Product manual

Articulated robot

IRB 140 type C

IRB 140T type C
IRB 140-6/0.8 type C
IRB 140T-6/0.8 type C
M2004
 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: C
© Copyright 2006-2008 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, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2006-2008 ABB. All rights reserved.

© Copyright 2006-2008 ABB All right reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
 Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 Installation and commissioning 35

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2.2 Working range, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
© Copyright 2006-2008 ABB. All rights reserved.

2.2.3 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3.4 Restricting the working space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.5 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3.7 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3.8 Bolt pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.1 Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.5 Making robot ready for operation (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.5.1 Additional installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3HAC027400-001 Revision: C 3
Table of Contents

3 Maintenance 59
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2.1 Maintenance schedule, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3.2 Inspection, robot cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.3 Inspection, timing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.4.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.5 Changing/ replacing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.5.1 Oil change, gearbox axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4 Repair 73
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2.4 Replacement of base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.3 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3.4 Replacement of cover, arm housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.4.1 Replacement of lower arm cover and gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.4.2 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4.3 Replacement of indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.5.1 Replacement of cover, console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.5.2 Replacement of console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5.3 Replacement of serial measurement unit and battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

© Copyright 2006-2008 ABB. All rights reserved.

4.5.4 Replacement of control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.6.2 Replacement of motor, axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.6.4 Replacement of motor, axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.6.5 Replacement of motor and timing belt, axes 5 or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.6.6 Adjustments and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.6.6.1 Measuring the gear play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.6.6.2 Measuring the gear play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.2 Service work on gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.7.3 Amount of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

4 3HAC027400-001 Revision: C
 Table of Contents

5 Calibration information 163

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

6 Robot description 173

6.1 Type C of IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

7 Reference information 175

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.2 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7.3 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.4 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.5 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

8 Spare part lists and exploded views 189

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
8.2 Spare parts - robot IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

9 Circuit diagram 199

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Index 201
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 5
6
Table of Contents

3HAC027400-001 Revision: C
© Copyright 2006-2008 ABB. All rights reserved.
 Overview

Overview

About This Manual

This manual contains instructions for
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.

Usage
This manual should be used during
• installation, from lifting the robot to its work site and securing it to the foundation to
making it ready for operation
• maintenance work
• repair work and calibration.

Who Should Read This Manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.

Prerequisites
A maintenance/repair/ installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.

Organization of Chapters
The manual is organized in the following chapters:
© Copyright 2006-2008 ABB. All rights reserved.

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- Required information about lifting and installation of the robot.
misioning
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.

Continues on next page

3HAC027400-001 Revision: C 7
Overview

Continued

References

Reference Document Id
Product manual - IRC5 3HAC021313-001
Product specification - IRB 140 3HAC9041-1
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

Revisions

Revision Description
- First edition, see also Type C of IRB 140 on page 173
A IRB 140-6/0.8 and IRB 140T-6/0.8 added.
B Cleanroom added.
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
C Content updated in section
• 2.5 Making robot ready for operation, Cleanroom / 2.5.1 Additional
installation procedure

© Copyright 2006-2008 ABB. All rights reserved.

8 3HAC027400-001 Revision: C
 Product documentation, M2004

Product documentation, M2004

General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.

Product manuals
All hardware, robots and controllers, will be delivered with a Product manual that contains:
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams

Technical reference manuals

The following manuals describe the robot software in general and contain relevant reference
information:
© Copyright 2006-2008 ABB. All rights reserved.

• 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.
• System parameters: Description of system parameters and configuration workflows.

Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters, CD
with PC software)
• How to use the application
• Examples of how to use the application

Continues on next page

3HAC027400-001 Revision: C 9
Product documentation, M2004

Continued

Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
includes:
• Getting started - IRC5 and RobotStudio
• IRC5 with FlexPendant
• RobotStudio
• Trouble shooting - IRC5 for the controller and robot

© Copyright 2006-2008 ABB. All rights reserved.

10 3HAC027400-001 Revision: C
 How to read the product manual

How to read the product manual

Reading the procedures

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

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

Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

References to required equipment

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

Action Note/Illustration
© Copyright 2006-2008 ABB. All rights reserved.

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

Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in chapter Safety on page 13.

3HAC027400-001 Revision: C 11
How to read the product manual

© Copyright 2006-2008 ABB. All rights reserved.

12 3HAC027400-001 Revision: C
 1 Safety
1.1. Introduction

1 Safety
1.1. Introduction

Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 29.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 13
1 Safety
1.2.1. Safety in the robot system

1.2 General safety information

1.2.1. Safety in the robot 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, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system are designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g.
• Operating Manual - IRC5 with FlexPendant (M2004)
• Product Manual

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.

Limitation of liability
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
are complied with.

Related information
© Copyright 2006-2008 ABB. All rights reserved.
Type of information Detailed in document Section
Installation of safety Product manual for the robot Installation and commissioning
devices
Changing operating Operating manual - IRC5 with Operating modes
modes FlexPendant (RobotWare 5.0)
Restricting the working Product manual for the robot Installation and commissioning
space

14 3HAC027400-001 Revision: C
 1 Safety
1.2.2.1. Safety risks during installation and service work on robot

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on robot

Overview
This section includes information of general safety risks to be considered when performing
installation and service work on the robot.

General risks during installation and service

• The instructions in the Product Manual - Installation and Commissioning must always
be followed.
• Emergency stop buttons must be positioned in easily accessible places so that the robot
can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are available for
the installation in question.
• Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.

Non-voltage related risks

• Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
• Turntables or the like should be used to keep the operator out of the robot's working
space.
• The axes are affected by the force of gravity when the brakes are released. In addition
© Copyright 2006-2008 ABB. All rights reserved.

to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, are dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
Continues on next page
3HAC027400-001 Revision: C 15
1 Safety
1.2.2.1. Safety risks during installation and service work on robot

Continued

Complete robot

Safety risk Description

Hot components!

CAUTION!
Motors and gears are HOT after running the robot!
Touching the motors and gears may result in burns!
Removed parts may result in
collapse of robot!

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

Cabling

Safety risk Description

Cable packs are sensitive to
mechanical damage!

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

Gearboxes and motors

Safety risk Description

Gears may be damaged if
excessive force is used!

© Copyright 2006-2008 ABB. All rights reserved.

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

16 3HAC027400-001 Revision: C
 1 Safety
1.2.2.2. Safety risks related to tools/workpieces

1.2.2.2. Safety risks related to tools/workpieces

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 workpieces in the event of a power
failure or a disturbance of the controller.
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 17
1 Safety
1.2.2.3. Safety risks related to pneumatic/hydraulic systems

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy
• Residual energy may be present in these systems. After shutdown, particular care must
be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.

Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.

© Copyright 2006-2008 ABB. All rights reserved.

18 3HAC027400-001 Revision: C
 1 Safety
1.2.2.4. Safety risks during operational disturbances

1.2.2.4. Safety risks during operational disturbances

General
• The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.

Qualified personnel
• 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.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 19
1 Safety
1.2.2.5. Risks associated with live electric parts

1.2.2.5. Risks associated with live electric parts

Voltage related risks, general

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

Voltage related risks, 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 rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• 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

© Copyright 2006-2008 ABB. All rights reserved.

disconnected from the mains.
• Additional connections.

Voltage related risks, robot

A danger of high voltage is associated with the robot in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230 VAC, see
chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.

20 3HAC027400-001 Revision: C
 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 robot to ensure safe robot installation and operation.

Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 21
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 robot system
(manipulator or controller)!

© Copyright 2006-2008 ABB. All rights reserved.

22 3HAC027400-001 Revision: C
 1 Safety
1.2.3.3. Emergency release of the robot’s arm

1.2.3.3. Emergency release of the robot’s arm

Description
In an emergency situation, any of the robot's axes may be released manually by pushing the
brake release buttons on the robot.
How to release the brakes is detailed in section:
• Manually releasing the brakes on page 43.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.

Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 23
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 motor wear normally. A test may 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 detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator
arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.

© Copyright 2006-2008 ABB. All rights reserved.

24 3HAC027400-001 Revision: C
 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".
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 25
1 Safety
1.2.3.6. Safe use of the FlexPendant

1.2.3.6. Safe use of the FlexPendant

NOTE!
The enabling device is a push button located on the side of the FlexPendant which, when
pressed halfway in, takes the system to MOTORS ON. When the enabling device is released
or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:
• The enabling device must never be rendered inoperative in any way.
• During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
• The programmer must always bring the FlexPendant with him/her, when entering the
robot's working space. This is to prevent anyone else taking control of the robot
without the programmer knowing.

© Copyright 2006-2008 ABB. All rights reserved.

26 3HAC027400-001 Revision: C
 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 robot’s work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position "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.
• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
• Test the motor brake on each axis, according to section Brake testing on page 24.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 27
1 Safety
1.2.3.8. Translate the information on safety and information labels

1.2.3.8. Translate the information on safety and information labels

Labels on the product

Both the robot 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 robot system, eg. during installation, service or operation.

Translation possibilities
The labels fitted to the product contain space for adding a fourth language underneath the
three standard languages (English, German and French).
Add a local language to the label by:
• Using a transparent sticker over the standard label with text added in a fourth
language. Drawings detailing the design (text, figure, dimensions) of the standard
labels can be ordered from ABB. Notice that each label is identified according to the
article number located in the lower corner of the label.

Example of transparent sticker

The figure below shows the location of the free space on one of the labels on the robot, where
the fourth language can be added. The figure also shows a transparent sticker, containing the
text in Swedish.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500002517

A Free space for adding a fourth language

28 3HAC027400-001 Revision: C
 1 Safety
1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general

General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.

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

Symbol Designation Signification

DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
danger impact, fall from height etc.
WARNING Warns that an accident may occur if the instructions
are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
© Copyright 2006-2008 ABB. All rights reserved.

warning crushing, impact, fall from height etc.

ELECTRICAL The electrocution or electrical shock symbol
SHOCK indicates electrical hazards which could result in
severe personal injury or death.

Electrical shock

CAUTION Warns that an accident may occur if the instructions

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

Continues on next page

3HAC027400-001 Revision: C 29
1 Safety
1.3.1. Safety signals, general

Continued

Symbol Designation Signification

ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.

Electrostatic discharge
(ESD)

NOTE Note symbols alert you to important facts and

conditions.

Note

TIP Tip symbols direct you to specific instructions, where

to find additional information or how to perform a
certain operation in an easier way.

Tip

© Copyright 2006-2008 ABB. All rights reserved.

30 3HAC027400-001 Revision: C
 1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!

1.3.2. DANGER - Moving manipulators are potentially lethal!

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

Elimination

Action Note
1. 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.
2. If possible, use the hold-to-run function How to use the hold-to-run function in
whenever possible. RobotWare 5.0 is detailed in section How
The hold-to-run function is used in manual to use the hold-to-run function in the
mode, not in automatic mode. Operating manual - IRC5 with
FlexPendant.
3. Make sure no personnel are present within
the manipulator working range before
pressing the start button.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 31
1 Safety
1.3.3. DANGER - First test run may cause injury or damage!

1.3.3. 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 (repair,
installation or maintenance):

Action
1. Remove all service tools and foreign objects from the robot and its working area!
2. Install all safety equipment properly!
3. Make sure all personnel are standing at a safe distance from the robot, i.e. out of its
reach behind safety fences, etc!
4. Pay special attention to the function of the part previously serviced!

© Copyright 2006-2008 ABB. All rights reserved.

32 3HAC027400-001 Revision: C
 1 Safety
1.3.4. WARNING - The unit is sensitive to ESD!

1.3.4. WARNING - The unit is sensitive to ESD!

Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.

Elimination

Action Note
1. Use a wrist strap Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a
current-limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

Location of wrist strap button

The wrist strap button is located in the top right corner as shown in the illustration below.
© Copyright 2006-2008 ABB. All rights reserved.

xx0500002171

A Wrist strap button

3HAC027400-001 Revision: C 33
1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

1.3.5. WARNING - Safety risks during work with gearbox oil

Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!

Warnings and elimination

Warning Description Elimination / Action

Changing and draining Make sure that protective gear
gearbox oil may require like goggles and gloves are
handling hot oil of up to 90 °C! always worn during this activity.

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

Possible pressure build

up in gearbox!
Overfilling of gearbox oil can Make sure not to overfill the
lead to internal over-pressure gearbox when filling with oil!
inside the gearbox which in After filling, check the correct oil
turn may: level.
-
• damage seals and
Do not overfill! gaskets
• completely press out
seals and gaskets
• prevent the manipulator
from moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
© Copyright 2006-2008 ABB. All rights reserved.
severe damage to the mix different types of oil unless
gearbox! specified in the instruction.
Always use the type of oil
- specified by the manufacturer!
Do not mix types of oil!
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

Heat up the oil!

The specified amount of oil is After refilling, check the oil level.
based on the total volume of
the gearbox. When changing
the oil, the amount of refilled oil
- may differ from the specified
Specified amount amount, depending on how
depends on drained much oil has previously been
volume! drained from the gearbox.

34 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.1. Introduction

2 Installation and commissioning

2.1. Introduction

General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 35
2 Installation and commissioning
2.2.1. Pre-installation procedure

2.2 Unpacking

2.2.1. Pre-installation procedure

General
This instruction is primarily intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installation

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

Action Note
1. Make sure only qualified installation personnel
conforming to all national and local codes are allowed
to perform the installation.
2. Make sure the manipulator has not been damaged,
by visually inspecting the manipulator and control
cabinet exterior.
3. Make sure the lifting device to be used is Specified in section Weight,
dimensioned to handle the weight of the manipulator. robot on page 36.
4. If the manipulator is not to be installed directly, it must Specified in section Storage
be stored. conditions, robot on page
37.
5. Make sure the appointed operating environment of Specified in section
the manipulator conforms to the specifications. Operating conditions, robot
on page 37.
6. Before taking the manipulator to its installation site, Specified in section :
make sure the site conforms to applicable • Loads on foundation,
requirements. robot on page 37
• Requirements,
foundation on page

© Copyright 2006-2008 ABB. All rights reserved.

37
• Protection classes on
page 38
7. Before moving the manipulator, make sure it does Described in section Risk of
not tip over! tipping/Stability on page 41.
8. When these prerequisites have been met, the Detailed in section Lifting
manipulator may be taken to its installation site. manipulator with lifting slings
on page 42.

Weight, robot
The net weight of the robot is approximately: 100 kg.

Continues on next page

36 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.2.1. Pre-installation procedure

Continued

Loads on foundation, robot

The table below shows the different 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 simultaneously!

Endurance load Max. load (emergency

Force
(operation) stop)
Force XY upright/suspended ± 1020 N ± 2000 N
Force XY wall ± 1750 N ± 2800 N
Force Z upright/suspended -1000 ± 1000 N -1000 ± 2000 N
Force Z wall ± 850 N ± 1600 N
Torque XY upright/suspended ± 700 Nm ± 1500 Nm
Torque XY wall ± 1020 Nm ± 1710 Nm
Torque Z upright/suspended ± 250 Nm ± 470 Nm
Torque Z wall ± 250 Nm ± 485 Nm

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

Requirement Value
Min. levelity 0.5 mm
Max. tilt 5°
Min. resonance frequency 22 Hz

Storage conditions, robot

The table below shows the allowed storage conditions for the robot:
© Copyright 2006-2008 ABB. All rights reserved.

Parameter Value
Max. ambient temperature +55° C
Max. ambient temperature (less than 24 hrs) +70° C
Min. ambient temperature -25° C
Max. ambient humidity Max. 95% at constant temperature

Operating conditions, robot

The table below shows the allowed operating conditions for robot:

Parameter Value
Max. ambient temperature +45° C
Min. ambient temperature +5° C
Max. ambient humidity Max. 95% at constant temperature

Continues on next page

3HAC027400-001 Revision: C 37
2 Installation and commissioning
2.2.1. Pre-installation procedure

Continued

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

Equipment Protection class

Robot IP 67
Control cabinet IP 54
Programming unit IP 54

© Copyright 2006-2008 ABB. All rights reserved.

38 3HAC027400-001 Revision: C
 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)

X Z Axis 2 Axis 3
0 450 712 0° 0°
© Copyright 2006-2008 ABB. All rights reserved.

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

Continues on next page

3HAC027400-001 Revision: C 39
2 Installation and commissioning
2.2.2. Working range, IRB 140

Continued

Working range axis 1

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

xx0200000061

© Copyright 2006-2008 ABB. All rights reserved.

40 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.2.3. Risk of tipping/Stability

2.2.3. Risk of tipping/Stability

General
The section below details instructions for making sure the manipulator does not tip over when
it has not been safely secured to the foundation.

Procedure
The procedure below details how to make sure the manipulator does not tip during installation
while not secured to the foundation.
CAUTION!
When the manipulator is not fastened to the floor, it will not be stable in any part of its
working area.
1. DO NOT change the manipulator position before securing it to its foundation. The
shipping position is the most stable.
2. If the manipulator, for some reason, must be move from its original position, ensure that
the centre of gravity not is displaced.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 41
2 Installation and commissioning
2.3.1. Lifting manipulator with lifting slings

2.3 On-site installation

2.3.1. Lifting manipulator with lifting slings

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

Equipment Note
Sling line Length: 2 m. Load: 500 kg.

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

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000084

1 Sling line for manipulator

2 Sling line for manipulator
3 Sling line for control cable

How to lift the manipulator

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

42 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.3.2. Manually releasing the brakes

2.3.2. Manually releasing the brakes

General
The section below details how to release the holding brakes of each axis' motor.
This may be done in one of three ways:
• using the 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
This section details how to release the holding brakes using the internal brake release unit.

Action Note/Illustration
1. The brake release button (A) is located at the base of
the robot.

xx0200000069

2.

DANGER!
© Copyright 2006-2008 ABB. All rights reserved.

When releasing the holding brakes, the robot axes may

move very quickly and sometimes in unexpected ways!
Make sure no personnel is near 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

3HAC027400-001 Revision: C 43
2 Installation and commissioning
2.3.2. 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/Illustration
1. Also, be careful not to interchange the
24V and 0V pins. If they are mixed up,
damage can be caused to a resistor
DANGER! diode and to the system board.

Incorrect connections, such as supplying

power to the wrong pin, may cause all brakes
to be released simultaneously!
2. Connect an external power supply to
connector XP1.

xx0200000071

• A: B16 24V DC
• B: B14 0V
3. Push the brake release button to release the
holding brakes, according to the previous
procedure.

© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

44 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.3.2. Manually releasing the brakes

Continued

Using External power supply

This section details how to release the holding brakes using a 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 Note/Illustration
1. Remove the screws and dismount the cover
on the back of the robot base.

xx0200000072

• A: 13 0V
• B: 15 24V DC
2. Locate the R1.MP4-6 connector and
disconnect.
3. Connect an external power supply to
release the holding brake on all axis.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 45
2 Installation and commissioning
2.3.3. Orienting and securing the manipulator

2.3.3. Orienting and securing the manipulator

General
This section details how to orient and secure the manipulator to the foundation in order to
safely run the robot.

Bolting requirements
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined
in section Loads on foundation, robot on page 37.
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 53.

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. © Copyright 2006-2008 ABB. All rights reserved.

Equipment Art. no.

Guide sleeves 3HAC9519-1

46 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.3.4. Restricting the working space

2.3.4. Restricting the working space

General
When installing the manipulator, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space should be
limited.
WARNING!
The working space can only be limited using software, for this reason the limited area can not
be classified as a safe zone. All work within this zone is prohibited.

Limiting devices
Limiting devices is listed below.
1. Light curtains.
2. Tread mats.
3. Other similar devices.
4. SoftWare.
Limiting the working space using software is described in the Technical reference manual -
System parameters.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 47
2 Installation and commissioning
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.

Illustration, holes on upper arm

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

© Copyright 2006-2008 ABB. All rights reserved.

xx0600003263

Continues on next page

48 3HAC027400-001 Revision: C
 2 Installation and commissioning
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.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 49
2 Installation and commissioning
2.3.6. Loads

2.3.6. Loads

General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of centre of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operation stops may result.

References
Load diagrams, permitted extra loads (equipment) and their positions as specified in the
Product Specification. The loads must also be defined in the software as detailed in 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.

© Copyright 2006-2008 ABB. All rights reserved.

50 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.3.7. Suspended mounting

2.3.7. Suspended mounting

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 robot’s mounting angle expressed in radians.
NOTE!
It is very important to configure gravity beta correctly so that the robot system can control the
movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will
result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some functions will not work properly: for example Load Identification & Collision
detection.

Mounting angles and values

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

Example of position Mounting angle Gravity Beta

Floor (pos 1) 0° 0.000000 (Default)
© Copyright 2006-2008 ABB. All rights reserved.

Tilted (pos 2) 45° 0.785398

Wall (pos 3) 90° 1.570796
Suspended (pos 4) 180° 3.141593

Continues on next page

3HAC027400-001 Revision: C 51
2 Installation and commissioning
2.3.7. Suspended mounting

Continued

xx0200000066

© Copyright 2006-2008 ABB. All rights reserved.

Defining the parameter
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 51.
The parameter is further detailed in the Technical reference manual - System parameters.
The parameter can be edited either with the FlexPendant or in RobotStudio. Read about how
to change the parameter in the Operating manual - IRC5 with FlexPendant or in the
Operating manual - RobotStudio.

52 3HAC027400-001 Revision: C
 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:
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000085

Continues on next page

3HAC027400-001 Revision: C 53
2 Installation and commissioning
2.3.8. Bolt pattern

Continued

Cross section, guide sleeve hole

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

xx0200000086

© Copyright 2006-2008 ABB. All rights reserved.

54 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.4.1. Customer connections on manipulator

2.4 Electrical connections

2.4.1. Customer connections on manipulator

General
For connection of extra equipment on the manipulator there are cables integrated into the
manipulator's cabling. There are both air and electrical connectors on the manipulator.

xx0200000074

Connections

Connections Description
1. For air on base / upper arm R1/4" Max. 8 bar/hose inner diameter: 6.5 mm
2. Signal connector on upper arm FCI UT 071412SH44N connector
Number of signals: 12 signals, 49V, 500mA
© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

3HAC027400-001 Revision: C 55
2 Installation and commissioning
2.4.1. Customer connections on manipulator

Continued

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

xx0200000132

ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains:
• Multipole connector 12 pin
• Adapter Tin plated 12 pin
• Pins for cable area 0.25-0.5 mm 2
• Pins for cable area 0.5-1.5 mm 2
• Shrinking hose, bootled shaped
• Shrinking hose angled
The connection set is delivered in a plastic bag also containing a Technical and assembly © Copyright 2006-2008 ABB. All rights reserved.

instruction.

56 3HAC027400-001 Revision: C
 2 Installation and commissioning
2.5.1. Additional installation procedure

2.5 Making robot ready for operation, Cleanroom

2.5.1. Additional installation procedure

General
Cleanroom robots are specially designed to work in a cleanroom environment.
Cleanroom robots are designed in order to prevent from particle emission from the robot. For
example is maintenance work possible to perform without cracking the paint. The robot is
painted with four layers of polyurethane paint. The last layer being a varnish over labels in
order to simplify cleaning.
Parts being replaced on a Cleanroom robot must be replaced with other parts designed for use
in cleanroom environments.

Cleanroom class 5
Particle emission from the robot fulfill Cleanroom class 5 standard according to DIN EN ISO
14644-1.

Preparations before commissioning a Cleanroom robot

During transport and handling of a Cleanroom robot, it is likely that the robot has been
contaminated with particles of different sorts. Therefore the Cleanroom robot must be
minutely cleaned before commissioning.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 57
2 Installation and commissioning
2.5.1. Additional installation procedure

© Copyright 2006-2008 ABB. All rights reserved.

58 3HAC027400-001 Revision: C
 3 Maintenance
3.1. Introduction

3 Maintenance
3.1. Introduction

Structure of this chapter

This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including intervals and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, that is required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.

Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Read the
chapter Safety on page 13 before performing any service work.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 59
3 Maintenance
3.2.1. Maintenance schedule, IRB 140

3.2 Maintenance schedules

3.2.1. Maintenance schedule, IRB 140

General
The robot, consisting of manipulator and controller cabinet, must be maintained regularly to
ensure its function. The maintenance activities and their respective intervals are specified in
the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.

Activities and intervals, standard equipment

The sections referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:

Maintenance
Equipment Interval Detailed in section:
activity
Inspection Damper, axes 2-3 Regularly *) Inspection, damper axes
2, 3 and 5 on page 62
Inspection Cable harnesses Regularly *) Inspection, robot cabling
on page 64
Inspection Timing belts 36 mths Inspection, timing belts on
page 65
Change Gearbox 5, oil 36 mths Oil change, gearbox axes
5 and 6 on page 69
Change Gearbox 6, oil 36 mths Oil change, gearbox axes
5 and 6 on page 69
Change Measurement Depending on battery type Replacement of serial
system, battery and operation pattern as measurement unit and
specified in section Battery battery pack on page 120. © Copyright 2006-2008 ABB. All rights reserved.
type selection on page 61.
Clean Complete Regularly *) Cleaning, complete robot
manipulator on page 68

*) "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.

Continues on next page

60 3HAC027400-001 Revision: C
 3 Maintenance
3.2.1. Maintenance schedule, IRB 140

Continued

Battery type selection

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

Change interval, Change interval,

Operation pattern
3-cell lithium 6-cell lithium
Max. 4 weeks power off per year 60 mths 60 mths
Weekend power off + operation pattern 1 24 mths 48 mths
Nightly power off + operation patterns 1 and 2 12 mths 24 mths

No longer change interval than 60 months are allowed regardless of the operation pattern due
to material ageing, etc.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 61
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

A Damper, axis 2

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000427

A Damper, axis 3

Continues on next page

62 3HAC027400-001 Revision: C
 3 Maintenance
3.3.1. Inspection, damper axes 2, 3 and 5

Continued

Required equipment

Equipment Art. no. Note

Standard toolkit - The contents are defined in section Standard toolkit
on page 182, in part 2 of the Product manual.

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

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Check all dampers for damage, such as cracks or Shown in the figure Location of
existing impressions that are larger than 1 mm. dampers on page 62.
3. Check attachment screws for deformation.
4. If any damage is detected, the damper must be Replacement is detailed in
replaced with a new one! sections:
• Replacement of damper,
axis 2 on page 108
• Replacement of damper,
axis 3 on page 99
• Replacement of damper,
axis 5 on page 101.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 63
3 Maintenance
3.3.2. Inspection, robot cabling

3.3.2. Inspection, robot cabling

Location, robot cabling

The robot cabling comprises the cabling between the 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 and exploded views on page 189, in part 2 of the product manual.

Required equipment

Equipment Note
Standard toolkit The contents are defined in section
Standard toolkit on page 182, in part 2 of
the Product manual.
Other tools and procedures may be required. See These procedures include references to
references to these procedures in the the tools required.
step-by-step instructions below.
Circuit diagram See chapter Circuit diagram in the
Product manual, reference information.

Inspection, robot cabling

The procedure below details how to inspect the robot cabling.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the
robot!
2. Visually inspect:
• the control cabling between the © Copyright 2006-2008 ABB. All rights reserved.
robot and control cabinet
• the cabling to motors 1 and 2.
Look for abrasions, cuts or crush
damages.
3. Replace the cabling if wear or damage is This is detailed in section Replacement of
detected. cable harness on page 74.

64 3HAC027400-001 Revision: C
 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000448
© Copyright 2006-2008 ABB. All rights reserved.

G Timing belt, axis 3

Continues on next page

3HAC027400-001 Revision: C 65
3 Maintenance
3.3.3. Inspection, timing belts

Continued

© Copyright 2006-2008 ABB. All rights reserved.

xx060000326

R Timing belt, axis 6

U Timing belt, axis 5

Required equipment

Equipment, etc. Art. no. Note

Standard toolkit 3HAC020812-001 The contents are defined in section
Standard toolkit on page 182, in part 2 of
the Product manual.
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Continues on next page
66 3HAC027400-001 Revision: C
 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
1. Gain access to each belt by These procedures are detailed in sections
removing covers, etc. Replacement of motor and timing belt, axis 3
on page 137 and Replacement of motor and
timing belt, axes 5 or 6 on page 145.
2. Check each belt for damage. Replace the timing belts if found defective as
detailed in sections Replacement of motor
and timing belt, axis 3 on page 137 and
Replacement of motor and timing belt, axes 5
or 6 on page 145.
3. Check each belt for tension. The belt tension should be:
If the belt tension is not correct, it • Axis 3: F = 35-60 N
should be adjusted. • Axis 5: F = 35-60 N
• Axis 6: F = 35-60 N
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000474

Belt tension adjustment is detailed in sections

Replacement of motor and timing belt, axis 3
on page 137 and Replacement of motor and
timing belt, axes 5 or 6 on page 145.

3HAC027400-001 Revision: C 67
3 Maintenance
3.4.1. Cleaning, complete robot

3.4 Cleaning activities

3.4.1. Cleaning, complete robot

General
The protection class of Foundry and Wash versions is IP 67, i.e. the robot is watertight.

Required equipment

Equipment, etc. Note

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

Do's 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 paintwork, rust inhibitors, signs, or labels!

© Copyright 2006-2008 ABB. All rights reserved.

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

Never!
• Never point the water jet at bearing seals, contacts, and other seals!
• Never spray from a distance closer than 0.4 m!
• Never remove any covers or other protective devices before cleaning the robot!
• Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
• Never spray connectors and similar items with a high pressure cleaner!

68 3HAC027400-001 Revision: C
 3 Maintenance
3.5.1. Oil change, gearbox axes 5 and 6

3.5 Changing/ replacing activities

3.5.1. Oil change, gearbox axes 5 and 6

Location of oil plugs

The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below.
A more detailed view of the components and its position may be found in section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0600002846

A Oil plug, draining and filling

B 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).
© Copyright 2006-2008 ABB. All rights reserved.

Amount at oil
change: 300 ml.
Oil collecting vessel Capacity: 400 ml.
Standard toolkit The contents are defined in
section Standard toolkit on
page 182, in part 2 of the
Product manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.

Continues on next page

3HAC027400-001 Revision: C 69
3 Maintenance
3.5.1. Oil change, gearbox axes 5 and 6

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, hydraulic and
pneumatic pressure supplies to the robot!
2.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 34.
3. Position the robot as shown in the figure to the Vessel capacity is specified in section
right: Required equipment on page 69!
• upper arm: upwards for a standing robot
• axis 4: 180º, 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
© Copyright 2006-2008 ABB. All rights reserved.

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 69.
the wrist unit properly.
5. Refit the oil plug, vent hole.

Continues on next page

70 3HAC027400-001 Revision: C
 3 Maintenance
3.5.1. Oil change, gearbox axes 5 and 6

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, hydraulic and
pneumatic pressure supplies to the robot!
2.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING -
Safety risks during work with gearbox oil on
page 34.
3. Remove the oil plug, draining and filling. Shown in the figure Location of oil
plugs on page 69!
4. 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 69!
robot
• axis 4: 90º, to a position where the oil
plug (A), faces upwards.
Fill oil in the wrist unit through the oil plug.
© Copyright 2006-2008 ABB. All rights reserved.

xx0500001435

• A: Oil plug, draining and filling

The position for an inverted robot is the
opposite.
5. Refit the oil plug.

3HAC027400-001 Revision: C 71
3 Maintenance
3.5.1. Oil change, gearbox axes 5 and 6

© Copyright 2006-2008 ABB. All rights reserved.

72 3HAC027400-001 Revision: C
 4 Repair
4.1. Introduction

4 Repair
4.1. Introduction

Structure of this chapter

This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate procedures, each detailing a specific repair activity. Each procedure
contains all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.

Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.

Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 73
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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

Required equipment

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

Cable harness 3HAC 7370-1 Standard and Foundry
versions
Clean room version
Includes cabling:
• Cable harness,
power axis 1-3
• Cable harness,
power axis 4-6
• Cable harness,
signals axis 1-3
• Cable harness,
signals axis 4-6
• Cable harness,
customer
connections
Standard toolkit 3HAC020812-001 The contents are defined
in section Standard toolkit
on page 182, in part 2 of
the Product manual.
Other tools and These procedures include
© Copyright 2006-2008 ABB. All rights reserved.
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit
diagram in the Product
manual, reference
information.

Continues on next page

74 3HAC027400-001 Revision: C
 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 commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Action Note/Illustration
1. Remove the serial Detailed in section Replacement of serial
measurement board. measurement unit and battery pack on page 120.
2. Disconnect connectors in the
manipulator base.

xx0300000090

Connectors:
© Copyright 2006-2008 ABB. All rights reserved.

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

Continues on next page

3HAC027400-001 Revision: C 75
4 Repair
4.2.1. Replacement of cable harness

Continued

Action Note/Illustration
3. Remove the cable holder by
unscrewing its attachment
screws.

xx0300000091

• A: Cable holder
• B: Attachment screws
• C: Cable securing screws
4. Remove the cables from the See figure above!
cable holder by unscrewing the
cable securing screws.
5. Remove the cover, arm Detailed in section Replacement of cover, arm
housing. housing, IRB 140.
6. Remove the lower arm cover. Detailed in section Replacement of lower arm
cover and gasket on page 105.
7. Gently knock out the VK cover. Detailed in section Removing the VK cover on
page 85.

© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

76 3HAC027400-001 Revision: C
 4 Repair
4.2.1. Replacement of cable harness

Continued

Action Note/Illustration
8. Disconnect connectors in the
rear of the upper arm.

xx0300000092

Connectors:
• A: R2.CS
• B: Pressurized air connection
• C: R3.FB4
• D: R3.FB5
• E: R3.FB6
• F: R3.MP5
• G: R3.MP4
• H: R3.MP6
Parts:
• J: Shield
9. Remove the shield by See figure above!
unscrewing its attachment
screws.
© Copyright 2006-2008 ABB. All rights reserved.

10. Cut any cable ties securing the

cabling inside the lower arm.

Continues on next page

3HAC027400-001 Revision: C 77
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 112.

© Copyright 2006-2008 ABB. All rights reserved.

14. Disconnect the connectors Connectors:
inside the console and undo • R3.MP1
the cable holders.
• R3.MP2
• R3.FB1
• R3.FB2
15. Gently pull the cabling from the
base up through the console.
16. Gently pull the cabling out of
the lower arm.

Continues on next page

78 3HAC027400-001 Revision: C
 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 Note/Illustration
1. Refit in reverse order to what is
detailed above.
Detailed below are some
recommendations on how to
route the cables.
2. Cable distribution in the cable
holder in the manipulator base.

xx0300000093

Cables:
• A: Signal
• B: Signal
© Copyright 2006-2008 ABB. All rights reserved.

• C: Customer signal
• D: Power cable, axes 4-6
• E: Pressurized air supply
• F: Power cable, axes 1-3

Continues on next page

3HAC027400-001 Revision: C 79
4 Repair
4.2.1. Replacement of cable harness

Continued

Action Note/Illustration
3. Cable layout in the lower arm.

xx0200000449

• A: Cable ties
• B: Pressurized air hose
• C: Power cables, axes 4, 5 and 6
• D: Customer cables, signal
• E: Signal cables, axes 4, 5 and 6
• F: Signal cable, axis 3 © Copyright 2006-2008 ABB. All rights reserved.

• G: Connectors R3.MP3 and R3.FB3

Continues on next page

80 3HAC027400-001 Revision: C
 4 Repair
4.2.1. Replacement of cable harness

Continued

Action Note/Illustration
4. Cable holder in the upper arm.

xx0300000094

Cables:
• A: Customer signal
• B: Signal
• C: Pressurized air supply
• D: Power cables
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 81
4 Repair
4.2.2. Replacement of complete upper arm

4.2.2. Replacement of complete upper arm

Location of upper arm

The upper arm is located on top of the manipulator as shown in the figure below.
A more detailed view of the components and its position may be found in section Spare part
lists and exploded views on page 189, in part 2 of the product manual

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000446

A Cover, armhousing
B Attachment screws, cover armhousing, (4 pcs)
C CS-connector
D Pressurized air connector
E VK cover
F Cable guide
G Attachment screws, cable guide
H Attachment screws, upper arm (6 pcs)
J Sealing ring

Continues on next page

82 3HAC027400-001 Revision: C
 4 Repair
4.2.2. Replacement of complete upper arm

Continued

Required equipment

Equipment Spare part no. Art. no. Note

Upper arm, spare Std/F 3HAC10466-1 Standard and Foundry
versions
Includes all required
sealings and gaskets.
Upper arm, spare CR 3HAC 10466-3 Clean room versions
Includes all required
sealings and gaskets.
Sealing ring 3HAB 3732-13 To be replaced if
damaged only
Included in the upper arm
assembly
VK cover 3HAC 2166-13
Gasket upper arm cover 3HAC 7867-1 To be replaced if
damaged only
Included in the upper arm
assembly
Standard toolkit 3HAC020812-001 The contents are defined
in section Standard toolkit
on page 182, in part 2 of
the Product manual.
Special socket - For fitting the CS-
connector
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step
instructions below.

WARNING!
© Copyright 2006-2008 ABB. All rights reserved.

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

Continues on next page

3HAC027400-001 Revision: C 83
4 Repair
4.2.2. Replacement of complete upper arm

Continued

Removal, upper arm

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

Action Note
1. Run the manipulator arm to a horizontal position.
2. Remove all brackets securing any exterior cabling
to the upper arm by unscrewing their attachment
screws respectively.
3. Remove the rear cover armhousing by unscrewing Shown in the figure Location of
its four attachment screws. upper arm on page 82!
4. DO NOT under any circumstance unscrew the six
screws on top of the lower arm! Doing so will cause
the manipulator to require a complete rebuild!

xx0300000101

• A: DO NOT touch these

screws! (NOTE! Only
two screws shown!)
5. Disconnect all cables to/from motors 4-6. Connectors
• R3.MP4
• R3.MP5
• R3.MP6
• R3.FB4 © Copyright 2006-2008 ABB. All rights reserved.
• R3.FB5
• R3.FB6
6. Disconnect any connector from the CS-connector. Shown in the figure Location of
upper arm on page 82!
7. Use a special socket to remove the CS-connector Shown in the figure Location of
from the housing and pull it into the upper arm upper arm on page 82!
assembly. Art. no. specified in section
Required equipment on page
83!
8. Remove the pressurized air connector from the Shown in the figure Location of
housing and pull it into the upper arm assembly. upper arm on page 82!
Art. no. specified in section
Required equipment on page
83!

Continues on next page

84 3HAC027400-001 Revision: C
 4 Repair
4.2.2. Replacement of complete upper arm

Continued

Action Note
9. Remove the VK-cover from the upper arm/lower Shown in the figure Location of
arm joint. upper arm on page 82!
Detailed in section Removing
the VK cover on page 85.
10. Remove the cable guide by unscrewing its two Shown in the figure Location of
attachment screws. upper arm on page 82!
11. Gently pull all cables and hoses out.
12. Remove the upper arm by unscrewing its six Shown in the figure Location of
attachment screws. upper arm on page 82!
13. Lift the upper arm and place it on a secure surface.

Removing the VK cover

The procedure below details how to remove the VK cover from the upper arm.
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000433

A Lower arm
B Lower arm cover gasket
C Cover l. arm, spare (without lamp unit)
D Cover l. arm, spare (with lamp unit)

Continues on next page

3HAC027400-001 Revision: C 85
4 Repair
4.2.2. Replacement of complete upper arm

Continued

Action Note
1. Remove the lower arm cover by unscrewing its
attachment screws.
2. Tap the VK coverwith a long blunt edged bar Make sure to press the
through the hole in the lower arm to press it out. circumference of the VK cover
evenly to avoid damaging it.
Shown in the figure in section
Location of upper arm on page 82!
3. If the VK cover is damaged, it must be replaced Specified in section Refitting of
on refitting. complete upper arm.

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

Action Note
1. Check the sealing ring to see whether it is Shown in the figure Location of
damaged. upper arm on page 82!
Replace if it is damaged! Art. no. specified in section
Required equipment on page 83!
2. Lift the upper arm into position.
3. Secure the upper arm with its six attachment Shown in the figure Location of
screws. upper arm on page 82!
Tightening torque: 35 Nm ± 3 Nm
4. Gently pull all cables and hoses through the
hole in the upper arm.
5. Reconnect all connectors to motors 4-6. Connectors
• R3.MP4
• R3.MP5
• R3.MP6
• R3.FB4
• R3.FB5
• R3.FB6 © Copyright 2006-2008 ABB. All rights reserved.
6. Refit the cable guide with its two attachment Shown in the figure Location of
screws. upper arm on page 82!
7. Pull the pressurized air connector through the Shown in the figure Location of
housing and secure it into fitting in the upper upper arm on page 82!
arm assembly.
8. Pull the CS-connector through the housing Shown in the figure Location of
and secure it into the fitting in the upper arm upper arm on page 82!
assembly. Art. no. specified in section
Use a special socketto secure it. Required equipment on page 83!
9. Reconnect any connector previously
connected externally to the CS connector.
10. Fit a newVK-cover to the upper arm/lower arm Shown in the figure Location of
joint. upper arm on page 82!
Gently knock it into position. Art. no. specified in section
Required equipment on page 83!
Use a plastic mallet or similar.

Continues on next page

86 3HAC027400-001 Revision: C
 4 Repair
4.2.2. Replacement of complete upper arm

Continued

Action Note
11. Refit the rear cover armhousing with its four Shown in the figure Location of
attachment screws. upper arm on page 82!
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

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.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 87
4 Repair
4.2.3. Replacement of complete lower arm

4.2.3. Replacement of complete lower arm

Location of lower arm

The lower arm is located between upper arm and frame as shown in the figure below.
A more detailed view of the components and its position may be found in section Spare part
lists and exploded views on page 189, in part 2 of the product manual

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000469

A Lower arm

Continues on next page

88 3HAC027400-001 Revision: C
 4 Repair
4.2.3. Replacement of complete lower arm

Continued

Required equipment

Equipment Spare part no. Art. no. Note

Lower arm, spare 3HAC 10468-1 Standard and Foundry
versions
Includes all required
bearings, oil and VK
cover.
Lower arm, spare 3HAC 10468-4 Clean room versions
Includes all required
bearings, oil and VK
cover.
Standard toolkit 3HAC020812-001 The contents are defined
in section Standard toolkit
on page 182, in part 2 of
the Product manual.
Lifting device for lower Lifting capacity minimum
arm 16 kg
Special socket - For fitting the
CS-connector
Other tools and These procedures
procedures may be include references to the
required. See references tools required.
to these procedures in the
step-by-step instructions
below.

Removal, lower arm

The procedure below details how to remove the complete lower arm.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
© Copyright 2006-2008 ABB. All rights reserved.

result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Action Info
1. Remove the console. Detailed in section Replacement of console on
page 115.

Continues on next page

3HAC027400-001 Revision: C 89
4 Repair
4.2.3. Replacement of complete lower arm

Continued

Action Info
2. DO NOT under any
circumstance unscrew the six
screws on top of the lower arm!
Doing so will cause the
manipulator to require a
complete rebuild!

xx0300000101

Parts:
• A: DO NOT touch these screws! (Note!
Only 2 screws are shown.)
3. Remove the VK cover by
pressing a screwdriver, or
similar, through it and pulling.

xx0300000097

© Copyright 2006-2008 ABB. All rights reserved.

Parts:
• A: Washer
• B: Lower arm attachment screws (10 pcs)
• C: VK cover
4. Unscrew thelower arm Shown in the figure above!
attachment screws.
Also remove the washer.
5. Raise the lifting device to
remove the lower arm.

Continues on next page

90 3HAC027400-001 Revision: C
 4 Repair
4.2.3. Replacement of complete lower arm

Continued

Refitting, lower arm

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

Action Note
1. Fit the lifting device and lift the
lower arm into position.
2. Fit the lower arm to gearbox, axis
2, and secure it with its
attachment screws and washers.

xx0300000097

Parts:
• A: Washer
• B: Lower arm attachment screws (10 pcs)
• C: VK cover
Tightening torque: 35 Nm ± 3 Nm
3. Fit a new VK cover by gently Shown in the figure above!
tapping it into position.
4. Refit the console. Detailed in section Replacement of console on
page 115.
5. Recalibrate the robot. Calibration is detailed in a separate calibration
© Copyright 2006-2008 ABB. All rights reserved.

manual, enclosed with the calibration tools.

General Calibration information is included in
section, Calibration information on page 163

3HAC027400-001 Revision: C 91
4 Repair
4.2.4. Replacement of base

4.2.4. 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000423

A Base
B Bottom plate
C Attachment screws, bottom plate (26 pcs)
D Attachment screws and washers, gearbox/base (20 pcs each)
E Joint, gearbox/base
F Damper, axis 1 © Copyright 2006-2008 ABB. All rights reserved.
G Washer

Required equipment

Equipment Spare part no. Art. no. Note

Base, spare 3HAC 10470-1 Standard and Foundry
versions.
Includes parallel pin
3HAC 3785-2.
Base, spare 3HAC 10470-3 Clean room versions.
Includes parallel pin
3HAC 3785-2.
Lifting slings -

Continues on next page

92 3HAC027400-001 Revision: C
 4 Repair
4.2.4. Replacement of base

Continued

Equipment Spare part no. Art. no. Note

Locking liquid Loctite 574
For sealing the base to the
gearbox 1-2.
Grease 3HAB 3537-1 For lubricating the V-ring.
Isopropanol For cleaning the mating
surfaces.
Standard toolkit - The contents are defined
in section Standard toolkit
on page 182, in part 2 of
the Product manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.

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

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the axis 1 and 2 motors. Detailed in sections:
• Replacement of motor, axis 1
on page 129
© Copyright 2006-2008 ABB. All rights reserved.

• Replacement of motor, axis 2

on page 133
3. Remove the cable harness. Detailed in section Replacement of
cable harness on page 74.
4. Remove the serial measurement unit. Detailed in section Replacement of
serial measurement unit and battery
pack on page 120.
5. Remove the complete upper arm. Detailed in section Replacement of
complete upper arm on page 82.
6. Remove the complete lower arm. Detailed in section Replacement of
complete lower arm on page 88.
7. Unfasten the base from the installation site by
removing the attachment bolts from the
foundation.
8. Fit the lifting slings to the robot, lift it and place it
with the side of the lower arm downwards on a
work bench.
9. Remove the bottom plate. Shown in the figure Location of base
on page 92.
Continues on next page
3HAC027400-001 Revision: C 93
4 Repair
4.2.4. Replacement of base

Continued

Action Note
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 92.
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, hydraulic and
pneumatic pressure supplies to the robot!
2. Place the robot with the side of the lower arm
downwards on a workbench.
3. Clean the mating surfaces between the base
and the gearbox unit with isopropanol.
4. Lubricate the mating surface on the base with
Loctite 574.
5. Lift the base to mounting position.
6. Secure the base to the gearbox unit with the Shown in the figure Location of base
gearbox/base attachment screws and washer. on page 92.
Tightening torque: 35 Nm ± 3Nm
7. Refit the bottom plate and secure it with its Shown in the figure Location of base
attachment screws. on page 92.
8. Turn the robot to stand upright.
9. Secure the base to the foundation. Attachment bolt and tightening torque
are specified in section Attachment
screws on page 46

© Copyright 2006-2008 ABB. All rights reserved.

10. Refit the complete lower arm. Detailed in section Replacement of
complete lower arm on page 88.
11. Refit the complete upper arm. Detailed in section Replacement of
complete upper arm on page 82.

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

motor, axis 1 on page 129 and
Replacement of motor, axis 2 on page
133 respectively.
13. Refit the serial measurement unit. Detailed in section Replacement of
serial measurement unit and battery
pack on page 120.
14. Refit the cable harness. Detailed in section Replacement of
cable harness on page 74.

Continues on next page

94 3HAC027400-001 Revision: C
 4 Repair
4.2.4. Replacement of base

Continued

Action Note
15. 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 163.
16.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 32.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 95
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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0600002847

A Attachment screws, wrist unit (3 pcs)

B Oil plug (only one shown)
C Wrist unit

Required equipment

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

© Copyright 2006-2008 ABB. All rights reserved.
Wrist, Standard/ Standard and Foundry versions.
Foundry O-ring sealingplate not included!
Note! The wrist, standard/
Foundry is not interchangeable
with art. no. 3HAC 10475-1!
Wrist unit (CR) 3HAC 026569-003 Clean room versions
O-ring sealingplate not included!
O-ring sealingplate Must be replaced.
Note! The o-ring sealingplate is
not interchangeable with art.no.
3HAC 7191-1!
Grease 3HAC 3537-1 For lubricating the o-ring
sealingplate.
Standard toolkit - The contents are defined in
section Standard toolkit on page
182, in part 2 of the Product
manual.
Continues on next page
96 3HAC027400-001 Revision: C
 4 Repair
4.3.1. Replacement of wrist unit

Continued

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

Arm 3HAC 9037-1 For adjusting the gear play,
motor/pinion.
Other tools and These procedures include
procedures may be references to the tools required.
required. See
references to these
procedures in the
step-by-step
instructions below.

Removal, wrist unit

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

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Drain the oil from the wrist unit. Detailed in section Oil change, gearbox
axes 5 and 6 on page 69.
3. Remove the wrist unit by unscrewing its Shown in the figure in section Location of
three attachment screws. wrist unit on page 96.

Refitting, wrist unit

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

Action Note
1. Move the robot to a position where the upper
arm is vertical.
© Copyright 2006-2008 ABB. All rights reserved.

2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Lightly lubricate the o-ring sealingplate with Art. no. is specified in section Required
grease. equipment on page 96.
4. In order to release the brake, connect the 24 Connect to connector R3.MP5 or 6:
VDC power supply to motors: • +: pin 7
• -: pin 8
5. Fit the o-ring sealingplate and the wrist unit to Do not tighten its attachment screws!
the upper arm with the attachment screws, but Use a new o-ring! Spare part no. is
do not tighten them. specified in Required equipment on
page 96.
6. Fit the arm to the rear of the motor. Art. no. is specified in section Required
equipment on page 96.

Continues on next page

3HAC027400-001 Revision: C 97
4 Repair
4.3.1. Replacement of wrist unit

Continued

Action Note
7. Manually push the wrist to adjust the wrist in
relation to the gear in the gearbox.
Minimize the gear play as shown in the figure.

xx0200000445

A. Wrist unit, axes 5 and 6 gears

B. Drive shafts from motors, axes
5 and 6 gears
C. Adjustment direction
D. Gear play
8. Tighten the wrist unit attachment screws. Tightening torque: 28 Nm.
9. Check the gear play by moving axes 5 and 6 by The gear play must be checked
hand. according to sub-sections Measuring
the gear play, axis 5 on page 148 and
Measuring the gear play, axis 6 on
page 150.
10. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 184.
11. Refill the wrist unit with oil. Detailed in section Oil change,
gearbox axes 5 and 6 on page 69.
12. Recalibrate the robot! Calibration is detailed in a separate
calibration manual, enclosed with the

© Copyright 2006-2008 ABB. All rights reserved.

calibration tools.
General calibration information is
included in section Calibration
information on page 163.
13.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 32.

98 3HAC027400-001 Revision: C
 4 Repair
4.3.2. Replacement of damper, axis 3

4.3.2. Replacement of damper, axis 3

Location of damper, axis 3

The damper, axis 3, is shown in the figure below.
A more detailed view of the components and its position may be found in section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000427

A Damper, axis 3

Required equipment

Equipment, etc. Spare part no. Note

Damper, axis 3 3HAC 7881-1
© Copyright 2006-2008 ABB. All rights reserved.

Standard toolkit The contents are defined in section

Standard toolkit on page 182, in part 2 of
the Product manual.

Continues on next page

3HAC027400-001 Revision: C 99
4 Repair
4.3.2. Replacement of damper, axis 3

Continued

Removal, damper axis 3

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

Action Note
1. Run the robot to a position that enables access to Shown in the figure Location of
damper, axis 3. damper, axis 3 on page 99.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Remove the damper by gently prying it from the cast
tab.

Refitting, damper axis 3

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

Action Note
1. Run the robot to a position that enables access to the Shown in the figure Location of
location where the damper, axis 3, is fitted. damper, axis 3 on page 99.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Refit the damper by gently pressing it onto the cast
tab on the upper arm.
4.

© Copyright 2006-2008 ABB. All rights reserved.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 32.

100 3HAC027400-001 Revision: C

 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

A Damper, axis 5
B Recess

Required equipment

Equipment, etc. Spare part no. Note

Damper, axis 5 3HAB 8964-1
Standard toolkit The contents are defined in section
Standard toolkit on page 182, in part 2 of
the Product manual.
© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

3HAC027400-001 Revision: C 101
4 Repair
4.3.3. Replacement of damper, axis 5

Continued

Removal, damper axis 5

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

Action Note
1. Run the robot to a position that enables the end of the Shown in the figure Location of
damper to be pushed into the recess in the wrist unit. damper, axis 5 on page 101.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Unhook the end of the damper, and push it into the
recess.
4. Manually move the wrist (robot axis 5) away from the
damper to pull it out.

Refitting, damper axis 5

The procedure below details how to refit the damper, axis 5.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Push the end of the damper into the gap between the Make sure the damper is
wrist unit and upper arm. turned the correct way!
3. Manually move the wrist (robot axis 5) in order to pull the
damper into position.
4. Fold out the damper hooks to secure it in position.
5. © Copyright 2006-2008 ABB. All rights reserved.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further detailed in
section DANGER - First test run may cause injury or
damage! on page 32.

102 3HAC027400-001 Revision: C

 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000464

A Cover, arm housing

B Attachment screws, cover, armhousing
C Gasket, upper arm cover

Required equipment

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

Cover, arm housing 3HAC 10473-1 Standard and Foundry
version
Includes gasket
3HAC 7867-1
Cover, arm housing 3HAC 10473-3 Clean Room versions
© Copyright 2006-2008 ABB. All rights reserved.

Includes gasket
3HAC 7867-1
Gasket, upper arm cover 3HAC 7867-1
Standard toolkit 3HAC020812-001 The contents are
defined in section
Standard toolkit on
page 182, in part 2 of
the Product manual.
Other tools and These procedures
procedures may be include references to
required. See references the tools required.
to these procedures in
the step-by-step
instructions below.

Continues on next page

3HAC027400-001 Revision: C 103
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 commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Action Note
1. Manually, run the robot to a position that enables
access to the rear of the upper arm.
2. Remove the cover, armhousing by unscrewing its Shown in the figure Location
attachment screws. of cover, armhousing on
page 103.
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 commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Action Note © Copyright 2006-2008 ABB. All rights reserved.

1. Manually, run the robot to a position that enables Shown in the figure Location
access to the rear of the upper arm. of cover, armhousing on
page 103.
2. Make sure the gasket inside the cover, arm housing Replace if damaged.
has not been damaged. Shown in the figure Location
of cover, armhousing on
page 103.
3. Secure the cover, arm housing to the upper arm with
its attachment screws.

104 3HAC027400-001 Revision: C

 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 and exploded views on page 189, in part 2 of the product manual
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000433

A Lower arm
B Gasket lower-arm cover
C Cover l. arm, spare (without lamp unit)
D Cover l. arm, spare (with lamp unit)

Continues on next page

3HAC027400-001 Revision: C 105
4 Repair
4.4.1. Replacement of lower arm cover and gasket

Continued

Required equipment

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

Cover l. arm, spare, Std/F 3HAC 10471-1 Standard and Foundry
versions
No lamp unit included
Includes gasket
3HAC 7869-1
Cover l. arm, spare, CR 3HAC 10471-3 Clean room versions
No lamp unit included
Includes gasket
3HAC 7869-1
Gasket lower-arm cover 3HAC 7869-1
Isopropanol 1177 1012-208 For cleaning sealing
surfaces
Standard toolkit 3HAC020812-001 The contents are
defined in section
Standard toolkit on
page 182, in part 2 of
the Product manual.
Other tools and procedures These procedures
may be required. See include references to
references to these the tools required.
procedures in the
step-by-step instructions
below.

Removal, lower arm cover and gasket

The procedure below details how to remove the lower arm cover and gasket.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns! © Copyright 2006-2008 ABB. All rights reserved.
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Action Note
1. Remove the lower arm cover by unscrewing its Shown in the figure Location
attachment screws. of lower arm cover and
gasket on page 105.
2. If the gasket is to be replaced, proceed below!
Use a knife to gently remove the old gasket from the
cover.
3. Clean the sealing surface with isopropanol, making Art. no. specified in section
sure it is completely clean and free from scratches Required equipment on
and burrs. page 106.

Continues on next page

106 3HAC027400-001 Revision: C
 4 Repair
4.4.1. Replacement of lower arm cover and gasket

Continued

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
1. If the Gasket lower-arm cover is to be replaced, Shown in the figure Location
proceed below. If not, see further down! of lower arm cover and
gasket on page 105.
2. Remove the protective backing from the Make absolutely sure it is
self-adhesive gasket and fit it onto the cover sealing correctly located!
surface.
3. Refit the lower arm coverwith its attachment screws. Shown in the figure Location
of lower arm cover and
gasket on page 105.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 107

4 Repair
4.4.2. Replacement of damper, axis 2

4.4.2. Replacement of damper, axis 2

Location of damper, axis 2

The damper, axis 2, is 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 and exploded views on page 189, in part 2 of the product manual

xx0200000426

A Damper, axis 2

Required equipment

Equipment, etc. Spare part no. Note

Damper ax. 2 3HAC 7880-1
Standard toolkit The contents are defined in section
Standard toolkit on page 182, in part
2 of the Product manual.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the © Copyright 2006-2008 ABB. All rights reserved.
step-by-step instructions below.

Continues on next page

108 3HAC027400-001 Revision: C
 4 Repair
4.4.2. Replacement of damper, axis 2

Continued

Removal, damper axis 2

The procedure below details how to remove the damper, axis 2.

Action Note
1. Run the robot to a position that enables you to access the
attachment screw of damper, axis 2.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic pressure
supplies to the robot!
3. Remove the damper by unscrewing the single attachment
screw and washer.

Refitting, damper axis 2

The procedure below details how to refit the damper, axis 2.

Action Note
1. Run the robot to a position that enables access to the
attachment screw of the damper, axis 2.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. Secure the damper with the attachment screw and 1 pc: M6 x 16.
washer.
4.
© Copyright 2006-2008 ABB. All rights reserved.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further detailed in
section DANGER - First test run may cause injury or
damage! on page 32.

3HAC027400-001 Revision: C 109

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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000472

A Indication lamp
B Lower arm cover

© Copyright 2006-2008 ABB. All rights reserved.

Required equipment

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

Indicator lamp 3HAC 9258-1
Standard toolkit 3HAC020812-001 The contents are defined in
section Standard toolkit on
page 182, in part 2 of the
Product manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.

Continues on next page

110 3HAC027400-001 Revision: C
 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 commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Action Note
1. Remove the lower arm cover. Detailed in section
Replacement of lower arm
cover and gasket on page
105.
2. Remove the damper by gently prying the plastic
semi-transparent damper from the cast tab.

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

Action Note
© Copyright 2006-2008 ABB. All rights reserved.

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

damper, axis 3.
2. Refit the damper by gently pressing it onto the cast
tab on the upper arm.

DANGER!
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.

3HAC027400-001 Revision: C 111

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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000462

A Cover, console
B Attachment screws, cover, console (4 pcs)

© Copyright 2006-2008 ABB. All rights reserved.

C Gasket
D Console

Continues on next page

112 3HAC027400-001 Revision: C
 4 Repair
4.5.1. Replacement of cover, console

Continued

Required equipment

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

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 3HAC 7868-1
Standard toolkit 3HAC020812-001 The contents are defined
in section Standard
toolkit on page 182, in
part 2 of the Product
manual.
Other tools and These procedures
procedures may be include references to the
required. See tools required.
references to these
procedures in the
step-by-step instructions
below.

Removal
The procedure below details how to remove the cover, console.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
© Copyright 2006-2008 ABB. All rights reserved.

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

Action Note
1. Manually, run the robot to a position that enables Shown in the figure Location
access to the top of the console. of cover, console on page
112.
2. Remove the cover, console by unscrewing its NOTE! Do not damage the
attachment screws. gasket inside the cover!

Continues on next page

3HAC027400-001 Revision: C 113
4 Repair
4.5.1. Replacement of cover, console

Continued

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

Action Note
1. Manually, move the robot to a position that enables Shown in the figure Location
access to the top of the console. of cover, console on page
112.
2. 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
112.
3. Secure the cover, console to the console with its
attachment screws.

© Copyright 2006-2008 ABB. All rights reserved.

114 3HAC027400-001 Revision: C

 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000462

A Cover, console
B Attachment screws, cover, console (4 pcs)
C Gasket
D Console
© Copyright 2006-2008 ABB. All rights reserved.

Required equipment

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

Console, spare 3HAC 10478-1 Standard and Foundry
version
Console, spare 3HAC 10478-3 Clean Room versions
Standard toolkit 3HAC020812-001 The contents are
defined in section
Standard toolkit on
page 182, in part 2 of
the Product manual.
Other tools and procedures These procedures
may be required. See include references to
references to these the tools required.
procedures in the
step-by-step instructions
below.

Continues on next page

3HAC027400-001 Revision: C 115
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 commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Action Note/Illustration
1. Remove the cable harness. Detailed in section Replacement of cable harness
on page 74.
2. Remove the serial Detailed in section Replacement of serial
measurement board. measurement unit and battery pack on page 120.
3. Remove the complete upper Detailed in section Replacement of complete upper
arm. arm on page 82.
4. DO NOT under any
circumstance unscrew the six
screws on top of the lower
arm! Doing so will cause the
manipulator to require a
complete rebuild!

xx0300000101

Parts:
• A: DO NOT touch these screws! (Note! Only © Copyright 2006-2008 ABB. All rights reserved.
two screws shown!)
5. Remove the motor of axis 3. Detailed in section Replacement of motor and
timing belt, axis 3 on page 137.
6. Attach the lifting device to the
lower arm.

Continues on next page

116 3HAC027400-001 Revision: C
 4 Repair
4.5.2. Replacement of console

Continued

Action Note/Illustration
7. 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 Shown in the figure above!
unscrewing its attachment
screws.
© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

3HAC027400-001 Revision: C 117
4 Repair
4.5.2. Replacement of console

Continued

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

Action Note/Illustration
1. Refit the console and secure it with
its attachment screws and washers.

xx0300000096

Parts:
• A: Console
• B: Bearing hub
• C: Bearing hub attachment screws © Copyright 2006-2008 ABB. All rights reserved.
(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
3. Refit the complete upper arm. Detailed in section Replacement of complete
upper arm on page 82.
4. Refit motor 3 and timing belt. Detailed in section Replacement of motor and
timing belt, axis 3 on page 137.
5. Refit the serial measurement board. Detailed in section Replacement of serial
measurement unit and battery pack on page
120.
6. Refit the cable harness. Detailed in section Replacement of cable
harness on page 74.

Continues on next page

118 3HAC027400-001 Revision: C
 4 Repair
4.5.2. Replacement of console

Continued

Action Note/Illustration
7. 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 163.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 119

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

4.5.3. Replacement of serial measurement unit and battery pack

Location of serial measurement unit and battery pack

The serial measurement unit and battery pack are located inside the manipulator base as
shown in the figure below.
A more detailed view of the components and its position may be found in section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000432

A Rear cable cover

B Battery pack
C Serial measurement board (SMB)
D SMB attachment screws (4 pcs) © Copyright 2006-2008 ABB. All rights reserved.
E Manipulator base bottom plate

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 Replace only if required!

Continues on next page

120 3HAC027400-001 Revision: C
 4 Repair
4.5.3. Replacement of serial measurement unit and battery pack

Continued

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

Standard Toolkit, IRB 140 3HAC020812-001 The contents are defined
in section Standard
toolkit on page 182, in
part 2 of the Product
manual.
Other tools and These procedures
procedures may be include references to the
required. See references tools required.
to these procedures in the
step-by-step instructions
below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit
diagram in the Product
manual, reference
information.

Removal
The procedure below details how to remove the serial measurement unit and battery pack.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to
electrostatic voltages.
© Copyright 2006-2008 ABB. All rights reserved.

• 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
1. Set the robot system to MOTORS OFF state. This will simplify calibration of the
robot after replacement since no
coarse calibration will be required.
2. Remove the rear cable cover from the base of Shown in the figure Location of
the robot by unscrewing its attachment screws. serial measurement unit and
battery pack on page 120!
Continues on next page
3HAC027400-001 Revision: C 121
4 Repair
4.5.3. Replacement of serial measurement unit and battery pack

Continued

Action Note
3. Remove the serial measurement unit by Shown in the figure Location of
unscrewing its attachment screws . serial measurement unit and
The removal is simplified by pushing the unit to battery pack on page 120!
the side and then pulling it backwards.
4. If only the battery is to be replaced, disconnect Connectors
the cables to the battery only! • R2.SMB
Disconnect all connectors from the serial • R2.FB1-3
measurement unit.
• R2.FB4-6
• R2.G
5. Lift the board out.
6. If the battery pack is to be replaced, proceed Shown in the figure Location of
below! serial measurement unit and
Cut the cable tie and disconnect the battery battery pack on page 120!
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.

© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

122 3HAC027400-001 Revision: C
 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 commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
• The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to
electrostatic voltages.
• Before handling, make sure you are connected to earth through a special ESD wrist
bracelet or similar.
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
1. Connect the new battery pack to the serial
measurement unit and secure it with a cable tie.
2. Reconnect all connectors to the unit. Connectors
© Copyright 2006-2008 ABB. All rights reserved.

• R2.SMB
• R2.FB1-3
• R2.FB4-6
• R2.G
3. Place the serial measurement unit in position Shown in the figure Location of
inside the manipulator base and secure it with its serial measurement unit and
four attachment screws. battery pack on page 120!
4. Make sure the gasket sealing the rear cable cover Shown in the figure Location of
has not been damaged. serial measurement unit and
Replace the gasket if required. battery pack on page 120!
Art. no. specified in section
Required equipment on page
120!
5. Making sure all cables are correctly located Shown in the figure Location of
behind the rear cable cover, refit it into position. serial measurement unit and
Make sure no cables or other equipment fitted battery pack on page 120!
behind the cover get pinched by the cover.

Continues on next page

3HAC027400-001 Revision: C 123
4 Repair
4.5.3. Replacement of serial measurement unit and battery pack

Continued

Action Note
6. Secure the rear cable cover to the base of the Shown in the figure Location of
robot with its attachment screws. serial measurement unit and
battery pack on page 120!
7. This is valid if NiCd type batteries are used only!
Lithium batteries do not require charging before
use.
Recharge the battery for at least 36 hrs by leaving
the mains supply switched on for this amount of
time.
8. Recalibrate the robot! Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
General calibration information
is included in section Calibration
information on page 163.

© Copyright 2006-2008 ABB. All rights reserved.

124 3HAC027400-001 Revision: C

 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000467

A Gasket, base-cover
B Attachment screws and washers (9 pcs each), control cable
C Control cable, spare

Required equipment

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

Control cable, spare 3HAC 10476-1 3m
Standard and Foundry
© Copyright 2006-2008 ABB. All rights reserved.

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

3HAC027400-001 Revision: C 125
4 Repair
4.5.4. Replacement of control cable

Continued

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

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 3HAC020812-001 The contents are defined
in section Standard toolkit
on page 182, in part 2 of
the Product manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step
instructions below.

© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

126 3HAC027400-001 Revision: C
 4 Repair
4.5.4. Replacement of control cable

Continued

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

Action Note
1. Make sure the robot system has been
switched off, and that no power is
supplied to the manipulator.
2. Remove the Control cable, spareby Shown in the figure Location of control cable
unscrewing its attachment screws. on page 125.
Make sure the gasket does not get
damaged!
3. Disconnect connectors inside the
manipulator base.

xx0300000090

Connectors:
© Copyright 2006-2008 ABB. All rights reserved.

• A: R1.MP1-3
• B: R1.CS
• C: Air hose
• D: R1.MP4-6
4. Pull the cable out of the manipulator
base.
5. Disconnect the connectors from the
control cabinet.

Continues on next page

3HAC027400-001 Revision: C 127
4 Repair
4.5.4. Replacement of control cable

Continued

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

Action Note
1. Place the control cable on the floor with Shown in the figure Location of control
the manipulator base cover close to the cable on page 125.
manipulator.
2. Connect the connectors inside the
manipulators base.

xx0300000090

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

© Copyright 2006-2008 ABB. All rights reserved.

3. Fit a new gasket when refitting the cover. Included in the spare part
4. Fit the cover onto the manipulator base Shown in the figure Location of control
and secure it with its attachment screws. cable on page 125.

128 3HAC027400-001 Revision: C

 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000407

A Motor, axis 1
B Cover for connector access
C Motor attachment screws (4 pcs)
D Cable gland attachment screws (4 pcs)
E Console

Required equipment
© Copyright 2006-2008 ABB. All rights reserved.

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

Rot. ac motor with 3HAC 10469-3 Clean room versions.
pinion 3HAC0 21966-001
Rot. ac motor with 3HAC 10469-1 Standard and Foundry
pinion 3HAC 021965-001 versions.

Rot. ac motor w 3HAC 10469-4 High performance version.

pinion TStd/TF
O-ring 2152 2012-426 Must be replaced when
replacing motor!
Included in the spare parts
motor kits
Grease 3HAB 3537-1 Used to lubricate the o-ring
Standard toolkit 3HAC020812-001 The contents are defined in
section Standard toolkit on
page 182, in part 2 of the
Product manual.

Continues on next page

3HAC027400-001 Revision: C 129
4 Repair
4.6.1. Replacement of motor, axis 1

Continued

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

Arm 3HAC 9037-1 For adjusting the gear play,
motor/pinion
Power supply 24 VDC, max. 1,5 A
For releasing the brakes
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit diagram
in the Product manual,
reference information.

Removal
The procedure below details how to remove motor, axis 1.
CAUTION!
If the manipulator normally works in an inverted position, it must be removed from this
position and placed on the floor before the work detailed in this instruction may be carried
out !
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is © Copyright 2006-2008 ABB. All rights reserved.
used!

Action Note
1. Remove the Cover for connector access on top of Shown in the figure Location
the motor by unscrewing its four attachment screws. of motor axis 1 on page 129.
Detailed in section
Replacement of cover,
console on page 112.
2. Disconnect the motor 1 connectors inside the Connectors:
console. • R3.MP1
• R3.FB1
3. Cut any cable ties and remove any brackets securing
the cables.
4. Remove the cable gland by removing its attachment Shown in the figure Location
screws, and pull the cables out from the console. of motor axis 1 on page 129.

Continues on next page

130 3HAC027400-001 Revision: C
 4 Repair
4.6.1. Replacement of motor, axis 1

Continued

Action Note
5. In order to release the brakes, connect the 24 VDC Connect to connector
power supply: R3.MP1
• +: pin 7
• -: pin 8
6. Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers. of motor axis 1 on page 129.
7. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
8. Remove the motor by gently lifting it straight up.

Refitting
The procedure below details how to refit motor, axis 1.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!

Action Note
1. Make sure the mating surfaces on the motor and
the gearbox are clean and free from burrs.
2. Make sure the o-ring on the circumference of the Art. no. is specified in section
motor is seated properly. Lightly lubricate the Required equipment on page
© Copyright 2006-2008 ABB. All rights reserved.

o-ring with grease . 129.

3. In order to release the brake, connect the 24 VDC Connect to connector R2.MP1
power supply: • +: pin 7
• -: pin 8
4. Fit the motor, making sure the motor pinion is Make sure the motor is turned
properly mated to gearbox 1. the right way, i.e. connections
rearwards.
Make sure the motor pinion does
not get damaged!
5. Fit the motor with four attachment screws and Tightening torque: approx 2 Nm
plain washers.
6. Fit the Arm to the end of the motor shaft. Art. no. is specified in section
Required equipment on page
129.
7. Adjust the motor in relation to the gear in the There should be a barely
gearbox. noticable gear play.
Use the Arm tool to wiggle the motor shaft back
and forth to feel the play.
Continues on next page
3HAC027400-001 Revision: C 131
4 Repair
4.6.1. Replacement of motor, axis 1

Continued

Action Note
8. Tighten the motor attachment screws. Tightening torque: approx 11 Nm
± 1 Nm
9. Disconnect the brake release voltage.
10. Make sure the cable gland gasket has not been Art. no. is specified in section
damaged. Replace, if it has. Required equipment on page
129.
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 184.
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 163.

© Copyright 2006-2008 ABB. All rights reserved.

132 3HAC027400-001 Revision: C

 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 below.
A more detailed view of the components and its position may be found in section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000408

A Motor, axis 2
B Cover for connector access
C Motor attachment screws (4 pcs)
D Cable gland attachment screws (4 pcs)
E Console

Required equipment

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

Rot. ac motor with 3HAC 10469-3 Clean room versions.
© Copyright 2006-2008 ABB. All rights reserved.

pinion, spare 3HAC 021966-001

Rot. ac motor with 3HAC 10469-1 Standard and Foundry
pinion, spare 3HAC 021965-001 versions.

Rot. ac motor with 3HAC 10469-4 High performance version

pinion, spare,
TStd/TF
O-ring 2152 2012-426 Must be replaced when
replacing motor.
Grease 3HAB 3537-1 For lubricating the o-ring.
Isopropanol - For cleaning mating surfaces.
Standard toolkit - The contents are defined in
section Standard toolkit on
page 182, in part 2 of the
Product manual.
Rotation tool, motor 3HAC 9037-1 For adjusting the gear play,
motor/pinion

Continues on next page

3HAC027400-001 Revision: C 133
4 Repair
4.6.2. Replacement of motor, axis 2

Continued

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

Power supply - 24 VDC, 1.5 A.
For releasing the brakes.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram - See chapter Circuit diagram in
the Product manual, reference
information.

Removal, motor axis 2

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

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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 133.
3. Disconnect the motor connectors inside the console. Connectors:
• R3.MP2
• R3.FB2
4. Cut any cable ties and remove any brackets or clamps
securing the cables.
5. Remove the cable gland by removing its attachment Shown in the figure Location

© Copyright 2006-2008 ABB. All rights reserved.

screws, and pull the cables out from the console. of motor axis 2 on page 133.
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 Connect to connector R3.MP2
power supply to the motor. • +: pin 7
• -: pin 8

Continues on next page

134 3HAC027400-001 Revision: C
 4 Repair
4.6.2. Replacement of motor, axis 2

Continued

Action Note
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 133.
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
1. Make sure the mating surfaces on the motor and the
gearbox are clean and free from burrs.
If necessary, clean the surfaces with isopropanol.
2. Make sure the o-ring on the circumference of the motor Art. no. is specified in section
is seated properly. Required equipment on page
Lightly lubricate the o-ring with grease. 133.

3. In order to release the brakes, connect the 24 VDC Connect to connector

power supply to the motor. R3.MP2:
• +: pin 7
• -: pin 8
© Copyright 2006-2008 ABB. All rights reserved.

4. Remove the motor cover from top of the motor. Shown in the figure Location
of motor axis 2 on page 133.
5. Fit the rotation tool to the end of the motor shaft. Art. no. is specified in section
Required equipment on page
133.
6. Fit the motor, making sure the motor pinion is properly Make sure the motor is turned
mated to gearbox 2. the right way, i.e. connections
Use the rotation tool to rotate the motor pinion, when rearwards.
mating it to the gear. Make sure the motor pinion
does not get damaged!
7. Secure the motor with four attachment screws and plain Tightening torque: approx 2
washers, but do not tighten yet. Nm.
8. Adjust the motor in relation to the gear in the gearbox. There should be a barely
Use the rotation tool to wiggle the motor shaft back and noticable gear play.
forth to feel the play. Tap with a plastic mallet.
9. Refit the motor cover to the top of the motor.
Be careful not to damage the cables!

Continues on next page

3HAC027400-001 Revision: C 135
4 Repair
4.6.2. Replacement of motor, axis 2

Continued

Action Note
10. Tighten the motor attachment screws. Tightening torque: approx 11
Nm ± 1 Nm
11. Disconnect the brake release voltage.
12. Make sure the cable gland cover gasket has not been Art no. is specified in section
damaged. Replace if it has. Required equipment on page
133.
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. Detailed in section Performing
a leak-down test on page 184.
16. Refill the gearbox with oil. Type of oil and amount is
specified in section Amount of
oil on page 161.
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 163.
18.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further detailed
in section DANGER - First test run may cause injury or
damage! on page 32.

© Copyright 2006-2008 ABB. All rights reserved.

136 3HAC027400-001 Revision: C

 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.
A more detailed view of the components and its position may be found in section Spare part
lists and exploded views on page 189, in part 2 of the product manual
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000448

A Lower arm cover

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

Continues on next page

3HAC027400-001 Revision: C 137
4 Repair
4.6.3. Replacement of motor and timing belt, axis 3

Continued

Required equipment

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

Rot. ac motor with 3HAC 7866-1
pinion 3HAC 021756-001
Timing belt 3HAC 6793-1
Grease 3HAB 3537-1 For lubricating the
o-ring.
Standard toolkit 3HAC020812-001 The contents are
defined in section
Standard toolkit on
page 182, in part 2 of
the Product manual.
Other tools and These procedures
procedures may be include references to
required. See the tools required.
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit
diagram in the Product
manual, reference
information.

Removal
The procedure below details how to remove motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! 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 © Copyright 2006-2008 ABB. All rights reserved.
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!

Action Note
1. Remove any equipment hindering Shown in the figure in section Location of
access to the lower arm cover. motor axis 3 on page 137.
2. Remove the lower arm cover by Shown in the figure in section Location of
unscrewing its attachment screws. motor axis 3 on page 137.

Continues on next page

138 3HAC027400-001 Revision: C
 4 Repair
4.6.3. Replacement of motor and timing belt, axis 3

Continued

Action Note
3. Cut the cable ties to facilitate
accessing the motor.

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
© Copyright 2006-2008 ABB. All rights reserved.

• F: Signal cable, axis 3

• G: Connectors R3.MP3 and R3.FB3
4. Disconnect motor connectors. Connectors:
• R3.MP3
• R3.FB3
• R3.H1 (if Safety lamp is fitted)
• R3.H2 (if Safety lamp is fitted)

Continues on next page

3HAC027400-001 Revision: C 139
4 Repair
4.6.3. Replacement of motor and timing belt, axis 3

Continued

Action Note
5. DO NOT under any circumstance
unscrew the three screws securing the
belt wheel! Doing so will cause the
manipulator to require a complete
rebuild!

xx0300000102

Parts:
• DO NOT touch these screws!
(3 pcs)
6. Remove the belt shield by unscrewing Shown in the figure in section Location of
its twoattachment screws. motor axis 3 on page 137.
7. Remove the remaining Shown in the figure in section Location of
motorattachment screws. motor axis 3 on page 137.
8. Remove the belt. Shown in the figure in section Location of
motor axis 3 on page 137.
9. Remove the motor. Shown in the figure in section Location of
motor axis 3 on page 137.

Refitting
The procedure below details how to refit motor, axis 3.

© Copyright 2006-2008 ABB. All rights reserved.

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
1. Make sure the mating surfaces on the
motor and the lower arm are clean and
free from burrs.
2. Fit the motor in the lower arm.
3. Fit the belt. Shown in the figure in section Location of
motor axis 3 on page 137.
4. Tighten the two motor attachment
screws slightly, but not completely.
Continues on next page
140 3HAC027400-001 Revision: C
 4 Repair
4.6.3. Replacement of motor and timing belt, axis 3

Continued

Action Note
5. Adjust the position of the motor in such a Correct belt tension F=35 - 60 N
way that the correct belt tension is
achieved.
6. DO NOT adjust the belt tension using the
intermediate wheel securing screws.
7. Fit the belt shield and secure it with the Tightening torque: 4 Nm ± 0.5 Nm
two remaining screws.
8. Tighten the last motor attachment Tightening torque: 4 Nm ± 0.5 Nm
screws.
9. Refit the cabling as shown.
© Copyright 2006-2008 ABB. All rights reserved.

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
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 163.

3HAC027400-001 Revision: C 141

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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0600003262

A Attachment screws, motor 4 (3 pcs)

B Motor, axis 4
C O-ring

Required equipment

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

Rot. ac motor with 3HAC 7842-1 Standard, Clean Room and
pinion Foundry versions.
© Copyright 2006-2008 ABB. All rights reserved.
3HAC 021757-001
Does not include the o-ring!
O-ring 3HAC 3772-24 Must be replaced when
replacing motor!
Replace if damaged.
Grease 3HAB 3537-1 Used for lubricating the
o-ring.
Standard toolkit 3HAC020812-001 The contents are defined in
section Standard toolkit on
page 182, in part 2 of the
Product manual.
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

142 3HAC027400-001 Revision: C
 4 Repair
4.6.4. Replacement of motor, axis 4

Continued

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

Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit diagram
in the Product manual,
reference information.

Removal, motor axis 4

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

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Manually move the robot to a position where the This will enable the motor 4 to be
upper arm points straight down. removed without draining the oil in
the gearbox.
3. Remove the motors for axes 5 and 6. Detailed in section Replacement
of motor and timing belt, axes 5 or
6 on page 145.
4. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP4
power supply to the motor. • +: pin 7
• -: pin 8
5. Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws. motor on page 142.
© Copyright 2006-2008 ABB. All rights reserved.

6. Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
7. Remove the motor by gently lifting it out. Make sure the motor pinion is not
damaged!

Continues on next page

3HAC027400-001 Revision: C 143
4 Repair
4.6.4. Replacement of motor, axis 4

Continued

Refitting, motor axis 4

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

Action Note
1. Clean the mating surfaces on the motor and the Shown in the figure Location of motor
gearbox. on page 142.
2. Make sure the o-ring on the circumference of Art. no. is specified in section
the motor is seated properly. Lightly lubricate Required equipment on page 142.
the o-ring with grease .
3. In order to release the brakes, connect the 24 Connect to connector R3.MP4
VDC power supply to the motor. • +: pin 7
• -: pin 8
4. Fit the motor with the attachment screws and Shown in the figure Location of motor
washers. on page 142.
Until the motor shaft is adjusted to the gear, as Tightening torque: approx. 2 Nm.
described in following steps, only tighten the
screws lightly.
5. Fit the rotational tool to the end of the motor Art. no. is specified in section
shaft. Required equipment on page 142.
6. Adjust the motor in relation to the gear in the There should be a barely noticable
gearbox. gear play.
Use the arm tool to wiggle the motor shaft back
and forth to feel the play.
7. Tighten the motor attachment screws. Shown in the figure Location of motor
on page 142.
Tightening torque: 6 Nm ± 0.6 Nm.
8. Refit motors 5 and 6. Detailed in section Replacement of
motor and timing belt, axes 5 or 6 on
page 145.
9. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 184.
10. Recalibrate the robot! Calibration is detailed in a separate

© Copyright 2006-2008 ABB. All rights reserved.

calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 163.
11.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 32.

144 3HAC027400-001 Revision: C

 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual
© Copyright 2006-2008 ABB. All rights reserved.

xx0600003261

A Lower arm cover

B Attachment screws, lower arm cover
C Cover, armhousing
D Attachment screws, cover armhousing (4 pcs)
E VK cover
F Pressurized air hose (on front of upper arm)
G CS connector
H Cable guide
J Attachment screws, cable guide
K Belt shield
L Attachment screws, belt shield
M Motor attachment screws, 4 pcs per motor

Continues on next page

3HAC027400-001 Revision: C 145
4 Repair
4.6.5. Replacement of motor and timing belt, axes 5 or 6

Continued

N Attachment screws, motor console

R Timing belt, axis 6
S Pulley, axis 6
U Timing belt, axis 5
V Pulley, axis 5
W Motor console, ax. 5-6
X Motor, axis 4
Y Motor, axis 5
Z Motor, axis 6

Required equipment

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

Rot. ac motor with 3HAC 021757-001 Axis 4
pinion Standard, Clean room and
Foundry versions
Rot. ac motor with 3HAC 021758-001 Axes 5 and 6
pinion Standard, Clean room and
Foundry versions
Timing belt 3HAC 6779-1 Axes 5 and 6
VK cover 3HAC 2166-13
Standard toolkit 3HAC020812-001 The contents are defined
in section Standard toolkit
on page 182, in part 2 of
the Product manual.
Special socket - For fitting the
(30 mm) CS-connector
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
© Copyright 2006-2008 ABB. All rights reserved.
step-by-step
instructions below.
Circuit Diagram 3HAC 6816-3 See chapter Circuit
diagram in the Product
manual, reference
information.

Continues on next page

146 3HAC027400-001 Revision: C
 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 commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!

Action Note
1. Run the robot to a position where the
upper arm is close to horizontal
2. Remove the lower arm cover by Shown in the figure in section Location
unscrewing its attachment screws. of motor and timing belt, axes 5 or 6 on
page 145!
3. Remove the rear cover armhousing by Shown in the figure in section Location
unscrewing its four attachment screws. of motor and timing belt, axes 5 or 6 on
page 145!
4. Disconnect all cables to/from motors 4-6. Connectors:
• R3.MP4
• R3.MP5
• R3.MP6
• R3.FB4
• R3.FB5
• R3.FB6
© Copyright 2006-2008 ABB. All rights reserved.

5. Disconnect any connector from the CS- Shown in the figure in section Location
connector. of motor and timing belt, axes 5 or 6 on
page 145!
6. Use a special socket to remove the CS- Shown in the figure in section Location
connector from the housing and pull it into of motor and timing belt, axes 5 or 6 on
the upper arm assembly. page 145!
Art. no. specified in section Required
equipment
7. Remove the pressurized air connector from Shown in the figure in section Location
the housing and pull it into the upper arm of motor and timing belt, axes 5 or 6 on
assembly. page 145!
Art. no. specified in section Required
equipment!
8. Remove the VK-cover from the upper arm/ Shown in the figure in section Location
lower arm joint. of motor and timing belt, axes 5 or 6 on
page 145!
Detailed in section Removing the VK
cover on page 85.

Continues on next page

3HAC027400-001 Revision: C 147
4 Repair
4.6.5. Replacement of motor and timing belt, axes 5 or 6

Continued

Action Note
9. Remove the cable guide by unscrewing its Shown in the figure in section Location
two attachment screws. of motor and timing belt, axes 5 or 6 on
page 145!
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 145!
12. Loosen the motor attachment screws. Shown in the figure in section Location
of motor and timing belt, axes 5 or 6 on
page 145!
13. Remove the pulley and belt from motor, Shown in the figure in section Location
axis 6. of motor and timing belt, axes 5 or 6 on
page 145!
14. Remove the pulley and belt from motor, Shown in the figure in section Location
axis 5. of motor and timing belt, axes 5 or 6 on
page 145!
15. Remove the motor console, ax. 5-6 by Shown in the figure in section Location
unscrewing its attachment screws. of motor and timing belt, axes 5 or 6 on
page 145!

Refitting
The procedure below details how to refit motor, axis 5.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force © Copyright 2006-2008 ABB. All rights reserved.
is used!

Action Note
1. Make sure the mating surfaces on the motor
and the console are clean and free from
burrs.
2. Fit the motors in the motor console without Shown in the figure in section
tightening the attachment screws. Location of motor and timing belt,
axes 5 or 6 on page 145!
3. Fit the motor console in the upper arm Shown in the figure in section
housing. Secure with its attachment screws. Location of motor and timing belt,
axes 5 or 6 on page 145!
Tightening torque: 4 Nm ± 0.5 Nm
4. Fit timing belt, axis 5. Shown in the figure in section
Location of motor and timing belt,
axes 5 or 6 on page 145!

Continues on next page

148 3HAC027400-001 Revision: C
 4 Repair
4.6.5. Replacement of motor and timing belt, axes 5 or 6

Continued

Action Note
5. Tighten the motor attachment screws to This will facilitate adjustment of the
enable the motor to be shifted slightly. belt tension.
6. Adjust the belt tension using a suitable tool Correct belt tension: axis 5, 25 - 50 N
and axis 6, 20 - 40 N
7. Secure the motor with its attachment screws Tightening torque: 4 Nm ± 0.5 Nm
including the ones in the motor console.
8. Fit timing belt, axis 6. Shown in the figure in section
Location of motor and timing belt,
axes 5 or 6 on page 145!
9. Repeat the belt adjustment procedure
detailed above for the remaining motor.
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 145!
Tightening torque: 4 Nm ± 0.5 Nm
12. Pull the pressurized air connector through Shown in the figure in section
the housing and secure it into fitting in the Location of motor and timing belt,
upper arm assembly. axes 5 or 6 on page 145!
Art. no. specified in section Required
equipment
13. Pull the CS-connector through the housing Shown in the figure in section
and secure it into the fitting in the upper arm Location of motor and timing belt,
assembly. axes 5 or 6 on page 145!
Use a special socketto secure it. Art. no. specified in section Required
equipment
14. Reconnect any connector to the CS- Shown in the figure in section
connector. Location of motor and timing belt,
axes 5 or 6 on page 145!
15. Reconnect all cables to/from motors 4-6. Connectors
• R3.MP4
• R3.MP5
© Copyright 2006-2008 ABB. All rights reserved.

• R3.MP6
• R3.FB4
• R3.FB5
• R3.FB6
16. Refit the cable guide with its two attachment Shown in the figure in section
screws. Location of motor and timing belt,
axes 5 or 6 on page 145!
17. Fit a newVK-cover to the upper arm/lower Shown in the figure in section
arm joint. Location of motor and timing belt,
Gently knock it into position. axes 5 or 6 on page 145!
Art. no. specified in section Required
equipment
Use a plastic mallet or similar.
18. Refit the rear cover armhousing with its four Shown in the figure in section
attachment screws. Location of motor and timing belt,
axes 5 or 6 on page 145!

Continues on next page

3HAC027400-001 Revision: C 149
4 Repair
4.6.5. Replacement of motor and timing belt, axes 5 or 6

Continued

Action Note
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 163.

© Copyright 2006-2008 ABB. All rights reserved.

150 3HAC027400-001 Revision: C

 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 The contents are defined in section
Standard toolkit on page 182, in part 2 of
the Product manual.
Arm 3HAC 9037-1 For adjusting the gear play, motor/pinion
Measurement dial with Accuracy 0,01 mm
magnetic base
Power supply 24 VDC, max. 1,5 A
For releasing the brakes
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the
step-by-step instructions
below.

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
© Copyright 2006-2008 ABB. All rights reserved.

result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Continues on next page

3HAC027400-001 Revision: C 151
4 Repair
4.6.6.1. Measuring the gear play, axis 5

Continued

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

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

xx0200000457

3. Remove the load and read

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

xx0200000458

© Copyright 2006-2008 ABB. All rights reserved.

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

152 3HAC027400-001 Revision: C

 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 The contents are defined in section
Standard toolkit on page 182, in part 2 of
the Product manual.
Arm 3HAC 9037-1 For adjusting the gear play, motor/pinion
Measurement dial with Accuracy 0,01 mm
magnetic base
Power supply 24 VDC, max. 1,5 A
For releasing the brakes
Other tools and These procedures include references to
procedures may be the tools required.
required. See references
to these procedures in the
step-by-step instructions
below.

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
© Copyright 2006-2008 ABB. All rights reserved.

• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Continues on next page

3HAC027400-001 Revision: C 153
4 Repair
4.6.6.2. Measuring the gear play, axis 6

Continued

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

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

xx0200000460

3. Remove the load and read

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

xx0200000461

5. Remove the load and read

Value 2.
6. Calculate the gear play value. Gear play value = value 1 - value 2 © Copyright 2006-2008 ABB. All rights reserved.
7. Determine whether or not the OK < 0.30 mm (10.3 arc minutes)
value is OK.

154 3HAC027400-001 Revision: C

 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 section Spare part
lists and exploded views on page 189, in part 2 of the product manual

xx0200000422

A Gearbox unit, axes 1-2

Required equipment

Equipment Spare part no. Art. no. Note

© Copyright 2006-2008 ABB. All rights reserved.

Gearbox, ax. 1-2 3HAC 10467-1 Standard and Foundry versions

spare, Std/F Includes:
• gearbox 3HAC 6603-1
• all required lubricant
• all o-rings and sealing
rings.
Gearbox, ax. 1-2 3HAC 10467-3 Clean room version
spare, CR Includes:
• gearbox 3HAC 6603-1
• all required lubricant
• all o-rings and sealing
rings.
Damper, axis 1 3HAC 7527-1
Isopropanol - For cleaning the mating
surfaces before fitting.
Flange sealing 1234 0011-116 2 ml

Continues on next page

3HAC027400-001 Revision: C 155
4 Repair
4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1

Continued

Equipment Spare part no. Art. no. Note

Locking liquid - Loctite 574
Sealing ring 3HAC 6965-1 Replace only when damaged!
Lifting slings -
Standard toolkit The contents are defined in
section Standard toolkit on page
182, in part 2 of the Product
manual.
Other tools and These procedures include
procedures may be references to the tools required.
required. See
references to these
procedures in the
step-by-step
instructions below.

Illustration, base

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000423

A Base
B Bottom plate
C Attachment screws, bottom plate (26 pcs)
D Attachment screws, gearbox/base (20 pcs)
E Joint, gearbox/base
F Damper, axis 1
G Washer, gearbox/base

Continues on next page

156 3HAC027400-001 Revision: C
 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, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the motor, axis 1. Detailed in section Replacement of
motor, axis 1 on page 129.
3. Remove the motor, axis 2. Detailed in section Replacement of
motor, axis 2 on page 133.
4. Remove the cable harness. Detailed in section Replacement of
cable harness on page 74.
5. Remove the serial measurement board. Detailed in section Replacement of
serial measurement unit and
battery pack on page
120Replacement of serial
measurement unit and battery pack
on page 120.
6. Remove the upper arm. Detailed in section Replacement of
complete upper arm on page 82.
7. Remove the lower arm. Detailed in section Replacement of
complete lower arm on page 88.
8. Drain the oil from gearbox, axis 1.
9. Unfasten the base from the installation site by
removing the attachment bolts from the
foundation.
10.
© Copyright 2006-2008 ABB. All rights reserved.

CAUTION!
The gearbox unit weighs 39 kg! All lifting
equipment used must be sized accordingly!
11. Fit the lifting slings to the base/gearbox unit and
place it with the lower arm side downwards, on top
of a suitable workbench.
12. Remove the bottom plate by unscrewing its 26 Shown in the figure Illustration,
attachment screws. base on page 156.
13. Secure the weight of the base with lifting slings.
14. Remove the gearbox/base attachment screws Shown in the figure Illustration,
and washer. base on page 156.
15. Separate the base from the gearbox unit.

Continues on next page

3HAC027400-001 Revision: C 157
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
1. Open the base of the robot. Detailed in section Removal, gearbox unit
axes 1-2 on page 157.
2. Remove the damper, axis 1.

Refitting of damper, axis 1

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

Action Note
1. Fit the damper, axis 1. Shown in the figure Refitting, gearbox unit
axes 1-2 on page 158.
2. Proceed with assembling the robot. Detailed in section Refitting, gearbox unit
axes 1-2 on page 158.

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, hydraulic and
pneumatic pressure supplies to the robot!
2.

CAUTION!

© Copyright 2006-2008 ABB. All rights reserved.

The gearbox unit weighs 39 kg! All lifting
equipment used must be sized accordingly!
3. Place the gearbox unit with the lower arm
side downwards on a suitable workbench.
4. Clean the mating surfaces of the base and
of the gearbox unit with isopropanol.
5. Fit a small amount of Loctite 574 on the Shown in the figure Illustration, base on
mating surface in the gearbox unit. page 156.
6. Fit the base to the gearbox unit and secure Shown in the figure Illustration, base on
it with the attachment screws and the page 156.
washer. 20 pcs, tightening torque: 35 Nm ± 3 Nm.
7. Refit the bottom plate and secure it with its Shown in the figure Location of gearbox
attachment screws. unit, axes 1-2 on page 155.
8. Fit the lifting slings to the base/gearbox unit,
turn it right side up and move it to the
installation site.

Continues on next page

158 3HAC027400-001 Revision: C
 4 Repair
4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1

Continued

Action Note
9. Secure the base to the foundation Attachment bolts and the tightening
torque are specified in section
Attachment screws on page 46
10. Refit the lower arm. Detailed in section Refitting of complete
lower arm.
11. Refit the upper arm. Detailed in section Refitting of complete
upper arm.
12. Refit the serial measurement board. Detailed in section Replacement of serial
measurement unit and battery pack on
page 120.
13. Refit the cable harness. Detailed in section Refitting of cable
harness.
14. Refit the motors, axes 1 and 2. Detailed in sections:
• Refitting of motor 1
• Refitting, motor axis 2 on page
135.
15. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 184.
16. Fill the two gearboxes with oil. Type of oil and amount is specified in
section Type and amount of oil in
gearboxes on page 161.
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 163.
18.

DANGER!
Make sure all safety requirements are met
© Copyright 2006-2008 ABB. All rights reserved.

when performing the first test run. These are

further detailed in section DANGER - First
test run may cause injury or damage! on
page 32.

3HAC027400-001 Revision: C 159

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 82.

© Copyright 2006-2008 ABB. All rights reserved.

160 3HAC027400-001 Revision: C

 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

Gearbox Type of oil Art. no. Amount

Axis 1 Mobilgear 600 XP320 11712016-604 1200 ml
Axis 2 Mobilgear 600 XP320 11712016-604 1000 ml
Axis 3 Mobilgear 600 XP320 11712016-604 400 ml
Axis 4 Mobilgear 600 XP320 11712016-604 200 ml
Axis 5-6 Optimol BM 100 3HAC 0860-1 Total amount: 350 ml
(new wrist)
Amount at oil change: 300 ml
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 161

4 Repair
4.7.3. Amount of oil

© Copyright 2006-2008 ABB. All rights reserved.

162 3HAC027400-001 Revision: C

 5 Calibration information
5.1. Introduction

5 Calibration information
5.1. Introduction

General
This chapter includes general information about different calibration methods and also details
procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.

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

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 164, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.

Contents of the revolution counter memory are lost

If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 168. This will occur when:
• the battery is discharged
• a resolver error occurs
• the signal between a resolver and measurement board is interrupted
• a robot axis is moved with the control system disconnected
© Copyright 2006-2008 ABB. All rights reserved.

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

The robot is rebuilt

If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Abslolute 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 from ABB.

Types of calibration

Type of
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, i.e. the axes positions (angles) are (standard method)
set to 0º. or
Standard calibration data is found in the file Levelmeter calibration
calib.cfg, supplied with the robot at delivery. (alternative method)
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Absolute Accuracy Based on standard calibration, and besides CalibWare
calibration positioning the robot at home position, the
(optional) Absolute Accuracy calibration also
compensates for:
• mechanical tolerances in the robot
structure
• deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies © Copyright 2006-2008 ABB. All rights reserved.
motor positions as well as
absacc-compensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy
performance, the robot must be recalibrated
for Absolute Accuracy!

xx0400001197

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164 3HAC027400-001 Revision: C
 5 Calibration information
5.2. Calibration methods

Continued

Calibration methods
Each calibration method is detailed in a separate manual. Below is a brief description of the
methods available.

Calibration Pendulum - standard method

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
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 for 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 for Levelmeter Calibration is ordered as separate parts for each
robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter
2000.

CalibWare - Absloute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the application manual
© Copyright 2006-2008 ABB. All rights reserved.

Absolute Accuracy CalibWare 2.0.

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.

References
Article numbers for the calibration tools are listed in section Special tools on page 183 in part
2 of the Product manual.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including Operating manual - Calibration Pendulum, which describes the method and the
different routines further.

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5 Calibration information
5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position

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

Calibration scales, IRB 140

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

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000157

166 3HAC027400-001 Revision: C

 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 etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.

Calibration movement directions, 6 axes

Note! The figure shows an IRB 7600, but 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!
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000089

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5 Calibration information
5.5. Updating revolution counters

5.5. Updating revolution counters

General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.

Action Note
1. Select axis-by-axis motion mode.
2. Jog the robot to place the calibration marks Shown in section Calibration scales and
within the tolerance zone. correct axis position on page 166.
IRB 140, 1400, 2400, 4400, 6600ID/
6650ID: Axes 5 and 6 must be positioned
together!
3. When all axes are positioned, store the Detailed in section:
revolution counter settings. Step 2 - Storing the revolution counter
setting with the FlexPendant on page 169
(RobotWare 5.0).

Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be
calibrated at the wrong turn, resulting in wrong calibrated robot.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before

© Copyright 2006-2008 ABB. All rights reserved.

the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the correct calibration position will be lost due to
uneven gear ratio. This affects the following robots:

Robot variant Axis 4 Axis 6

IRB 140 Yes Yes

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).

Continues on next page

168 3HAC027400-001 Revision: C
 5 Calibration information
5.5. Updating revolution counters

Continued

Step 2 - Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).

Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.

en0400000771

3. Tap Update Revolution Counters....

© Copyright 2006-2008 ABB. All rights reserved.

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
5. A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.

Continues on next page

3HAC027400-001 Revision: C 169
5 Calibration information
5.5. Updating revolution counters

Continued

Action
6.

CAUTION!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 171.

© Copyright 2006-2008 ABB. All rights reserved.

170 3HAC027400-001 Revision: C

 5 Calibration information
5.6. Checking the calibration position

5.6. Checking the calibration position

General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the teach pendant.

Using a MoveAbsJ instruction on the FlexPendant, IRC5

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

Action Note
1. On ABB menu tap Program Editor.
2. Create a new program.
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,
9E9]]\NoEOffs, v1000, z50, Tool0
5. Run the program in manual mode.
6. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution section Calibration scales and
counters! correct axis position on page 166.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 168.

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.
© Copyright 2006-2008 ABB. All rights reserved.

Action Note
1. Tap Jogging in the ABB menu.
2. Tap Motion mode to choose group of axes to jog.
3. Tap axes 1-3 to jog axes 1, 2 or 3.
4. Manually run the robots axes to a position where
the axis position value read on the FlexPendant, is
equal to zero.
5. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution section Calibration scales and
counters! correct axis position on page 166.
How to update the counters is
detailed in section Updating
revolution counters on page 168.

3HAC027400-001 Revision: C 171

5 Calibration information
5.6. Checking the calibration position

© Copyright 2006-2008 ABB. All rights reserved.

172 3HAC027400-001 Revision: C

 6 Robot description
6.1. Type C of IRB 140

6 Robot description
6.1. Type C of IRB 140

Type C- new upper arm and wrist

Type C of IRB 140 have 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 sealingplate

How to know which type the robot is?

The identification plate on the cabinet and the lower arm of the robot tells if the robot has a
new upper arm and wrist or not.
Those robots with a new upper arm and wrist are named IRB 140, type C.
Those robots which are not equipped with a new upper arm and wrist are simply named IRB
140 (no type specified).

Which parts are interchangeable and which are not?

The following parts are interchangeable
• The upper arm, complete with spare part no. 3HAC026567-001 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 sealingplate with spare part no. 3HAC025420-001 is not interchangeable
with spare part no. 3HAC 7191-1.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 173

6 Robot description
6.1. Type C of IRB 140

© Copyright 2006-2008 ABB. All rights reserved.

174 3HAC027400-001 Revision: C

 7 Reference information
7.1. Introduction

7 Reference information
7.1. Introduction

General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 175

7 Reference information
7.2. Unit conversion

7.2. Unit conversion

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

Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal

© Copyright 2006-2008 ABB. All rights reserved.

176 3HAC027400-001 Revision: C

 7 Reference information
7.3. Screw joints

7.3. Screw joints

General
This section details how to tighten the various types of screw joints on the robot.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.

UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!

Gleitmo treated screws

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

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
© Copyright 2006-2008 ABB. All rights reserved.

of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or

smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

Continues on next page

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7 Reference information
7.3. Screw joints

Continued

Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatical 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%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.

Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0

The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.

Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, Class 10.9, Class 12.9,
oil-lubricated oil-lubricated oil-lubricated
© Copyright 2006-2008 ABB. All rights reserved.
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340

The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.

Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34
M10 55 66
M12 96 115
M16 235 280
Continues on next page
178 3HAC027400-001 Revision: C
 7 Reference information
7.3. Screw joints

Continued

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

Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90
© Copyright 2006-2008 ABB. All rights reserved.

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7 Reference information
7.4. Weight specifications

7.4. 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 high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.

Example
Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

CAUTION!
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!

© Copyright 2006-2008 ABB. All rights reserved.

180 3HAC027400-001 Revision: C

 7 Reference information
7.5. Document references

7.5. Document references

General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.

Product specification, robot

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

Document name Document ID

Product specification 3HAC9041-1 (M2000, M2004)

Product manuals, controller

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

Document name Document ID

Product manual, IRC5 M2004 3HAC021313-001

Operating manual
The operating manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operating manuals for different robot systems.

Document name Document ID

Operating manual - IRC5 with FlexPendant 3HAC16590-1

Calibration manuals
© Copyright 2006-2008 ABB. All rights reserved.

Document name Document ID Note

Operating manual - Calibration 3HAC16578-1 Enclosed with the Calibration
Pendulum Pendulum tool set

Additional documentation

Document name Document ID Note

Operating manual - Service 3HAC025709-001 Details the Service Information System
Information System IRC5 of the robot systems M2004.
Application manual - 3HAC021395-001 IRC5 based robot systems.
Additional axes and stand
alone controller

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7 Reference information
7.6. Standard toolkit

7.6. Standard toolkit

General
All service (repairs, maintenance and installation) procedures contain 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 table below.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.

Contents, standard toolkit

Qty Tool
1 Ring-open-end spanner 8-19 mm
1 Socket head cap 2.5-17 mm
1 Torx socket no: 20-60
1 Torque wrench 10-100 Nm
1 Small screwdriver
1 Plastic mallet
1 Ratchet head for torque wrench 1/2
1 Socket head cap no: 5, socket 1/2" bit L 20 mm
1 Socket head cap no: 6, socket 1/2" bit L 20 mm
1 Socket head cap no: 8, socket 1/2" bit L 20 mm
1 Small cutting plier

© Copyright 2006-2008 ABB. All rights reserved.

182 3HAC027400-001 Revision: C

 7 Reference information
7.7. Special tools

7.7. 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 section Standard toolkit on page 182,
and of special tools, listed directly in the instructions and also gathered in this section.

Calibration equipment, Levelmeter (alternative method)

The table below specifies the calibration equipment required when calibrating the robot with
the alternative method, Levelmeter Calibration.

Description Art. no. Note

Angel bracket 68080011-LP
Calibration bracket 3HAC 13908-9
Calibration tool ax1 3HAC 13908-4
Levelmeter 2000 kit 6369901-347 Includes one sensor.
Measuring pin 3HAC 13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC 0392-1
Sync. adapter 3HAC 13908-1
Turn disk fixture 3HAC 68080011-GU

Calibration equipment, Calibration Pendulum

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

Description Art. no. Note

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes
operating manual.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 183

7 Reference information
7.8. Performing a leak-down test

7.8. Performing a leak-down test

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

Required equipment

Equipment, etc. Art. no.

Leakdown tester 3HAC 0207-1
Leak detection spray -

Procedure

Action Note
1. Finish the refitting procedure of the motor or
gear in question.
2. Remove the topmost oil plug on the gear in Art. no. is specified above!
question, and replace it with the leakdown
tester.
Adapters may be required, which are
included in the leakdown tester kit.
3. Apply compressed air, and raise the Recommended value:
pressure with the knob until the correct 0.2 - 0.25 bar (20 - 25 kPa)
value is shown on the manometer.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure If the compressed air is significantly colder
loss must be detected. or warmer than the gearbox to be tested, a
slight pressure increase or decrease
respectively may occur. This is quite
normal.
6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil © Copyright 2006-2008 ABB. All rights reserved.
plug.
The test is complete.
7. Spray suspected leak areas with leak
detection spray.
Bubbles indicate a leak.
8. When the leak has been localized: take the
necessary measures to correct the leak.

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 7 Reference information
7.9. Lifting equipment and lifting instructions

7.9. Lifting equipment and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 185

7 Reference information
7.10. Mounting instructions for bearings

7.10. Mounting instructions for bearings

General
This section details how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc. Art. no. Note

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

Assembly of all bearings

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

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered
bearing on the robot.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
Note! The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the © Copyright 2006-2008 ABB. All rights reserved.
bearing.

Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
• The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available volume.
• Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the split
condition.

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 7 Reference information
7.11. Mounting instructions for seals

7.11. Mounting instructions for seals

General
This sections details how to mount different types of seals to the robot.

Equipment

Equipment, etc. Art. no. Note

Grease 3HAB 3537-1 Used to lubricate the seals.

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

Action Note
1. Check the seal to ensure that:
• the seal is of the correct type (provided with cutting
edge).
• there is no damage to the sealing edge (feel with a
fingernail).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced, as it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
© Copyright 2006-2008 ABB. All rights reserved.

early as there is a risk of dirt and foreign particles adhering Equipment on page 187.
to the seal.)
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.

Continues on next page

3HAC027400-001 Revision: C 187
7 Reference information
7.11. Mounting instructions for seals

Continued

Flange seals and static seals

The procedure below details 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.
2. Clean the surfaces properly and in accordance with ABB recommendations.
3. Distribute the sealing compound evenly over the surface, preferably with a brush.
4. Tighten the screws evenly when fastening the flange joint.

O-rings
The procedure below details how to fit o-rings.

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

© Copyright 2006-2008 ABB. All rights reserved.

188 3HAC027400-001 Revision: C

 8 Spare part lists and exploded views
8.1. Introduction

8 Spare part lists and exploded views

8.1. Introduction

Definitions
This chapter specifies all spare parts and replacement articles of the robot.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 189

8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

8.2. 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 194 to Robot IRB 140, exploded view 5 of 5 on page 198.

Item Qty Art. no. Name Rem.

1 1 3HAC 10470-1 Base spare
2 1 3HAC 8999-1 Bottom plate
3 26 9ADA 629-44 Torx pan head roll. screw M5x12
4 1 3HAC 6599-1 Gasket bottom plate
5 1 3HAC 9522-1 Serial meas. board ass.
6 1 4944 026-4 Battery pack 7.2V 4Ah NiCd
7 2 2166 2055-6 Cable straps, outdoors 7.6x368
8 28 9ADA 618-46 Torx pan head screw M5x20
9 1 3HAC 9030-1 Cable bracket
10 1 3HAC 9415-1 Clamp
11 1 3HAC 6755-1 Cable holder
12 4 9ADA 618-50 Torx pan head screw M5x40
13 1 3HAC 10476-1 Control cable spare Std/F L=3m
14 1 3HAC 10477-1 Control cable spare Std/F L=7m
15 1 3HAC 7527-1 Damper axis 1
16 20 3HAB 3402-52 Hex. socket head cap screw M10x35 8.8
Gleitmo 610
17 2 3HAC 7950-1 Washer
18 2 3HAC 9860-1 Protecting plate
19 1 3HAC 8466-1 Protective earth cable
20 2 3HAC 9063-1 Hose clip D = 10
21 1 SK 615 503-2 Membrane

© Copyright 2006-2008 ABB. All rights reserved.

22 1 SK 616 013-F Bracket CBK
23 1 1SFA Actuator black
616100R1006
24 1 3HAC 7870-1 Gasket base-cover
25 10 9ADA 290-1 Hexagon nut with flange M5
26 1 2529 1920-2 Plug R 1/8"
27 2 2522 2101-8 Protective hood D=11.4-13
28 1 3HAC 8806-1 Clamp
29 1 3HAC 7370-1 Cable harness IRB 140
30 1 3HAC 2589-1 Instruction plate Battery
replacement
31 10 2166 2055-3 Cable straps, outdoors 4.8x208
32 20 ml 1234 0011-116 Flange sealing Lotctite 574
33 1 3HAC 10470-3 Base, spare CR
34 1 3HAC 10476-4 Control cable spare CR L=3m
35 1 3HAC 10477-2 Control cable spare CR L=7m

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190 3HAC027400-001 Revision: C
 8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Item Qty Art. no. Name Rem.

36 1 3HAC 11331-1 Control cable spare Std/F L = 15 m
37 1 3HAC 11331-2 Control cable spare CR L = 15 m
38 1 3HAC 13089-1 Control cable spare Std/F L = 30 m
39 1 3HAC 13090-1 Control cable spare Std/F L = 22 m
50 1 3HAC 10467-1 Gearbox axes 1-2, spare Std/F Item 67 incl.
51 2 3HAC 10469-1 / Motor with pinion spare Std/F
3HAC 021965-001
51 2 3HAC021966-001 Motor with pinion spare
Cleanroom
52 24 3HAB 3409-25 Hex socket head cap screw M6x20 12.9
Gleitmo 610
53 18 9ADA 312-6 Plain washer 6.4x12x1.6
54 2 2152 2012-426 O-ring 74.5x3
55 1 3HAC 6788-1 Bearing hub
56 1 3HAC 10478-1 Console spare Std/F
57 1 3HAC 10472-1 Cover console spare Std/F Item 58 incl.
58 1 3HAC 7868-1 Gasket console-cover
59 1 3HAC 5894-1 Cable bracket T=1.5
60 1 3HAC 6965-1 Sealing ring 150x189x8.5
61 3 3HAC 3785-6 Parallel pin D = 6 m6 L = 16
62 2 3HAB 3732-19 Sealing ring (V-ring) 85x11
63 11 9ADA 618-55 Torx pan head screw M6x12
64 2 2166 2018-2 Clamp D = 11
65 1 3HAC 10481-1 Connector bracket
66 25 2166 2055-1 Cable straps, outdoors 2.5x101
67 3000 1171 2016-604 Lubricating oil
ml
68 1 3HAC 10467-3 Gearbox axes 1-2, spare CR
© Copyright 2006-2008 ABB. All rights reserved.

69 2 3HAC 10469-3 / Motor with pinion, spare CR

3HAC 021966-001
70 1 3HAC 10478-3 Console, spare CR
71 1 3HAC 10472-3 Cover console, spare CR
72 1 3HAC 10645-1 Clamp D = 4.7
100 1 3HAC 10468-1 Lower arm (axis 3), spare Item 67, 107
and 108 incl.
101 1 3HAC 10471-1 Cover, without lamp unit Item 103 incl.
102 1 3HAC 10474-1 Cover, with lamp unit Item 103 incl.
103 1 3HAC 7869-1 Gasket lower-arm cover
104 1 3HAC 7866-1 / Rot. ac motor incl. pinion
3HAC 021756-001
105 1 3HAC 6793-1 Timing belt
106 1 3HAC 6762-1 Belt shield
107 1 3HAB 3643-17 Groove ball bearing 80x100x10
108 2 3HAA 2166-13 VK-Cover D = 100 B = 10

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3HAC027400-001 Revision: C 191
8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Item Qty Art. no. Name Rem.

109 1 3HAC 7880-1 Damper axis 2
110 1 3HAA 2356-14 Washer SRKB 6.4x18x1.6
111 4 3HAB 3402-15 Hex. socket head cap screw M5x20 8.8
Gleitmo 610
112 12 9ADA 312-5 Plain washer 5.3x10x1
113 1 3HAC 9258-1 Indicator lamp
114 1 3HAC 10468-4 Lower arm, spare CR
115 1 3HAC 10471-3 Cover, without lamp unit
116 1 3HAC 10474-3 Cover, with lamp unit
150 1 3HAC 026581-001 Upper arm compl. with wrist Motors incl
151 1 3HAC 026569-001 Wrist, spare Std/F Item 155, 181
and 182 incl.
152 1 3HAC 025420-001 O-ring sealing plate
153 3 3HAB 3409-37 Hex. socket head cap screw M8x25 12.9
Gleitmo 610
154 3 9ADA 312-7 Plain washer 8.4x16x1.6
155 3 2529 1920-2 Plug R 1/8"
157 6 3HAB 3409-39 Hex. socket head cap screw M8x35 12.9
Gleitmo 610
158 6 9ADA 334-7 Spring washer, conical 8.4x18x2
159 1 3HAB 3732-13 Sealing ring (V-ring) 99x10.5
160 1 3HAC 7842-1 / Rot. ac motor with pinion
3HAC 021758-001
161 1 3HAB 3772-24 O-ring 29x3
162 2 3HAC 021757-001 Rot. ac motor with pinion
163 4 3HAB 3402-18 Hex. socket head cap screw M5x35 8.8
Gleitmo 610
164 1 3HAC 024360-001 Motor Console axes 5-6
166 3 3HAA 2356-15 Washer SRKB 5.3x15x1.2
167 1 3HAC 7367-1 Cable holder © Copyright 2006-2008 ABB. All rights reserved.
168 1 3HAC 8572-1 Clamp
169 2 3HAC 6779-1 Timing belt
170 1 3HAC 025596-001 Timing Belt Pulley Z2/5
171 1 3HAC 025601-001 Timing Belt Pulley Z2/6
173 1 3HAC 7391-1 Belt shield
174 1 3HAC 10473-1 Cover armhousing spare Item 175 incl.
175 1 3HAC 7867-1 Gasket upper arm cover
176 1 3HAC 7881-1 Damper axis 3
177 1 3HAC 6761-1 Cable guide
178 1 3HAC 7561-3 Dustcap for receptacles 12p
179 2 2125 2052-178 Distance bolt M5X55
180 1 3HAC 6598-1 Hose nipple G 1/4"
181 1 3HAB 8964-1 Damper axis 5

Continues on next page

192 3HAC027400-001 Revision: C
 8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Item Qty Art. no. Name Rem.

182 550 ml 3HAC 0860-1 Lubricating oil Optimol
Optigear BM
100
183 1 3HAC 026581-003 Upper arm, spare CR
184 1 3HAC 026569-003
186 1 3HAC 10439-3 Cover armhousing, spare CR
187 1 3HAC 11922-1 Slip strip
© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

3HAC027400-001 Revision: C 193
8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Robot IRB 140, exploded view 1 of 5

© Copyright 2006-2008 ABB. All rights reserved.

xx0600003264

Continues on next page

194 3HAC027400-001 Revision: C
 8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Robot IRB 140, exploded view 2 of 5

© Copyright 2006-2008 ABB. All rights reserved.

xx0600003265

Continues on next page

3HAC027400-001 Revision: C 195
8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Robot IRB 140, exploded view 3 of 5

© Copyright 2006-2008 ABB. All rights reserved.

xx0600003266

Continues on next page

196 3HAC027400-001 Revision: C
 8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Robot IRB 140, exploded view 4 of 5

© Copyright 2006-2008 ABB. All rights reserved.

xx0600003267

Continues on next page

3HAC027400-001 Revision: C 197
8 Spare part lists and exploded views
8.2. Spare parts - robot IRB 140

Continued

Robot IRB 140, exploded view 5 of 5

© Copyright 2006-2008 ABB. All rights reserved.

xx0600003268

198 3HAC027400-001 Revision: C

 9 Circuit diagram
9.1. Introduction

9 Circuit diagram
9.1. Introduction

Overview
This chapter includes the circuit diagram for the robot.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC027400-001 Revision: C 199

9 Circuit diagram
9.1. Introduction

© Copyright 2006-2008 ABB. All rights reserved.

200 3HAC027400-001 Revision: C

 Circuit Diagram
CONTENTS
Page

Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............................................................101-108

IRB 140
Manipulator Circuit Diagram 3HAC 6816-3

LIST OF CONTENTS

IRB 140 No. of Sheets 8 Sheet no. 101

Manipulator Circuit Diagram 3HAC 6816-3

CONNECTION POINT LOCATIONS

IRB 140 No. of Sheets 8 Sheet no. 102

Manipulator Circuit Diagram 3HAC 6816-3

SERIAL MEASUREMENT BOARD

IRB 140 No. of Sheets 8 Sheet no. 103

Manipulator Circuit Diagram 3HAC 6816-3

MOTOR AXIS 1 - 3

IRB 140 No. of Sheets 8 Sheet no. 104

Manipulator Circuit Diagram 3HAC 6816-3

FEEDBACK AXIS 1 - 3

IRB 140 No. of Sheets 8 Sheet no. 105

Manipulator Circuit Diagram 3HAC 6816-3

MOTOR AXIS 4 - 6

IRB 140 No. of Sheets 8 Sheet no. 106

Manipulator Circuit Diagram 3HAC 6816-3

FEED-BACK AXIS 4 - 6

IRB 140 No. of Sheets 8 Sheet no. 107

Manipulator Circuit Diagram 3HAC 6816-3

CUSTOMER CONNECTIONS

IRB 140 No. of Sheets 8 Sheet no. 108

 Index

A documentation
Absolute Accuracy, calibration 165 article numbers, other manuals 181
calibration 181
B controller 181
base robot system 181
brake release buttons 43 E
replacing 92
screws, tightening torque 94 ESD
spare part number 92 damage elimination 33
brake release unit sensitive equipment 33
releasing the brakes 43 wrist strap connection point 33
brakes explanation, safety symbols 29
testing function 24 F
brakes, releasing
figures
external power supply to connector R1.MP 44
brake release buttons 43
manually 43
power supply to connector R1.MP 44
power supply to motor axis 2 134
FlexPendant
power supply to motor axis 4 143
jogging to calibration position 171
C MoveAbsJ instruction 171
calibrating updating revolution counters 169
roughly 168 frame
calibration replacing 155
Absolute Accuracy type 164 spare part number 155
alternative method 165 G
Levelmeter calibration 165
gearbox, axes 1-2
marks/scales 166
replacing 155
rough 168
spare part number 155
standard type 164
gearboxes, axes 5 and 6
when to calibrate 163
amount and type of oil 69
calibration manual, article number 181
oil change 69
calibration manuals 165
Gravity Beta 51
calibration position 168
checking 171 I
jogging to, FlexPendant 171 illustrations
scales 166 brake release buttons 43
calibration, Absolute Accuracy 165 power supply to connector R1.MP 44
CalibWare 164 inspection 62
cleaning, robot 68 inverted mounting 51
© Copyright 2006-2008 ABB. All rights reserved.

Connection of external safety devices 14

cracks, damper 63 L
Levelmeter calibration 165
D
damage, damper 63 M
damper, axis 2 62 motor axis 2
attachment screw 109 brake release with power supply 134
replacing 108 replacing 133
spare part number 108 spare part number 133
damper, axis 3 tightening torque 136
inspection 62 motor axis 4
replacing 99 brake release with power supply 143
spare part number 99 replace 142
damper, axis 5 screws, tightening torque 144
inspection 62 spare part number 142
replacing 101 MoveAbsJ instruction
spare part number 101 FlexPendant 171
direction of axes 167
N
negative directions, axes 167

3HAC027400-001 Revision: C 201

Index

O V
oil change Validity and responsibility 14
gearbox axes 5 and 6 69 VK-covers, spare part number
safety risks 34 at base 92
wrist unit 69
W
operators manual, article number 181
wall mounting 51
P weight
position, robot 166 gearbox unit 157, 158
when draining wrist unit 70 wrist unit
when filling oil in wrist unit 71 amount and type of oil 69
positive directions, axes 167 oil change 69
product manual, controller, article number 181 replacing 96
product specification, article number 181 screws, tightening torque 98
push button unit spare part number 96
releasing the brakes 43
R
releasing brakes
external power supply to connector R1.MP 44
manually 43
revolution counters
storing on FlexPendant 169
updating 168
robot
cleaning 68
robot position 166
when draining wrist unit 70
when filling oil in wrist unit 71
S
Safety, service 14
safety, symbols 29
scales on robot 166
special tools 183
suspended mounting 51
symbols, safety 29
sync marks 166
system parameter

© Copyright 2006-2008 ABB. All rights reserved.

Gravity Beta 51
T
testing, brakes 24
tightening torques, attachment screws
base-gearbox unit 94
motor axis 2 136
motor axis 4 144
wrist unit 98
tilted mounting 51
tools
calibration equipment, Levelmeter 183
Calibration Pendulum equipment 183
for service 183
rotational tool, article number 142
U
updating revolution counters 168

202 3HAC027400-001 Revision: C

 3HAC 027400-001, Revision C, en

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