achieved.

Note
The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.

Make sure the bearing is properly aligned as this will directly affect the durability of the bearing.

Greasing of bearings
The bearings must be greased after assembly according to the following
instructions:

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.
Continues on next page

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8 Reference information
8.10 Mounting instructions for bearings
Continued

Ensure that grease is handled and stored properly to avoid contamination.

Grease the different types of bearings as following description:

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.

206

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8 Reference information
8.11 Mounting instructions for seals

8.11 Mounting instructions for seals

General
This section describes how to mount different types of seals onto the robot.
Equipment
Equipment, etc.

Art. no.

Note

Grease

3HAB3537-1

Used to lubricate the seals.

Rotating seals
The procedure below describes 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.
Action

Note

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).

Inspect the sealing surface before mounting. If scratches

or damage are found, the seal must be replaced since it
may result in future leakage.

Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
early - there is a risk of dirt and foreign particles adhering Equipment on page 207.
to the seal.)
Fill 2/3 of the space between the dust tongue and sealing
lip with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.

Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in
leakage.

Continues on next page

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8 Reference information
8.11 Mounting instructions for seals
Continued
Flange seals and static seals
The following procedure describes how to fit flange seals and static seals.
Action
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 compound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.

Clean the surfaces properly in accordance with the recommendations of ABB.

Distribute the sealing compound evenly over the surface, preferably with a brush.

Tighten the screws evenly when fastening the flange joint.

O-rings
The following procedure describes how to fit o-rings.
Action

Note

Ensure that the correct o-ring size is used.

Check the o-ring for surface defects, burrs,

shape accuracy, and so on.

Check the o-ring grooves.

Defective o-rings may not be used.
The grooves must be geometrically correct and
should be free of pores and contamination.

Lubricate the o-ring with grease.

Tighten the screws evenly while assembling.

Defective o-rings may not be used.

208

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9 Spare part lists

9.1 Introduction

9 Spare part lists

9.1 Introduction
Definitions
This chapter specifies all spare parts and replacement articles of the robot.

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9 Spare part lists

9.2 Spare parts - robot IRB 140

9.2 Spare parts - robot IRB 140

Robot IRB 140, spare parts list
The items specified below are shown in the figures Robot IRB 140, exploded view
1 of 5 on page 214 to Robot IRB 140, exploded view 5 of 5 on page 218.
Item

Qty

Art. no.

Name

Rem.

3HAC10470-1

Base spare

3HAC8999-1

Bottom plate

26

9ADA629-44

Torx pan head roll. screw

3HAC6599-1

Gasket bottom plate

3HAC9522-1

Serial meas. board ass.

4944026-4

Battery pack

7.2V 4Ah NiCd

21662055-6

Cable straps, outdoors

7.6x368

28

9ADA618-46

Torx pan head screw

M5x20

3HAC9030-1

Cable bracket

10

3HAC9415-1

Clamp

11

3HAC6755-1

Cable holder

12

9ADA618-50

Torx pan head screw

M5x40

13

3HAC10476-1

Control cable spare Std/F

L=3m

14

3HAC10477-1

Control cable spare Std/F

L=7m

15

3HAC7527-1

Damper axis 1

16

20

3HAB3402-52

Hex. socket head cap screw

17

3HAC7950-1

Washer

18

3HAC9860-1

Protecting plate

19

3HAC8466-1

Protective earth cable

20

3HAC9063-1

Hose clip

21

SK615 503-2

Membrane

22

SK616 013-F

Bracket

23

1SFA616100R1006 Actuator black

24

3HAC7870-1

Gasket base-cover

25

10

9ADA290-1

Hexagon nut with flange

M5

26

25291920-2

Plug

R 1/8"

27

25222101-8

Protective hood

D=11.4-13

28

3HAC8806-1

Clamp

29

3HAC7370-1

Cable harness IRB 140

30

3HAC2589-1

Instruction plate

Battery replacement

31

10

21662055-3

Cable straps, outdoors

4.8x208

32

20 ml

12340011-116

Flange sealing

Loctite 574

M5x12

M10x35 8.8
Gleitmo 610

D = 10

CBK

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued
Item

Qty

Art. no.

Name

Rem.

33

3HAC10470-3

Base, spare CR

34

3HAC10476-4

Control cable spare CR

L=3m

35

3HAC10477-2

Control cable spare CR

L=7m

36

3HAC11331-1

Control cable spare Std/F

L = 15 m

37

3HAC11331-2

Control cable spare CR

L = 15 m

38

3HAC13089-1

Control cable spare Std/F

L = 30 m

39

3HAC13090-1

Control cable spare Std/F

L = 22 m

50

3HAC10467-1

Gearbox axes 1-2, spare Std/F Item 67 incl.

51

3HAC10469-1 /
3HAC021965-001

Motor with pinion spare Std/F

52

24

3HAB3409-25

Hex socket head cap screw

M6x20 12.9
Gleitmo 610

53

18

9ADA312-6

Plain washer

6.4x12x1.6

54

21522012-426

O-ring

74.5x3

55

3HAC6788-1

Bearing hub

56

3HAC10478-1

Console spare Std/F

57

3HAC10472-1

Cover console spare Std/F

58

3HAC7868-1

Gasket console-cover

59

3HAC5894-1

Cable bracket

T=1.5

60

3HAC6965-1

Sealing ring

150x189x8.5

61

3HAC3785-6

Parallel pin

D = 6 m6 L = 16

62

3HAB3732-19

Sealing ring (V-ring)

85x11

63

11

9ADA618-55

Torx pan head screw

M6x12

64

21662018-2

Clamp

D = 11

65

3HAC10481-1

Connector bracket

66

25

21662055-1

Cable straps, outdoors

67

2700 ml 11712016-604

Lubricating oil

68

3HAC10467-3

Gearbox axes 1-2, spare CR

69

3HAC10469-3 /
3HAC021966-001

Motor with pinion, spare CR

70

3HAC10478-3

Console, spare CR

71

3HAC10472-3

Cover console, spare CR

72

3HAC10645-1

Clamp

D = 4.7

100

3HAC10468-1

Lower arm (axis 3), spare

Item 67, 107 and

108 incl.

101

3HAC10471-1

Cover, without lamp unit

Item 103 incl.

102

3HAC10474-1

Cover, with lamp unit

Item 103 incl.

103

3HAC7869-1

Gasket lower-arm cover

104

3HAC7866-1 /
3HAC021756-001

Rot. ac motor incl. pinion

Item 58 incl.

2.5x101

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued
Item

Qty

Art. no.

Name

Rem.

105

3HAC6793-1

Timing belt

106

3HAC6762-1

Belt shield

107

3HAB3643-17

Groove ball bearing

80x100x10

108

3HAA2166-13

VK-Cover

D = 100 B = 10

109

3HAC7880-1

Damper axis 2

110

3HAA2356-14

Washer SRKB

6.4x18x1.6

111

3HAB3402-15

Hex. socket head cap screw

M5x20 8.8
Gleitmo 610

112

12

9ADA312-5

Plain washer

5.3x10x1

113

3HAC9258-1

Indicator lamp

114

3HAC10468-4

Lower arm, spare CR

115

3HAC10471-3

Cover, without lamp unit

116

3HAC10474-3

Cover, with lamp unit

150

3HAC026581-001

Upper arm compl. with wrist

Standard

150

3HAC026581-003

Upper arm compl. with Cleanroom

151

3HAC027003-001

Wrist, spare Standard/Foundry Item 155, 181

and 182 incl.

151

3HAC026569-004

Wrist Cleanroom

151

3HAC028059-002

Wrist spare Foundry Plus

152

3HAC025420-001

O-ring sealing plate

153

3HAB3409-37

Hex. socket head cap screw

M8x25 12.9
Gleitmo 610

154

9ADA312-7

Plain washer

8.4x16x1.6

155

25291920-2

Plug

R 1/8"

157

3HAB3409-39

Hex. socket head cap screw

M8x35 12.9
Gleitmo 610

158

9ADA334-7

Spring washer, conical

8.4x18x2

159

3HAB3732-13

Sealing ring (V-ring)

99x10.5

160

3HAC7842-1 /
3HAC021757-001

Rot. ac motor with pinion

161

3HAB3772-24

O-ring

162

163

3HAB3402-18

Hex. socket head cap screw

164

3HAC024360-001

Motor Console axes 5-6

166

3HAA2356-15

Washer SRKB

167

3HAC7367-1

Cable holder

168

3HAC8572-1

Clamp

169

3HAC6779-1

Timing belt

Motors incl

29x3

Rot. ac motor with pinion

M5x35 8.8
Gleitmo 610

5.3x15x1.2

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued
Item

Qty

Art. no.

Name

Rem.

170

3HAC025596-001

Timing Belt Pulley Z2/5

171

3HAC025601-001

Timing Belt Pulley Z2/6

173

3HAC7391-1

Belt shield

174

3HAC10473-1

Cover armhousing spare

175

3HAC7867-1

Gasket upper arm cover

176

3HAC7881-1

Damper axis 3

177

3HAC6761-1

Cable guide

178

3HAC7561-3

Dustcap for receptacles 12p

179

21252052-178

Distance bolt

M5X55

180

3HAC6598-1

Hose nipple

G 1/4"

181

3HAB8964-1

Damper axis 5

182

300 ml 3HAC0860-1

Lubricating oil

183

3HAC026581-003

Upper arm, spare CR

184

3HAC026569-003

Wrist, CR/Wash

186

3HAC10439-3

Cover armhousing, spare CR

187

3HAC036283-001

Cable protection

Item 175 incl.

Optimol Optigear BM 100

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued

31

Inside of base

Inside of cover

10

11

Base complete

30

24

35 Nm

33

16

15

17

32

18

25

12

27

R1/4

13

26

34

35

21

36

37

38

39

29

22

23

31

28

20

19

Robot IRB 140, exploded view 1 of 5

xx0600003264

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued
Robot IRB 140, exploded view 2 of 5

xx0600003265

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued

0.3 l

Lower arm shown without cables

th

n tl

r w

Nm

41N

Lower arm com lete with ca les

shown without cover

th

n tl

r w

Robot IRB 140, exploded view 3 of 5

xx0600003266

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued

Upper arm (shown without cables)

Robot IRB 140, exploded view 4 of 5

xx0600003267

Continues on next page

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9 Spare part lists

9.2 Spare parts - robot IRB 140
Continued
Robot IRB 140, exploded view 5 of 5

xx0600003268

218

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10 Circuit diagram
10.1 About circuit diagrams

10 Circuit diagram
10.1 About circuit diagrams
Overview
The circuit diagrams are not included in this manual, but delivered as separate
documents on the documentation DVD. See the article numbers in the tables below.
Controllers
Product

Article numbers for circuit diagrams

Circuit diagram - IRC5 (drive system 09)

3HAC024480-005

Circuit diagram - IRC 5 Compact

3HAC031403-003

Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-006

troller
Circuit diagram - Euromap

3HAC024120-004

Product

Article numbers for circuit diagrams

Circuit diagram - IRB 120

3HAC031408-003

Circuit diagram - IRB 140 type C

3HAC6816-3

Circuit diagram - IRB 260

3HAC025611-001

Circuit diagram - IRB 360

3HAC028647-009

Circuit diagram - IRB 460

3HAC036446-005

Circuit diagram - IRB 660

3HAC025691-001

Circuit diagram - IRB 760

3HAC025691-001

Circuit diagram - IRB 1410

3HAC2800-3

Circuit diagram - IRB 1600 type A

3HAC021351-003

Circuit diagram - IRB 1520

3HAC039498-007

Circuit diagram - IRB 2400

3HAC6670-3

Circuit diagram - IRB 2600

3HAC029570-007

Circuit diagram - IRB 4400/4450S

3HAC9821-1

Circuit diagram - IRB 4600

3HAC029038-003

Circuit diagram - IRB 6400RF

3HAC8935-1

Circuit diagram - IRB 6600 type A

3HAC13347-1
3HAC025744-001

Circuit diagram - IRB 6600 type B

3HAC13347-1
3HAC025744-001

Circuit diagram - IRB 6620

3HAC025090-001

Circuit diagram - IRB 6620LX

3HAC025090-001

Circuit diagram - IRB 6640

3HAC025744-001

Robots

Continues on next page

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10 Circuit diagram
10.1 About circuit diagrams
Continued
Product

Article numbers for circuit diagrams

Circuit diagram - IRB 6650S

3HAC13347-1
3HAC025744-001

Circuit diagram - IRB 6660

3HAC025744-001
3HAC029940-001

Circuit diagram - IRB 7600

3HAC13347-1
3HAC025744-001

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Index

Index
A
Absolute Accuracy, calibration, 183
aluminum, 189

B
base
brake release buttons, 57
replacing, 108
screws, tightening torque, 110
spare part number, 108
batteries, 189
handling, 44
battery shutdown service routine, 137
brake release unit
releasing the brakes, 57
brakes
testing function, 27
brakes, releasing
external power supply to connector R1.MP, 58
manually, 57
power supply to motor axis 2, 151
power supply to motor axis 4, 161

C
calibrating
roughly, 186
calibration
Absolute Accuracy type, 182
alternative method, 183
Levelmeter calibration, 183
rough, 186
standard type, 182
when to calibrate, 181
calibration, Absolute Accuracy, 183
calibration manuals, 183
calibration marks, 184
calibration position, 186
checking, 188
jogging to, 188
scales, 184
calibration scales, 184
CalibWare, 182
carbon dioxide extinguisher, 25
cleaning
robot, 82
connection
external safety devices, 16
copper, 189
cracks, damper, 77

D
damage, damper, 77
damper, axis 2, 76
attachment screw, 126
replacing, 125
spare part number, 125
damper, axis 3
inspection, 76
replacing, 116
spare part number, 116
damper, axis 5
inspection, 76
replacing, 118
spare part number, 118

danger levels, 33
direction of axes, 185

E
emergency stop
definition, 31
devices, 32
enabling device, 29
environmental information, 189
ESD
damage elimination, 42
sensitive equipment, 42
wrist strap connection point, 42
extended lifetime of SMB battery, 137

F
fence dimensions, 24
figures
brake release buttons, 57
power supply to connector R1.MP, 58
fire extinguishing, 25
FlexPendant
jogging to calibration position, 188
MoveAbsJ instruction, 188
updating revolution counters, 186
foundation
requirements, 50
frame
replacing, 173
spare part number, 173

G
gearbox, axes 1-2
replacing, 173
spare part number, 173
gearboxes, axes 5 and 6
amount and type of oil, 84
oil change, 84
Gravity Beta, 64
grease
disposal, 189

H
hazardous material, 189
hold-to-run, 29

I
illustrations
brake release buttons, 57
power supply to connector R1.MP, 58
inspection, 76
inverted mounting, 64

L
labels
manipulator, 35
Levelmeter calibration, 183
lifetime extension of SMB lithium battery, 137
lifting accessory, 200
Litium, 189

M
manipulator
symbols, 35
motor axis 2

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Index

brake release with power supply, 151

replacing, 150
spare part number, 150
tightening torque, 152
motor axis 4
brake release with power supply, 161
replace, 160
screws, tightening torque, 162
spare part number, 160
MoveAbsJ instruction, 188

N
negative directions, axes, 185
neodymium, 189
NiCad, 189

O
oil
disposal, 189
oil change
gearbox axes 5 and 6, 84
safety risks, 45
wrist unit, 84

P
plastic, 189
position, robot
when draining wrist unit, 85
when filling oil in wrist unit, 86
positive directions, axes, 185
protection classes, 51
protection standards, 194
push button unit
releasing the brakes, 57

R
releasing brakes
external power supply to connector R1.MP, 58
manually, 57
requirements on foundation, 50
responsibility and validity, 16
restricting
working range, 69
revolution counters
storing on FlexPendant, 186
updating, 186
risk of tipping, 54
robot
cleaning, 82
protection class, 51
symbols, 35
robot position
when draining wrist unit, 85
when filling oil in wrist unit, 86
rubber, 189

S
safety
brake testing, 27
emergency stop, 31
ESD, 42
fence dimensions, 24
fire extinguishing, 25
FlexPendant, 29
introduction, 15
manipulator system, 16
moving manipulators, 40

reduced speed function, 28

release manipulator arm, 26
service, 16
signals, 33
signals in manual, 33
symbols, 33
symbols on manipulator, 35
test run, 41
working range, 30
wrist strap, 42
safety risk
electric parts, 23
hot parts, 19
hydraulic system, 21
installation, 17
oil change, 45
operational disturbance, 22
pneumatic system, 21
service work, 17
tools, 20
voltage, 23
safety risks
work pieces, 20
safety signals
in manual, 33
safety standards, 194
scales on robot, 184
signals
safety, 33
SMB battery
extension of lifetime, 137
special tools, 202
stability, 54
standards
ANSI, 194
CAN, 194
EN, 194
EN IEC, 194
EN ISO, 194
protection, 194
safety, 194
suspended mounting, 64
symbols
safety, 33
sync marks, 184
system parameter
Gravity Beta, 64

T
testing
brakes, 27
tightening torques, attachment screws
base-gearbox unit, 110
motor axis 2, 152
motor axis 4, 162
wrist unit, 114
tools
calibration equipment, Levelmeter, 202
Calibration Pendulum equipment, 202
for service, 202
rotational tool, article number, 160

U
updating revolution counters, 186

V
validity and responsibility, 16

222

3HAC027400-001 Revision: J
Copyright 2004-2012 ABB. All rights reserved.

Index

VK-covers, spare part number

at base, 108

W
wall mounting, 64
weight
gearbox 1, 175, 176
robot, 200

working range
restricting, 69
wrist unit
amount and type of oil, 84
oil change, 84
replacing, 112
screws, tightening torque, 114
spare part number, 112

3HAC027400-001 Revision: J

223
Copyright 2004-2012 ABB. All rights reserved.

ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VSTERS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics
Discrete Automation and Motion
Box 265
N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.
5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics

3HAC027400-001, Rev J, en

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