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

Product manual (part 1 of 2), procedures
Articulated robot
IRB 140
M2000, M2000A, M2004

Product manual (part 1 of 2), procedures

IRB 140
M2000
M2000A
M2004
Document ID: 3HAC 023297-001
Revision: -
The information in this manual is subject to change without notice and

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

ABB Automation Technologies AB
Robotics
SE-721 68 Vsters
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Safety
13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4.3 Emergency release of the robots arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Installation and commissioning
41
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.2.2 Working range, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2.3 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3.4 Restricting the working space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3.5 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3.7 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.8 Bolt pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4.1 Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3HAC 023297-001 Revision: -
Table of Contents
3 Maintenance
63
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2.1 Maintenance schedule, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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

3.3.2 Inspection, robot cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3.3 Inspection, timing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.5 Changing/ replacing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.5.1 Oil change, gearbox, axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4 Repair
77
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.4 Replacement of base, spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
85
91
95
4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3.4 Replacement of cover, arm housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4.1 Replacement of lower arm cover and gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.4.3 Replacement of indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5.1 Replacement of cover, console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4.5.2 Replacement of console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.5.3 Replacement of serial measurement unit and battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5.4 Replacement of control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.6.5 Replacement of motor and timing belt, axes 5 or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.6.6 Adjustments and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.6.6.1 Measuring the gear play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.6.6.2 Measuring the gear play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

4.7.2 Service work on gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5 Calibration information
163
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
163
164
166
167
Table of Contents
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Table of Contents
Overview
Overview
About this manual
This manual contains instructions for
mechanical and electrical installation of the robot
maintenance of the robot
mechanical and electrical repair of the robot.
Usage
This manual should be used during
installation, from lifting the robot to its work site and securing it to the foundation to
making it ready for operation
maintenance work
repair work and calibration.
Who should read this manual?

This manual is intended for:
installation personnel
maintenance personnel
repair personnel.
Prerequisites
The reader should...
be a trained maintenance/repair craftsman
have the required knowledge of mechanical and electrical installation/repair/

maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter
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
commissioning
Required information about lifting and installation of the robot.
Maintenance
Step-by-step procedures that describe how to perform

maintenance of the robot. Based on a maintenance schedule
that may be used in the work of planning periodical maintenance.
Repair
Step-by-step procedures that describe how to perform repair

activities of the robot. Based on available spare parts.
Calibration information
Procedures that does not require specific calibration equipment.

General information about calibration.
Decommissioning
Environmental information about the robot and its components.
Overview
Revisions
Revision
Description
First edition.
Replaces previous manuals:
Installation and commissioning manual
Maintenance manual
Repair manual, part 1
Repair manual, part 2
Changes made in the material from the previous manuals:
Model M2004 implemented.
Chapter Calibration replaced with chapter Calibration information.
Chapter Safety, service replaced with new safety chapter.
Information about the controller removed from the manual.
Additional spare part numbers for the motors.
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
Installation information
Repair information
Maintenance information
In addition, spare part information is supplied for the entire option.
Product documentation, M2004

General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
RAPID Overview: An overview of the RAPID programming language.
RAPID reference manual part 1: Description of all RAPID instructions.
RAPID reference manual part 2: Description of all RAPID functions and data types.
Technical reference manual - System parameters: Description of system

parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
10
The purpose of the application (what it does and when it is useful)
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
How to use the application
Examples of how to use the application
Operators manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
Operators manual - IRC5 with FlexPendant
Operators manual - RobotStudioOnline
Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)
11
How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material etc. The references are read as
described below.
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an procedure.
Step Action
Note/Illustration
8.
Shown in the figure Location of

gearbox on page xx.
Remove the rear attachment screws, gearbox.
References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in an procedure.
Step Action
Note/Illustration
3.
Art. no. is specified in Required

equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in chapter Safety on page 13.
12
1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 34.
13
1 Safety
1.2.1. Introduction
1.2 General safety information

1.2.1. Introduction
Definitions
This section details general safety information for service personnel i.e. personnel performing
installation, repair and maintenance work.
Sections
The general safety information is divided into the following sections:
1. General information contains lists of:
Safety, service
Limitation of liability
Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split
into different categories:
Safety risks during service work on robot
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
14
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
Signal lamp (optional)
1 Safety
1.2.2.1. Safety, service
1.2.2. General information

1.2.2.1. Safety, service
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. Users Guide and Product
Manual.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for
connecting safety devices between the robot and the peripheral equipment.
15
1 Safety
1.2.2.2. Limitation of Liability
1.2.2.2. Limitation of Liability

General
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
have been complied with.
16
1 Safety
1.2.2.3. Related information
1.2.2.3. Related information

General
The list below specifies documents which contain useful information:
Documents
Type of information
Detailed in document
Section
Installation of safety devices
Product manual for the

manipulator
Installation and commissioning
Changing robot modes
Users Guide
Start-up
Restricting the working space Product manual for the

manipulator
Installation and commissioning
17
1 Safety
1.2.3.1. Safety risks during service work on robot
1.2.3. Safety risks

Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.
18
1 Safety
Complete robot
Safety risk
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!
Caution!
Whenever parting/mating motor and gearbox, the gears

may be damaged if excessive force is used!
19
1 Safety
Balancing device
Safety risk
Description
Dangerous balancing device!
Warning!
Do not under any circumstances, deal with the balancing

device in any other way than that detailed in the product
documentation! For example, attempting to open the
balancing device is potentially lethal!
20
1 Safety
1.2.3.2. Safety risks related to gripper
1.2.3.2. Safety risks related to gripper

CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
21
1 Safety
1.2.3.3. Safety risks related to tools/workpieces
1.2.3.3. Safety risks related to tools/workpieces

Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
22
1 Safety
1.2.3.4. Safety risks related to pneumatic/hydraulic systems
1.2.3.4. Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safe design
23
1 Safety
1.2.3.5. Safety risks during operational disturbances
1.2.3.5. Safety risks during operational disturbances

General
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Care must be taken at all times.
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
Qualified personnel
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.
24
1 Safety
1.2.3.6. Safety risks during installation and service
1.2.3.6. Safety risks during installation and service

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

To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Non-voltage related risks
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
When dismantling/assembling mechanical units, watch out for falling objects.
Be aware of stored heat energy in the controller.
Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
25
1 Safety
1.2.3.7. Risks associated with live electric parts
1.2.3.7. Risks associated with live electric parts

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

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

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

Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.
26
1 Safety
1.2.4.1. Safety fence dimensions
1.2.4. Safety actions

1.2.4.1. Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
27
1 Safety
1.2.4.2. Fire extinguishing
1.2.4.2. Fire extinguishing

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

Description
In an emergency situation, any of the robots axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
Manually releasing the brakes on page 49.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
29
1 Safety
1.2.4.4. Brake testing
1.2.4.4. Brake testing

When to test
During operation the holding brakes of each axis motor wear normally. A test may be
performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator
arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
30
1 Safety
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!
Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant
Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
31
1 Safety
1.2.4.6. Safe use of the Teach Pendant Unit
1.2.4.6. Safe use of the Teach Pendant Unit

NOTE!
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
32
The enabling device must never be rendered inoperative in any way.
During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
The programmer must always bring the Teach Pendant Unit with him/her, when
entering the robot's working space. This is to prevent anyone else taking control over
the robot without the programmer knowing.
1 Safety
1.2.4.7. Work inside the manipulators working range
1.2.4.7. Work inside the manipulators working range

WARNING!
If work must be carried out within the robots work envelope, the following points must be
observed:
The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
The robots speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% full speed may only be used by trained personnel who are
aware of the risks that this entails.
Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
Test the motor brake on each axis, according to section Brake testing on page 30.
33
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions

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

hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol
Designation
Signification
DANGER
Warns that an accident will occur if the instructions

are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
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
crushing, impact, fall from height etc.
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol

indicates electrical hazards which could result in
severe personal injury or death.
CAUTION
Warns that an accident may occur if the instructions

are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
danger
warning
Electrical shock
caution
34
1 Safety
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates

DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE
Note symbols alert you to important facts and

conditions.
TIP
Tip symbols direct you to specific instructions, where

to find additional information or how to perform a
certain operation in an easier way.
Note
Tip
35
1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
1.3.2. DANGER - Moving manipulators are potentially lethal!

Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.
Elimination
Step
36
Action
Info/Illustration
1.
Before attempting to run the manipulator,

Emergency stop equipment such as
make sure all emergency stop equipment gates, tread mats, light curtains, etc.
has been correctly installed and connected.
2.
If possible, use the hold-to-run button

whenever possible.
The hold-to-run button is used in manual
mode, not in automatic mode.
3.
Make sure no personnel is present within

the manipulator working range before
pressing the start button.
How to use the hold-to-run control in

RobotWare 5.0 is detailed in section
How to use the hold-to-run switch in
the Operators Manual, IRC5.
How to use the hold-to-run control in
RobotWare 4.0 is detailed in section
The Teach Pendant unit in the Users
Guide.
1 Safety
1.3.3. WARNING - The unit is sensitive to ESD!
1.3.3. WARNING - The unit is sensitive to ESD!

Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not connected to ground potential may transfer
high static charges. This discharge may destroy sensitive electronics.
Elimination
Step
Action
Note/Illustration
1.
Use a wrist strap
Wrist straps must be tested frequently to

ensure that they are not damaged and are
operating correctly.
2.
Use an ESD protective floor mat.
The mat must be grounded through a currentlimiting resistor.
3.
Use a dissipative table mat.
The mat should provide a controlled discharge

of static voltages and must be grounded.
37
1 Safety
1.3.4. WARNING - Safety risks during work with gearbox oil

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

Make sure that protective gear
gearbox oil may require
like goggles and gloves are
handling hot oil of up to 90 C! always worn during this activity.
Hot oil!
When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
-
Possible pressure build

up in gearbox!
Do not overfill!
Overfilling of gearbox oil can

lead to internal over-pressure
inside the gearbox which in
turn may:
damage seals and
gaskets
completely press out
seals and gaskets
prevent the manipulator
from moving freely.
Make sure not to overfill the

gearbox when filling with oil!
After filling, check the correct oil
levels.
Mixing types of oil may cause

severe damage to the
gearbox!
When filling gearbox oil, do not

mix different types of oil unless
specified in the instruction.
Always use the type of oil
specified by the manufacturer!
Do not mix types of oil!
38
1 Safety
Warning
Description
Elimination / Action
Warm oil drains quicker than

cold oil.
When changing gearbox oil, first

run the robot for a time to heat
up the oil.
Heat up the oil!
Specified amount
depends on drained
volume!
The specified amount of oil is After refilling, check the oil level.
based on the total volume of
the gearbox. When changing
the oil, the amount of refilled oil
may differ from the specified
amount, depending on how
much oil has previously been
drained from the gearbox.
39
1 Safety
40

2.1. Introduction

2.1. Introduction
General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
41

2.2.1. Pre-installation procedure
2.2 Unpacking
General
This instruction is primarily intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Checking the pre-requisites for installation
The check-list below details what must be observed before proceeding with the actual
installation of the manipulator:
Step
Action
Info/Illustration
1.
Make sure only qualified installation

personnel conforming to all national and
local codes are allowed to perform the
installation.
2.
Make sure the manipulator has not been

damaged, by visually inspecting the
manipulator and control cabinet exterior.
3.
Make sure the lifting device to be used is

dimensioned to handle the weight of the
manipulator.
Specified in section Weight,

manipulator on page 42.
4.
If the manipulator is not to be installed

directly, it must be stored.
Specified in section Storage

conditions, manipulator on page 43.
5.
Make sure the appointed operating

Specified in section Operating
environment of the manipulator conforms to conditions, manipulator on page 43.
the specifications.
6.
Before taking the manipulator to its

Specified in section :
installation site, make sure the site conforms
Loads on foundation,
to applicable requirements.
manipulator on page 43
Requirements on foundation,
manipulator on page 43
Protection classes on page 44
7.
Before moving the manipulator, make sure it Described in section Risk of tipping/
does not tip over!
Stability on page 47.
8.
When these prerequisites have been met,

the manipulator may be taken to its
installation site.
Detailed in section Lifting manipulator

with lifting slings on page 48.
Weight, manipulator
The net weight of the manipulator is approximately: 100 kg.
42

Loads on foundation, manipulator

The table below shows the different forces and torques working on the manipulator during
different kinds of operation.
NOTE! These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum simultaneously!
Force
Endurance load
(operation)
Max. load (emergency

stop)
Force xy (upright/suspended)
1300 N
3200 N
Force z (upright)
-1000 1000 N
-1000 2000 N
Forze z (suspended)
-2800 1000 N
+1000 2000 N
Mxy
1300 Nm
220 Nm
Mz
300 Nm
750 Nm
Torque
Requirements on foundation, manipulator

Requirement
Value
Min. levelity
0.5 mm
Max. tilt
Min. resonance frequency
22 Hz
Storage conditions, manipulator

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

The table below shows the allowed operating conditions for manipulator:
Parameter
Value
Max. ambient temperature
+45 C
Min. ambient temperature
+5 C
Max. ambient humidity
Max. 95% at constant temperature
43

Protection classes
The table below shows the protection class of the main parts of the robot system:
44
Equipment
Protection class
Manipulator
IP 67
Control cabinet
IP 54
Programming unit
IP 54

2.2.2. Working range, IRB 140

Working range axis 2 -3
The illustration below shows the unrestricted working range axis 2-3.
xx0200000058
Pos
Position at wrist centre
Angle (degrees)
Axis 2
Axis 3
450
712
70
1092
-90
314
421
+50
765
99
+110
-90
255
-119
+110
+4
-480
23
-90
-150
596
-90
+50
218
558
+110
-230
-670
352
-90
-90
45

Working range axis 1

The illustrations below shows the unrestricted working range of axis 1.
xx0200000061
46

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

General
The section below details instructions for making sure the manipulator does not tip over when
it has not been safely secured to the foundation.
Procedure
The procedure below details how to make sure the manipulator does not tip during installation
while not secured to the foundation.
CAUTION!
When the manipulator is not fastened to the floor, it will not be stable in any part of its
working area.
1. DO NOT change the manipulator position before securing it to its foundation. The
shipping position is the most stable.
2. If the manipulator, for some reason, must be move from its original position, ensure that
the centre of gravity not is displaced.
47

2.3.1. Lifting manipulator with lifting slings
2.3 On-site installation

2.3.1. Lifting manipulator with lifting slings
General
This section details how to lift the manipulator using lifting slings.
Equipment
Note
Sling line
Length: 2 m. Load: 500 kg.
Illustration
The following figures shows how to lift the manipulator with lifting slings.
xx0200000084
Sling line for manipulator
Sling line for manipulator
Sling line for control cable
How to lift the manipulator

1. Adjust the manipulator to lifting position according to the picture.
2. Put one sling line around each leg on the lower arm (Pos. 1 and 2).
3. Use further one sling line to secure the lifting of the control cable (Pos. 3).
48

2.3.2. Manually releasing the brakes

General
The section below details how to release the holding brakes of each axis motor.
This may be done in one of three ways:
using the pushbutton when the manipulator is connected to the controller.
using the pushbutton on the manipulator with an external power supply.
using an external voltage supply.
DANGER!
When releasing the holding brakes, the manipulator axes may move very quickly and
sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Using the pushbutton when the manipulator is connected to the controller
This section details how to release the holding brakes using the internal brake release unit.
Step
1.
Action
Info/Illustration
Push the "brake release button" to release the

holding brakes.
xx0200000069
A: Pushbutton
49

Using the pushbutton on the manipulator with an external power supply

This section details how to release the holding brakes with the pushbutton using an external
voltage supply.
Step
1.
Action
Info/Illustration
Connect an external power supply to connector XP1.
xx0200000071
2.
A: B16 24V DC
B: B14 0V
Push the "brake release button" to release the

holding brakes.
NOTE!
Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can
be caused to a resistor diode and to the system board.
Using External power supply
This section details how to release the holding brakes using a external voltage supply. If the
positions of the manipulator axes are to be changed without connecting the controller, an
external voltage supply (24 V DC) must be connected to enable the brake release buttons on
the manipulator.
Step
1.
Action
Info/Illustration
Remove the screws and dismount the

cover on the back of the manipulator
base.
xx0200000072
50
A: 13 0 V
B: 15 24 V DC

Step
Action
2.
Locate the R1.MP4-6 connector and

disconnect.
3.
Connect an external power supply to

release the holding brake on all axis.
Info/Illustration
51

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

General
This section details how to orient and secure the manipulator to the foundation in order to
safely run the robot.
Bolting requirements
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined
in section Loads on foundation, manipulator on page 43.
NOTE!
When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must
be used to secure the bolted joint.
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
manipulator to the base plate/foundation.
Suitable screws, lightly lubricated:
M12
Quality
Quality 8.8
Suitable washer:
Thickness: 2.5 mm
Outer diameter: 24 mm
Inner diameter: 13.4 mm
Tightening torque:
85 Nm
Hole configuration and cross section

The bolt pattern requirements are shown in section Bolt pattern on page 59.
Guide sleeves
Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be
remounted without re-adjusting the program.
52
Equipment
Art. no.
Guide sleeves
3HAC 9519-1

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

General
When installing the manipulator, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space should be
limited.
WARNING!
The working space can only be limited using soft ware, for this reason the limited area can
not be classified as a safe zone. All work within this zone is prohibited.
Limiting devices
Limiting devices is listed below.
1. Light curtains.
2. Tread mats.
3. Other similar devices.
4. SoftWare.
Limiting the working space using software is described in the Users Guide chapter: System
Parameters.
53

2.3.5. Fitting equipment on manipulator

General
The manipulator features mounting holes for additional equipment.
In addition to the stock mounting holes, extra mounting holes may be added on the
manipulator under certain conditions. These special conditions are specified in the Product
Specification.
Illustration, holes on upper arm
The illustration below shows the stock holes available for fitting extra equipment on the upper
arm.
xx0200000062
54

Illustration, holes on mounting flange

The illustration below shows the stock holes available for fitting equipment on the mounting
flange.
xx0200000063
Fastener quality
When fitting tools on the mounting flange (see the figures in sections Illustration, holes on
upper arm on page 54 and Illustration, holes on mounting flange on page 55), use only screws
with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be
used.
55

2.3.6. Loads
2.3.6. Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of centre of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operation stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions as specified in the
Product Specification. The loads must also be defined in the software as detailed in Users
Guide.
Brake performance
Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB.
56

2.3.7. Suspended mounting

General
Initially the system is configured for mounting on the floor, without leaning. The method for
mounting the manipulator in a suspended position is basically the same as for floor mounting.
NOTE!
With inverted installation, make sure that the gantry or corresponding structure is rigid
enough to prevent unacceptable vibrations and deflections, so that optimum performance can
be achieved.
System Parameters
If the robot is mounted at any other angle, the system parameter gravity beta must be
updated. Gravity beta specifies the robots mounting angle expressed in radians.
NOTE!
It is very important to configure gravity beta correctly so that the robot system can control the
movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will
result in:
Overloading the mechanical structure.
Lower path performance and path accuracy.
Some S4 functions will not work properly: e.g Load Identification & Collision
detection.
Mounting Angles and Values

The parameter gravity beta specifies the robots mounting angle in radians. It is calculated
in the following way for a mounting angle of 45.
Gravity beta = 45 x 3.141593/180 = 0.785398 radians.
Examples of Position
Mounting Angle
Gravity Beta
Floor (pos 1)
0.000000 (Default)
Tilted (pos 2)
45
0.785398
Wall (pos 3)
90
1.570796
Ceiling (pos 4)
180
3.141593
57

xx0200000066
Defining the parameters

Following steps describes how to enter the correct gravity beta values.
Step
Action
1.
Choose Topics: Manipulator.
2.
Choose Types: Robot.
3.
Select Master and press Enter.
Info/Illustration
xx0200000073
58
4.
Select the desired parameter gravity beta and

change its value.
5.
Press OK to confirm.

2.3.8. Bolt pattern
2.3.8. Bolt pattern

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

2.3.8. Bolt pattern
Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes:
xx0200000086
60

2.4.1. Customer connections on manipulator
2.4 Electrical connections

General
For connection of extra equipment on the manipulator there are cables integrated into the
manipulators cabling. There are both air and electrical connectors on the manipulator.
xx0200000074
Connections
Connections
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
61

Recommended parts
To connect power and signal conductors to the upper arm connector, the following parts are
recommended
xx0200000132
ABBs recommended contact set, for connector R2.CS (3HAC 12497-1) contains:
Multipole connector 12 pin
Adapter Tin plated 12 pin
Pins for cable area 0.25-0.5 mm 2
Pins for cable area 0.5-1.5 mm 2
Shrinking hose, bootled shaped
Shrinking hose angled
The connection set is delivered in a plastic bag also containing a Technical and assembly
instruction.
62
3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
Structure of this chapter
This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including periodicity and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, e.g. required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Make sure
to read through the chapter Safety on page 13.
63
3 Maintenance
3.2.1. Maintenance schedule, IRB 140
3.2 Maintenance schedules

General
The robot, consisting of manipulator and controller cabinet, must be maintained regularly to
ensure its function. The maintenance activities and their respective intervals are specified in
the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Activities and intervals, standard equipment
The sections referred to in the table can be found in the different chapters for every
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
activity
Equipment
Inspection
Damper, axes 2-3 Regularly *)
Inspection, damper axes

2-3 on page 66
Inspection
Cable harnesses
Regularly *)
Inspection, robot cabling

on page 68
Inspection
Timing belts
36 mths
Inspection, timing belts on

page 69
Change
Gearbox 5, oil
36 mths
Oil change, gearbox,

axes 5 and 6 on page 73
Change
Gearbox 6, oil
36 mths
Oil change, gearbox,

axes 5 and 6 on page 73
Change
Measurement
system, battery
Depending on battery type Replacement of serial

and operation pattern as
measurement unit and
specified in section Battery battery pack on page 122.
type selection on page 65.
Clean
Complete
manipulator
Regularly *)
Interval
Detailed in section:
Cleaning, complete robot

on page 72
*) "Regularly" implies that the activity is to be performed regularly, but the actual interval
may not be specified by the robot manufacturer. The interval depends on the operation cycle
of the robot, its working environment and movement pattern.
Generally, the more contaminated environment, the shorter intervals. The more demanding
movement pattern (sharper bending cable harness), the shorter intervals.
64
3 Maintenance
Battery type selection

The table below shows the selection criteria for the three available battery types.
Operation pattern
Change interval,
3-cell lithium
Change interval,
6-cell lithium
Max. 4 weeks power off per year
60 mths
60 mths
Weekend power off + operation pattern 1
24 mths
48 mths
Nightly power off + operation patterns 1 and 2 12 mths
24 mths
No longer change interval than 60 months are allowed regardless of the operation pattern due
to material ageing, etc.
65
3 Maintenance
3.3.1. Inspection, damper axes 2-3
3.3 Inspection activities

Location of dampers, axes 2-3
The figure below shows the location of all the dampers to be inspected.
xx0200000426
Damper, axis 2
xx0200000427
66
Damper, axis 3
3 Maintenance
Required equipment
Equipment
Art. no.
Note
Standard toolkit
3HAC020812-001
The contents are defined in section

Standard toolkit in the Product manual,
reference information!
Inspection, damper axis 2-3

The procedure below details how to inspect the dampers, axis 2-3
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note
1.
Check all dampers for damage, such as cracks or

existing impressions larger than 1 mm.
Shown in the figure in

section Location of dampers,
axes 2-3 on page 66!
2.
Check attachment screws for deformation.
3.
If any damage is detected, the damper must be

replaced with a new one!
Art. no. specified in section

Required equipment on
page 67!
Replacement is detailed in
section Replacement of
damper, axis 2 on page 111
and Replacement of
damper, axis 3 on page 102.
67
3 Maintenance
3.3.2. Inspection, robot cabling
3.3.2. Inspection, robot cabling

Location, robot cabling
The robot cabling comprises the cabling between the manipulator and controller cabinet as
well as the externally visible cabling around motors 1 and 2.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
Required equipment
Equipment
Art. no.
Note
Standard toolkit
3HAC020812-001
The contents are defined in

section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may

be required. See references to
these procedures in the stepby-step instructions below.
Circuit diagram
These procedures include

references to the tools required.
3HAC 6816-3
WARNING!
result in burns!
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Inspection
The procedure below details how to inspect the robot cabling.
Step
68
Action
1.
Visually inspect the control cabling between the

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

Location of timing belts
Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below.
xx0200000448
Timing belt, axis 3
69
3 Maintenance
xx0200000453
Timing belt, axis 6
Timing belt, axis 5
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC020812-001

Other tools and procedures

may be required. See
references to these
procedures in the step-bystep instructions below.
70
These procedures include references to

the tools required.
3 Maintenance
Inspection
The procedure below details how to inspect the timing belts.
WARNING!
Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.
Step
Action
Note
1.
Gain access to each belt by

removing covers, etc.
These procedures are detailed in sections

Replacement of motor and timing belt, axis 3
on page 139 and Replacement of motor and
timing belt, axes 5 or 6 on page 147.
2.
Check each belt for damage.
Replace the timing belts if found defective as

detailed in sections Replacement of motor
and timing belt, axis 3 on page 139 and
Replacement of motor and timing belt, axes 5
or 6 on page 147.
3.
Check each belt for tension.

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

Axis 3: F = 35-60 N
Axis 5: F = 35-60 N
Axis 6: F = 35-60 N
xx0200000474
Belt tension adjustment is detailed in sections

Replacement of motor and timing belt, axis 3
on page 139 and Replacement of motor and
timing belt, axes 5 or 6 on page 147.
71
3 Maintenance
3.4.1. Cleaning, complete robot
3.4 Cleaning activities

3.4.1. Cleaning, complete robot
General
The protection class is IP 67, i.e. the manipulator is watertight.
Required equipment
Equipment, etc.
Art. no. Note
May be used on Foundry

versions only!
Steam cleaner
May be used on Foundry

versions only!
High pressure water cleaner
Vacuum cleaner
Cloth with mild detergent
Water pressure at nozzle: max. 2,500 kN/

m 2 (25 bar)
Type of nozzle: fan jet, min. 45 spread
Flow: max. 100 litres/min.
Water temperature: max. 80 C
Max. water pressure on enclosures: 50 kN/
m 2 (0.5 bar)
Fan jet nozzle should be used, min. 45
spread
Flow: max. 100 litres/min.
May be used on Standard version
Dos and donts!

The section below specifies some special considerations when cleaning the manipulator.
Always!
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never point the water jet at bearing seals, contacts, and other seals!
Never spray from a distance closer than 0.4 m!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Although the manipulator is watertight, avoid spraying connectors and similar items
with a high pressure cleaner!
Never!
72
3 Maintenance
3.5.1. Oil change, gearbox, axes 5 and 6
3.5 Changing/ replacing activities

Location of oil plugs
The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below.
xx0200000475
Oil plug, gearbox axis 5
Oil plug, gearbox, axis 6
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
1171 2016-604
3HAC 0860-1
Corresponds to:
Optimol, BM 100
Amount, gearbox 5 and 6: 350 ml
Oil collecting vessel

Standard Toolkit, IRB 140

references to these
Capacity: 400 ml.

3HAC020812-001

the tools required.
73
3 Maintenance
WARNING!
result in burns!
TIP!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
WARNING!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
WARNING!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
damage seals and gaskets
completely press out seals and gaskets
prevent the manipulator from moving freely
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
Draining, axes 5 and 6
The procedure below details how to drain the oil from gearboxes, axes 5 and 6.
Step
74
Action
Note
1.
Move the robot to a position where the upper arm is

close to horizontal and axis 4 in the calibration
position.
2.
Remove the oil plugs.

The cavity behind the plugs, containing the oil, is
common to gearboxes 5 and 6, but during draining,
both must be removed.
3.
Move axis 4 90 to a position where the axis 6 oil plug

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

section Required equipment
on page 73!
5.
Move axis 4 another 90.
This allows the remaining oil

to be drained.
6.
Refit the oil plug.
Shown in the figure Location

of oil plugs on page 73!
3 Maintenance
Refill, axes 5 and 6

The procedure below details how to refill the oil in gearboxes, axes 5 and 6.
Step
Action
Note
1.
Run the robot to a position where the upper arm

is close to horizontal and axis 4 in the calibration
position.
2.
Remove the oil plug, axis 5..

The cavity behind the plugs, containing the oil, is oil plugs on page 73!
common to gearboxes 5 and 6, but during
draining, both must be removed.
3.
Fill oil in gearbox 5 until the oil level reaches the The figure shows the
oil plug hole on the side of the wrist.
manipulator positions for filling
and draining respectively for a
standing manipulator:
xx0300000161
Positions:
A: Draining position
B: Filling position
The figure shows the
manipulator positions for filling
and draining respectively for an
inverted manipulator:
xx0300000162
Positions:
A: Draining position
B: Filling position
The oil quality is specified in
section Required equipment on
page 73!
4.
Refit the oil plug.
75
3 Maintenance
76
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter
This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate units, each detailing a specific repair activity. Each unit contains all
information required to perform the activity, e.g. spare parts numbers, required special tools
and materials.
The units are gathered in different sections, divided according to the component location on
the robot.
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.
77
4 Repair
4.2.1. Replacement of cable harness
4.2 Complete robot

Location of cable harness
The cable harness runs from the base to the motors of axes 3-6.
Required equipment
Equipment, etc.
Spare part no. Art. no.
Note
Cable harness
3HAC 7370-1
Standard and Foundry

versions
Clean room version
Includes cabling:
Cable harness,
power axis 1-3
Cable harness,
power axis 4-6
Cable harness,
signals axis 1-3
Cable harness,
signals axis 4-6
Cable harness,
customer
connections
Standard toolkit
3HAC020812-001
Other tools and

procedures may be
required. See
references to these
procedures in the stepby-step instructions
below.
Circuit Diagram
78
The contents are defined

in section Standard toolkit
in the Product manual,
references to the tools
required.
3HAC 6816-3
See chapter Circuit

diagram in the Product
manual, reference
information.
4 Repair
Removal, cable harness

The procedure below details how to remove the cable harness.
WARNING!
result in burns!
CAUTION!
Step
Action
Note/Illustration
1.
Remove the serial

measurement board.
Detailed in section Replacement of serial

measurement unit and battery pack on page 122.
2.
Disconnect connectors in the

manipulator base.
xx0300000090
Connectors:
A: R1.MP1-3
B: R1.CS
C: Air hose
D: R1.MP4-6
3.
Remove the cable holder by

unscrewing its attachment
screws.
xx0300000091
A: Cable holder
B: Attachment screws
C: Cable securing screws
79
4 Repair
Step
Action
Note/Illustration
4.
Remove the cables from the

See figure above!
cable holder by unscrewing the
cable securing screws.
5.
Remove the cover, arm

housing.
Detailed in section Replacement of cover, arm

housing, IRB 140.
6.
Remove the lower arm cover.
Detailed in section Replacement of lower arm

cover and gasket on page 108.
7.
Gently knock out the VK cover. Detailed in section Removing the VK cover on
page 88.
8.
Disconnect connectors in the

rear of the upper arm.
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

screws.
See figure above!
10. Cut any cable ties securing the

cabling inside the lower arm.
80
4 Repair
Step
Action
Note/Illustration
11. Disconnect the connectors

inside the lower arm.
xx0200000449
G: Connectors R3.MP3 and R3.FB3
12. Pull the cables out of the upper

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

on page 115.
14. Disconnect the connectors

inside the console and undo
the cable holders.
Connectors:
R3.MP1
R3.MP2
R3.FB1
R3.FB2
15. Gently pull the cabling from the

base up through the console.
16. Gently pull the cabling out of
the lower arm.
81
4 Repair
Refitting, cable harness

The procedure below details how to refit the cable harness.
WARNING!
Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
Step
Action
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.
Note/Illustration
xx0300000093
Cables:
A: Signal
B: Signal
C: Customer signal
D: Power cable, axes 4-6
E: Pressurized air supply
F: Power cable, axes 1-3
82
4 Repair
Step
3.
Action
Note/Illustration
Cable layout in the lower arm.
xx0200000449
A: Cable ties
B: Pressurized air hose
C: Power cables, axes 4, 5 and 6
D: Customer cables, signal
E: Signal cables, axes 4, 5 and 6
F: Signal cable, axis 3
83
4 Repair
Step
4.
Action
Note/Illustration
Cable holder in the upper arm.
xx0300000094
Cables:
A: Customer signal
B: Signal
C: Pressurized air supply
D: Power cables
84
4 Repair
4.2.2. Replacement of complete upper arm

Location of upper arm
The upper arm is located on top of the manipulator as shown in the figure below.
xx0200000446
Cover, armhousing
Attachment screws, cover armhousing, (4 pcs)
CS-connector
Pressurized air connector
VK cover
Cable guide
Attachment screws, cable guide
Attachment screws, upper arm (6 pcs)
Sealing ring
85
4 Repair
Required equipment
Equipment
Note
Upper arm, spare Std/F
3HAC 10466-1

versions
Includes all required
sealings and gaskets.
Upper arm, spare CR
3HAC 10466-3
Clean room versions

sealings and gaskets.
Sealing ring
3HAB 3732-13
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

Special socket
For fitting the CSconnector
Other tools and

procedures may be
required. See references
to these procedures in
the step-by-step
instructions below.
To be replaced if
damaged only
Included in the upper arm
assembly

required.
WARNING!
result in burns!
Removal, upper arm

The procedure below details how to remove the complete upper arm.
Step
86
Action
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.
Note/Illustration
4 Repair
Step
Action
Note/Illustration
3.
Remove the rear cover armhousing by unscrewing Shown in the figure Location of
its four attachment screws.
upper arm on page 85!
4.
DO NOT under any circumstance unscrew the six

screws on top of the lower arm! Doing so will cause
the manipulator to require a complete rebuild!
xx0300000101
A: DO NOT touch these

screws! (NOTE! Only
two screws shown!)
5.
Disconnect all cables to/from motors 4-6.
6.
Disconnect any connector from the CS-connector. Shown in the figure Location of
7.
Use a special socket to remove the CS-connector

from the housing and pull it into the upper arm
assembly.

Required equipment on page
86!
8.
Remove the pressurized air connector from the

housing and pull it into the upper arm assembly.

86!
9.
Remove the VK-cover from the upper arm/lower

arm joint.

Detailed in section Removing
the VK cover on page 88.
10. Remove the cable guide by unscrewing its two

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

11. Gently pull all cables and hoses out.

12. Remove the upper arm by unscrewing its six
attachment screws.

13. Lift the upper arm and place it on a secure surface.
87
4 Repair
Removing the VK cover

The procedure below details how to remove the VK cover from the upper arm.
xx0200000433
Lower arm
Lower arm cover gasket
Cover l. arm, spare (without lamp unit)
Cover l. arm, spare (with lamp unit)
Step
88
Action
Note
1.
Remove the lower arm cover by unscrewing its

attachment screws.
2.
Tap the VK coverwith a long blunt edged bar

Make sure to press the
through the hole in the lower arm to press it out. circumference of the VK cover
evenly to avoid damaging it.
Shown in the figure in section
Location of upper arm on page 85!
3.
If the VK cover is damaged, it must be replaced Specified in section Refitting of

on refitting.
complete upper arm.
4 Repair
Refitting
The procedure below details how to refit the complete upper arm.
Step
Action
Note
1.
Check the sealing ring to see whether it is

damaged.
Replace if it is damaged!

Required equipment on page 86!
2.
Lift the upper arm into position.
3.
Secure the upper arm with its six attachment

screws.
4.
Gently pull all cables and hoses through the

hole in the upper arm.
5.
Reconnect all connectors to motors 4-6.
Connectors
R3.MP4
R3.MP5
R3.MP6
R3.FB4
R3.FB5
R3.FB6
6.
Refit the cable guide with its two attachment

screws.

7.
Pull the pressurized air connector through the Shown in the figure Location of
housing and secure it into fitting in the upper upper arm on page 85!
arm assembly.
8.
Pull the CS-connector through the housing

and secure it into the fitting in the upper arm
assembly.
Use a special socketto secure it.
9.
Reconnect any connector previously

connected externally to the CS connector.

Tightening torque: 35 Nm 3 Nm

10. Fit a newVK-cover to the upper arm/lower arm Shown in the figure Location of
joint.
Gently knock it into position.
Use a plastic mallet or similar.
11. Refit the rear cover armhousing with its four
attachment screws.

12. Refit any brackets securing any exterior

cabling to the upper arm with their attachment
screws respectively.
13. Recalibrate the robot.
Calibration is detailed in separate

calibration manuals.
Art. no. for the manuals are
specified in section Document
references in the Product manual,
reference information.
89
4 Repair
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
90
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
special attention is paid to the function of the part previously serviced.
4 Repair
4.2.3. Replacement of complete lower arm

Location of lower arm
The lower arm is located between upper arm and frame as shown in the figure below.
xx0200000469
Lower arm
91
4 Repair
Required equipment
Equipment
Note
Lower arm, spare
3HAC 10468-1

versions
bearings, oil and VK cover.
Lower arm, spare
3HAC 10468-4
Clean room versions

bearings, oil and VK cover.
Standard toolkit
3HAC020812-001 The contents are defined in

section Standard toolkit in
the Product manual,
Lifting device for lower

arm
Special socket
Other tools and
procedures may be
the step-by-step
instructions below.
Lifting capacity xx kg
-

required.
Removal, lower arm

The procedure below details how to remove the complete lower arm.
WARNING!
92
result in burns!
4 Repair
Step
Action
Info/Illustration
1.
Remove the console.
Detailed in section Replacement of console on

page 118.
2.
DO NOT under any

circumstance unscrew the six
screws on top of the lower arm!
Doing so will cause the
manipulator to require a
complete rebuild!
xx0300000101
Parts:
A: DO NOT touch these screws! (Note!
Only 2 screws are shown.)
3.
Remove the VK cover by

pressing a screwdriver, or
similar, through it and pulling.
xx0300000097
Parts:
A: Washer
B: Lower arm attachment screws (10 pcs)
C: VK cover
4.
Unscrew thelower arm

attachment screws.
Also remove the washer.
5.
Raise the lifting device to

remove the lower arm.
Shown in the figure above!
93
4 Repair
Refitting, lower arm

The procedure below details how to refit the complete lower arm.
Step
Action
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.
Info/Illustration
xx0300000097
Parts:
A: Washer
B: Lower arm attachment screws (10 pcs)
C: VK cover
94
3.
Fit a new VK cover by gently

tapping it into position.
4.
Refit the console.
Detailed in section Replacement of console on

page 118.
5.
Recalibrate the robot.
Calibration is detailed in separate calibration

manuals.
Art. no. for the manuals are specified in section
Document references in the Product manual,
4 Repair
4.2.4. Replacement of base, spare

Location of base
The base is located at the bottom of the manipulator as shown in the figure below.
xx0200000423
Base
Bottom plate
Bottom plate attachment screws (26 pcs)
Gearbox/base attachment screws and washers (20 pcs each)
Joint, gearbox/base
Damper, axis 1
Washer
Required equipment
Equipment
Note
Base, spare
3HAC 10470-1

versions
Includes Parallel pin 3HAC
3785-2
Base, spare
3HAC 10470-3
Clean room versions

Includes Parallel pin 3HAC
3785-2
Lifting slings
Min. capacity 20 kg
95
4 Repair
Equipment
Note
LocTite 574
Standard toolkit
For sealing the base to the

gearbox 1-2
3HAC020812-001
Other tools and

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

the Product manual,
required.
Removal, base
The procedure below details how to remove the base.
WARNING!
result in burns!
Step
96
Action
Info
1.
Remove motors 1 and 2.
Detailed in sections Replacement of

motor, axis 1 on page 130 and
Replacement of motor, axis 2 on page
135 respectively.
2.
Remove the cable harness.
Detailed in section Replacement of

cable harness on page 78.
3.
Remove the serial measurement board.

serial measurement unit and battery
pack on page 122.
4.
Remove the complete upper arm.

complete upper arm on page 85.
5.
Remove the complete lower arm.

complete lower arm on page 91.
6.
Place the remaining base/gearbox axes 1- Shown in the figure Location of base.
2 assembly upside down on a work bench.
Remove the bottom plate.
7.
Remove the gearbox/base attachment

screws.
8.
Separate the base from the gearbox 1-2.
Shown in the figure Location of base.
4 Repair
Refitting
The procedure below details how to refit the complete lower arm.
WARNING!
result in burns!
Step
Action
Note
1.
Place the gearbox 1-2 and the base on a

workbench.
2.
After making sure the mating surface

Art. no. is specified in section
between the base and gearbox is completely Required equipment on page 95.
clean, apply Loctite to it.
3.
Secure the gearbox to the base with the

gearbox/base attachment screws and
washers.

Tightening torque: 35 Nm 3Nm
4.
Refit the bottom plate and secure it with its

attachment screws.
5.
Turn the base into standing upright.
6.
Refit the complete lower arm.

complete lower arm on page 91.
7.
Refit the complete upper arm.

complete upper arm on page 85.
8.
Refit motors 1 and 2.
Detailed in sections Replacement of

motor, axis 1 on page 130 and
Replacement of motor, axis 2 on page
135 respectively.
9.
Refit the serial measurement board.

serial measurement unit and battery
pack on page 122.
10. Refit the cable harness.

cable harness on page 78.

Art. no. for the manuals are specified
in section Document references in
the Product manual, reference
information.
DANGER!
it is vital that:
97
4 Repair
98
4 Repair
4.3.1. Replacement of wrist unit
4.3 Upper arm

Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm.
xx0200000438
Wrist unit attachment screws (3 pcs)
Oil plug (one shown)
Wrist unit
Required equipment
Equipment, etc.
Note
Wrist unit (Std/F)
3HAC 10475-1

versions
O-ring sealing plate not
included!
Wrist unit (CR)
3HAC 10475-4
Clean room versions

O-ring sealing plate not
included!
O-ring sealing plate
3HAC 7191-1
Must be replaced
Grease
3HAC 3537-1
For lubricating the o-ring

sealing plate
99
4 Repair
Equipment, etc.
Note
Standard toolkit
3HAC020812-001

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

motor/pinion
Other tools and

procedures may be
required. See
references to these
below.

required.
Removal, wrist unit

The procedure below details how to remove the complete wrist unit.
Step
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2.
Drain the oil from the wrist unit.
Detailed in section Oil

change, gearbox, axes 5
and 6 on page 73.
3.
Remove the wrist unit by unscrewing its three

attachment screws.
Shown in the figure in

section Location of wrist unit
on page 99.
Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.
Step
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
100
2.
Run the robot to a position where the upper

arm is vertical. The axis 5 motion plane
should be horizontal.
3.
Lightly lubricate the o-ring sealing plate with Art. no. is specified in section Required
grease.
equipment on page 99.
4 Repair
Step
Action
Note
4.
Fit the o-ring sealing plate and the wrist unit Do not tighten its attachment screws!
to the upper arm with the attachment
screws, but do not tighten them.
5.
In order to release the brake, connect the

24 VDC power supply to motors:
Connect to connector R3.MP5 or 6:

+: pin 7
-: pin 8
6.
Fit the Arm to the rear of the motor.
Art. no. is specified in section Required

equipment on page 99.
7.
Manually push the motor to adjust the motor

in relation to the gear in the gearbox.
Minimize the gear play as shown in the
figure.
xx0200000445
A: Wrist unit, axes 5 and 6

gears
B: Drive shafts from motors,
axes 5 and 6 gears
C: Adjustment direction
D: Gear play
8.
Tighten the wrist unit attachment screws.
9.
Check the gear play by moving axes 5 and The gear play should be xx to pass the
6 by hand.
test.
10. Perform a leak-down test.
Detailed in section Leak-down test.
11. Refill the wrist unit with oil.
Detailed in section Oil change,

gearbox, axes 5 and 6 on page 73.
12. Recalibrate the robot!

Art. no. for the manuals are specified in
section Document references in the
information.
DANGER!
it is vital that:
101
4 Repair
4.3.2. Replacement of damper, axis 3

Location of damper, axis 3
The damper, axis 3, is shown in the figure below!
xx0200000427
Damper, axis 3
Required equipment
Equipment, etc.
Damper axis 3
3HAC 7881-1
Standard toolkit
Other tools and

procedures may be
the step-by-step
instructions below.
102
Note
3HAC020812-001 The contents are defined

These procedures
include references to the
tools required.
4 Repair
Removal, damper axis 3

The procedure below details how to remove the damper, axis 3.
Step
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Run the robot to a position that enables access to Shown in the figure Location of
damper, axis 3.
damper, axis 3 on page 102.
3.
Remove the damper by gently prying it from the

cast tab.
Refitting, damper axis 3

The procedure below details how to refit the damper, axis 3.
Step
Action
Note
1.
Danger!
2.
Run the robot to a position that enables access to the Shown in the figure Location
location where the damper, axis 3, is fitted.
of damper, axis 3 on page
102.
3.
Refit the damper by gently pressing it onto the cast

tab on the upper arm.
DANGER!
it is vital that:
103
4 Repair

The damper, axis 5, is located as shown in the figure below!
xx0200000429
Damper, axis 5
Recess
Required equipment
Equipment, etc.
Damper axis 5
3HAC 8964-1
Standard toolkit
Other tools and

procedures may be
the step-by-step
instructions below.
104
Note
3HAC020812-001

These procedures
tools required.
4 Repair

Step
Action
Note
1.
Danger!
2.
Run the robot to a position that enables the end of the Shown in the figure in
damper to be pushed into the recess in the wrist unit section Location of damper,
axis 5 on page 104.
3.
Unhook the end of the damper, and push it into the

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

damper to pull it out.

Step
Action
Note
1.
Danger!
2.
Push the end of the damper into the gap between the Make sure the damper is
wrist unit and upper arm.
turned the correct way!
3.
Manually move the wrist (robot axis 5) in order to pull

the damper into position.
4.
Fold out the damper hooks to secure it in position.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach
- special attention is paid to the function of the part previously serviced.
105
4 Repair
4.3.4. Replacement of cover, arm housing

Location of cover, armhousing
The cover, armhousing is located on the rear of the upper arm as shown in the figure below.
xx0200000464
Cover, arm housing
Attachment screws, cover, armhousing
Gasket, upper arm cover
Required equipment
Equipment, etc.
Spare part. no.
Cover, arm housing
3HAC 10473-1

version
Includes gasket 3HAC
7867-1
Cover, arm housing
3HAC 10473-3
Clean Room versions

7867-1
Note
Gasket, upper arm cover
3HAC 7867-1
Standard toolkit
3HAC020812-001
Other tools and

procedures may be
the step-by-step
instructions below.
106
Art. no.
The contents are

defined in section
Standard toolkit in the
Product manual,
These procedures
include references to
the tools required.
4 Repair
Removal
The procedure below details how to remove the cover, armhousing.
WARNING!
result in burns!
Step
Action
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

attachment screws.
Note

of cover, armhousing on
page 106.
NOTE! Do not damage the
gasket inside the cover!
Refitting
The procedure below details how to refit cover, armhousing.
WARNING!
result in burns!
Step
Action
Note
1.
Manually, run the robot to a position that enables

access to the rear of the upper arm.

page 106.
2.
Make sure the gasket inside the cover, arm housing

has not been damaged.
Replace if damaged.
page 106.
3.
Secure the cover, arm housing to the upper arm with

its attachment screws.
107
4 Repair
4.4.1. Replacement of lower arm cover and gasket
4.4 Lower arm

Location of lower arm cover and gasket
The lower arm cover and gasket are located as shown in the figure below.
xx0200000433
108
Lower arm
Gasket lower-arm cover
Cover l. arm, spare (without lamp unit)
Cover l. arm, spare (with lamp unit)

4 Repair
Required equipment
Equipment, etc.
Note
Cover l. arm, spare, Std/F
3HAC 10471-1

versions
No lamp unit included
7869-1
Cover l. arm, spare, CR
3HAC 10471-3
Clean room versions

No lamp unit included
7869-1
Gasket lower-arm cover
3HAC 7869-1
Isopropanol
1177 1012-208
For cleaning sealing

surfaces
Standard toolkit
3HAC020812-001
The contents are

defined in section
Product manual,

references to these
These procedures
the tools required.
Removal, lower arm cover and gasket

The procedure below details how to remove the lower arm cover and gasket.
WARNING!
result in burns!
Step
Action
Note
1.
Remove the lower arm cover by unscrewing its

attachment screws.

of lower arm cover and
gasket on page 108.
2.
If the gasket is to be replaced, proceed below!

Use a knife to gently remove the old gasket from the
cover.
3.
Clean the sealing surface with isopropanol, making

sure it is completely clean and free from scratches
and burrs.

Required equipment on
page 109.
109
4 Repair
Refitting, lower arm cover and gasket

The procedure below details how to refit the lower arm cover and gasket.
WARNING!
- Motors and gears are HOT after running the robot! Burns may result from touching
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
Step
110
Action
Note
1.
If the Gasket lower-arm cover is to be replaced,

proceed below. If not, see further down!

gasket on page 108.
2.
Remove the protective backing from the selfadhesive gasket and fit it onto the cover sealing
surface.
Make absolutely sure it is

correctly located!
3.
Refit the lower arm coverwith its attachment screws. Shown in the figure Location
gasket on page 108.
4 Repair

The damper, axis 2, is located as shown in the figure below!
xx0200000426
Damper, axis 2
Required equipment
Equipment, etc.
Spare part no.
Damper ax. 2
3HAC 7880-1
Standard toolkit
Other tools and

procedures may be
required. See
references to these
below.
Art. no.
Note

the Product manual,
required.
111
4 Repair

Step
Action
Note
1.
Danger!
2.
Run the robot to a position that enables you to access the

attachment screw of damper, axis 2.
3.
Remove the damper by unscrewing the single attachment

screw and washer.

Step
Action
Note
1.
Danger!
2.
Run the robot to a position that enables access to the

attachment screw of the damper, axis 2.
3.
Secure the damper with its single attachment screw

and washer.
1 pc: M6 x 16.
DANGER!
it is vital that:
112
4 Repair
4.4.3. Replacement of indicator lamp

Location of indicator lamp
The indicator lamp is located on the side of the lower arm as shown in the figure below.
xx0200000472
Indication lamp
Lower arm cover
Required equipment
Equipment, etc. Spare part no. Art. no.
Indicator lamp
Standard toolkit
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
Note
3HAC 9258-1
3HAC020812-001

information!
required.
113
4 Repair
Removal
The procedure below details how to remove the indicator lamp.
WARNING!
result in burns!
Step
Action
Note
1.
Remove the lower arm cover.
Detailed in section
Replacement of lower arm
cover and gasket on page
108.
2.
Remove the damper by gently prying the plastic semitransparent damper from the cast tab.
Refitting
The procedure below details how to refit the indicator lamp.
WARNING!
result in burns!
Step
Action
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.
Note
DANGER!
it is vital that:
114
4 Repair
4.5.1. Replacement of cover, console
4.5 Frame and base

Location of cover, console
The cover, console is located on top of the console as shown in the figure below.
xx0200000462
Cover, console
Attachment screws, cover, console (4 pcs)
Gasket
Console
Required equipment
Equipment, etc.
Spare part. no.
Cover, console, spare
3HAC 10472-1

version
7868-1
Cover, console, spare
3HAC 10472-3
Clean Room versions

7868-1
Gasket, cover console
Art. no.
Note
3HAC 7868-1
115
4 Repair
Equipment, etc.
Standard toolkit
Spare part. no.
Art. no.
Note

in section Standard
toolkit in the Product
manual, reference
information!
Other tools and

procedures may be
required. See
references to these
below.
These procedures
tools required.
Removal
The procedure below details how to remove the cover, console.
WARNING!
result in burns!
Step
Action
Note
1.
Manually, run the robot to a position that enables Shown in the figure Location of
access to the top of the console.
cover, console on page 115.
2.
Remove the cover, console by unscrewing its

attachment screws.
NOTE! Do not damage the

gasket inside the cover!
Refitting
The procedure below details how to refit cover, console.
WARNING!
result in burns!
Step
1.
116
Action
Note
Manually, move the robot to a position that enables Shown in the figure Location of
access to the top of the console.
4 Repair
Step
Action
Note
2.
Make sure the gasket inside the cover, console

Replace if damaged.
3.
Secure the cover, console to the console with its

attachment screws.
117
4 Repair
4.5.2. Replacement of console

Location of console
The console is located on top of gearbox, axes 1-2 as shown in the figure below.
xx0200000462
Cover, console
Attachment screws, cover, console (4 pcs)
Gasket
Console
Required equipment
Equipment, etc.
Spare part. no.
Console, spare
3HAC 10478-1

version
Console, spare
3HAC 10478-3
Clean Room versions
Standard toolkit

references to these
118
Art. no.
Note
3HAC020812-001 The contents are

defined in section
Product manual,
These procedures
the tools required.
4 Repair
Removal
The procedure below details how to remove the cover, console.
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Remove the cable harness.
Detailed in section Replacement of cable harness

on page 78.
2.
Remove the serial

measurement board.

3.
Remove the complete upper

arm.
Detailed in section Replacement of complete upper

arm on page 85.
4.
DO NOT under any

circumstance unscrew the six
screws on top of the lower
arm! Doing so will cause the
manipulator to require a
complete rebuild!
xx0300000101
Parts:
A: DO NOT touch these screws! (Note! Only
two screws shown!)
5.
Remove the motor of axis 3.
6.
Attach the lifting device to the

lower arm.
Detailed in section Replacement of motor and

timing belt, axis 3 on page 139.
119
4 Repair
Step
7.
Action
Note/Illustration
Remove the bearing hub by

screws.
xx0300000096
Parts:
8.
Remove the console by

screws.
A: Console
B: Bearing hub
C: Bearing hub attachment screws (6 pcs)
D: Console attachment screws (10 pcs)
E: Washers (10 pcs)
Refitting
The procedure below details how to refit cover, console.
WARNING!
120
result in burns!
4 Repair
Step
1.
Action
Note/Illustration
Refit the console and secure it with

its attachment screws and washers.
xx0300000096
Parts:
A: Console
B: Bearing hub
C: Bearing hub attachment screws (6
pcs)
D: Console attachment screws (10 pcs)
E: Washers (10 pcs)
2.
Refit the bearing hub and secure it

with its attachment screws.

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

upper arm on page 85.
4.
Refit motor 3 and timing belt.
Detailed in section Replacement of motor and

timing belt, axis 3 on page 139.
5.
Refit the serial measurement board. Detailed in section Replacement of serial

measurement unit and battery pack on page
122.
6.
Refit the cable harness.
Detailed in section Replacement of cable

harness on page 78.
7.
Recalibrate the robot!

manuals.
121
4 Repair
4.5.3. Replacement of serial measurement unit and battery pack

Location of serial measurement unit and battery pack
The serial measurement unit and battery pack are located inside the manipulator base as
shown in the figure below.
xx0200000432
Rear cable cover
Battery pack
Serial measurement board (SMB)
SMB attachment screws (4 pcs)
Manipulator base bottom plate
Required equipment
Equipment, etc.
Spare part. no. Art. no.
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
Gasket base-cover
122
Note
Indoors
3HAC 7870-1
Replace only if required!
4 Repair
Equipment, etc.
Note
Standard Toolkit, IRB 140

in section Standard
toolkit in the Product
manual, reference
information!
Other tools and

procedures may be
to these procedures in the
step-by-step instructions
below.
These procedures
tools required.
Circuit Diagram
3HAC 6816-3
See chapter Circuit

manual, reference
information.
Removal
The procedure below details how to remove the serial measurement unit and battery pack.
WARNING!
result in burns!
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to

electrostatic voltages.
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
CAUTION!
This component is classified as Hazardous waste and must be disposed of accordingly!
If in doubt of the correct disposal procedure, please contact your local environmental
authority!
123
4 Repair
CAUTION!
Step
Action
Note
1.
Set the robot system to MOTORS OFF state.
This will simplify calibration of the

robot after replacement since no
coarse calibration will be required.
2.
Remove the rear cable cover from the base of Shown in the figure Location of
the robot by unscrewing its attachment screws. serial measurement unit and
battery pack on page 122!
3.
Remove the serial measurement unit by

unscrewing its attachment screws .
serial measurement unit and
The removal is simplified by pushing the unit to battery pack on page 122!
the side and then pulling it backwards.
4.
If only the battery is to be replaced, disconnect Connectors

the cables to the battery only!
R2.SMB
Disconnect all connectors from the serial
R2.FB1-3
measurement unit.
R2.FB4-6
R2.G
5.
Lift the board out.
6.
If the battery pack is to be replaced, proceed

below!
Cut the cable tie and disconnect the battery
connector to remove the battery pack.
Battery includes protection circuits. Replace it
only with the specified spare part in the refitting
instruction or with an ABB approved eqvivalent.
Refitting
The procedure below details how to refit the serial measurement unit and battery pack.
WARNING!
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
124
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to

electrostatic voltages.
Before handling, make sure you are connected to earth through a special ESD wrist
bracelet or similar.
4 Repair
CAUTION!
This component is classified as Hazardous waste and must be disposed of accordingly!
If in doubt of the correct disposal procedure, please contact your local environmental
authority!
CAUTION!
Step
Action
Note
1.
Connect the new battery pack to the serial

measurement unit and secure it with a cable tie.
2.
Reconnect all connectors to the unit.
3.
Place the serial measurement unit in position

inside the manipulator base and secure it with its serial measurement unit and
four attachment screws.
4.
Make sure the gasket sealing the rear cable cover Shown in the figure Location of
Replace the gasket if required.
122!
5.
Making sure all cables are correctly located

behind the rear cable cover, refit it into position.
Make sure no cables or other equipment fitted
behind the cover get pinched by the cover.

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

robot with its attachment screws.

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!
Connectors
R2.SMB
R2.FB1-3
R2.FB4-6
R2.G
Calibration is detailed in
separate calibration manuals.
references in the Product
manual, reference information.
125
4 Repair
4.5.4. Replacement of control cable

Location of control cable
The control cable is located on the rear of the manipulator base as shown in the figure below.
xx0200000467
Gasket, base-cover
Attachment screws and washers (9 pcs each), control cable
Control cable, spare
Required equipment
126
Equipment, etc.
Note
3HAC 10476-1
3m
versions
Cover gasket included
3HAC 10477-1
7m
versions
3HAC 11331-1
15 m
versions
3HAC 13090-1
22 m
versions
4 Repair
Equipment, etc.
Note
3HAC 13089-1
30 m
versions
3HAC 10476-4
3m
Clean Room versions
3HAC 10477-2
7m
Clean Room versions
3HAC 11331-2
15 m
Clean Room versions
3HAC 13090-2
22 m
Clean Room versions
3HAC 13089-2
30 m
Clean Room versions
Standard toolkit

Other tools and

procedures may be
the step-by-step
instructions below.

required.
Removal
The procedure below details how to remove the control cable.
WARNING!
result in burns!
127
4 Repair
Step
Action
1.
Make sure the robot system has been

switched off, and that no power is
supplied to the manipulator.
2.
Remove the Control cable, spareby

unscrewing its attachment screws.
3.
Disconnect connectors inside the

manipulator base.
Note/Illustration
Shown in the figure Location of control cable

on page 126.
Make sure the gasket does not get
damaged!
xx0300000090
Connectors:
A: R1.MP1-3
B: R1.CS
C: Air hose
D: R1.MP4-6
128
4.
Pull the cable out of the manipulator

base.
5.
Disconnect the connectors from the

control cabinet.
4 Repair
Refitting
The procedure below details how to refit control cable.
WARNING!
result in burns!
Step
Action
Note/Illustration
1.
Place the control cable on the floor with

the manipulator base cover close to the
manipulator.
Shown in the figure Location of control

cable on page 126.
2.
Connect the connectors inside the

manipulators base.
xx0300000090
Connectors:
A: R1.MP1-3
B: R1.CS
C: Air hose
D: R1.MP4-6
3.
Fit a new gasket when refitting the cover. Included in the spare part
4.
Fit the cover onto the manipulator base Shown in the figure Location of control
and secure it with its attachment screws. cable on page 126.
129
4 Repair
4.6.1. Replacement of motor, axis 1
4.6 Motors
Location of motor axis 1
The motor axis 1 is located on the rear of the manipulator as shown in the figure below:
xx0200000407
Motor, axis 1
Cover for connector access
Motor attachment screws (4 pcs)
Cable gland attachment screws (4 pcs)
Console
Required equipment
130
Equipment, etc.
Spare part no.
Art no.
Note
Rot. ac motor with

pinion
3HAC 10469-3
3HAC 021966-001
Clean room versions.
Rot. ac motor with

pinion
3HAC 10469-1
3HAC 021965-001

versions.
Rot. ac motor w
pinion TStd/TF
3HAC 10469-4
High performance version.
O-ring
2152 2012-426
Must be replaced when

replacing motor!
Included in the spare parts
motor kits
Cable gland gasket
3HAC xx
Fitted onto the console

cable gland
4 Repair
Equipment, etc.
Spare part no.
Art no.
Note
Grease
3HAB 3537-1
Used to lubricate the o-ring
Standard toolkit

the Product manual,
Arm
3HAC 9037-1

motor/pinion
Power supply
24 VDC, max. 1,5 A

For releasing the brakes
Other tools and

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

required.
Circuit Diagram
3HAC 6816-3
See chapter Circuit diagram

131
4 Repair
Removal
The procedure below details how to remove motor, axis 1.
CAUTION!
If the manipulator normally works in an inverted position, it must be removed from this
position and placed on the floor before the work detailed in this instruction may be carried
out !
WARNING!
result in burns!
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Step
132
Action
Note
1.
Remove the Cover for connector access on top of Shown in the figure Location
the motor by unscrewing its four attachment screws. of motor axis 1 on page 130.
Detailed in section
Replacement of cover,
console on page 115.
2.
Disconnect the motor 1 connectors inside the

console.
3.
Cut any cable ties and remove any brackets securing

the cables.
4.
Remove the cable gland by removing its attachment Shown in the figure Location
screws, and pull the cables out from the console.
of motor axis 1 on page 130.
5.
In order to release the brakes, connect the 24 VDC

power supply:
6.
Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers.
7.
Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
8.
Remove the motor by gently lifting it straight up.
Connectors:
R3.MP1
R3.FB1
Connect to connector
R3.MP1
+: pin 7
-: pin 8
4 Repair
Refitting
The procedure below details how to refit motor, axis 1.
WARNING!
NOTE!
used!
Step
Action
Note
1.
Make sure the mating surfaces on the motor

and the gearbox are clean and free from burrs.
2.
Make sure the o-ring on the circumference of Art. no. is specified in section
the motor is seated properly. Lightly lubricate Required equipment on page 130.
the o-ring with grease .
3.
In order to release the brake, connect the 24

VDC power supply:
4.
Fit the motor, making sure the motor pinion is Make sure the motor is turned the
properly mated to gearbox 1.
right way, i.e. connections
rearwards.
Make sure the motor pinion does not
get damaged!
5.
Fit the motor with four attachment screws and Tightening torque: approx 2 Nm
plain washers.
6.
Fit the Arm to the end of the motor shaft.

Required equipment on page 130.
7.
Adjust the motor in relation to the gear in the

gearbox.
Use the Arm tool to wiggle the motor shaft
back and forth to feel the play.
There should be a barely noticable

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

Nm
9.
Disconnect the brake release voltage.
10. Make sure the cable gland gasket has not

been damaged. Replace, if it has.
Connect to connector R2.MP1

+: pin 7
-: pin 8

11. Push the cables into the console, and refit the
cable gland with its attachment screws.
133
4 Repair
Step
134
Action
Note
Detailed in section .

4 Repair

The motor axis 2 is located on the front of the manipulator as shown in the figure below.
xx0200000408
Motor, axis 2
Cover for connector access
Motor attachment screws (4 pcs)
Cable gland attachment screws (4 pcs)
Console
Required equipment
Equipment, etc. Spare part no.
Art. no.
Note
Rot. ac motor with

pinion, spare
3HAC 10469-3
3HAC 021966-001
Clean room versions.
Rot. ac motor with

pinion, spare
3HAC 10469-1
3HAC 021965-001

versions.
Rot. ac motor with

pinion, spare,
TStd/TF
3HAC 10469-4
High performance version.
O-ring
2152 2012-426

replacing motor!
Cable gland gasket
3HAC xx
Fitted onto the console cable

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

information!
135
4 Repair
Equipment, etc. Spare part no.
Art. no.
Note
Arm
3HAC 9037-1

motor/pinion
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Other tools and

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

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

the Product manual,
Removal
WARNING!
result in burns!
NOTE!
used!
Step
136
Action
Note
1.
Remove the Cover for connector access on top of Shown in the figure in
the motor by unscrewing its four attachment screws. section Location of motor
axis 2 on page 135.
2.
Disconnect the motor 2 connectors inside the

console.
3.
Cut any cable ties and remove any brackets securing

the cables.
4.
Remove the cable gland by removing its attachment Shown in the figure in
screws, and pull the cables out from the console.
section Location of motor
axis 2 on page 135.
5.
In order to release the brakes, connect the 24 VDC

power supply:
6.
Remove the motor by unscrewing its four attachment Shown in the figure Location
screws and plain washers.
7.
Lift the motor to get the pinion away from the gear.
Connectors:
R3.MP2
R3.FB2
Connect to connector
R3.MP2
+: pin 2
-: pin 5
4 Repair
Step
Action
Note
8.
9.
Remove the motor by gently pulling it out.

There is a real danger of oil running out of the motor
attachment hole when removing the motor. Take any
necessary measures to collect the oil.
10. Remove any remaining oil from the gearbox by

siphoning it out.
Refitting
WARNING!
NOTE!
used!
Step
Action
Note
1.
Make sure the mating surfaces on the motor and

the gearbox are clean and free from burrs.
2.
Make sure the o-ring on the circumference of the Art no. is specified in section
motor is seated properly. Lightly lubricate the oRequired equipment on page
ring with grease .
135.
3.
In order to release the brake, connect the 24 VDC Connect to connector R2.MP2
power supply:
+: pin 7
-: pin 8
4.
Fit the motor, making sure the motor pinion is

properly mated to gearbox 2.
5.
Fit the motor with four attachment screws and plain Tightening torque: approx 2
washers.
Nm
6.
7.

There should be a barely
gearbox.
noticable gear play.
Use the Arm tool to wiggle the motor shaft back and
forth to feel the play.
8.
Make sure the motor is turned

the right way, i.e. connections
rearwards.
Make sure the motor pinion
does not get damaged!
Art no. is specified in section

135.
Tightening torque: approx 11

Nm 1 Nm
137
4 Repair
Step
9.
Action
Note
10. Make sure the cable gland cover gasket has not
been damaged. Replace if it has.
Art no. is specified in section

135.
11. Push the cables into the console, and refit the cable
gland with its attachment screws.
Detailed in section Leak-down

test.
13. Refill the gearbox with oil.

138
Calibration is detailed in
separate calibration manuals.
references in the Product
manual, reference information.
4 Repair
4.6.3. Replacement of motor and timing belt, axis 3

The motor axis 3 is located behind the lower arm cover on the right hand side of the
manipulator as shown in the figure below.
xx0200000448
Lower arm cover
Attachment screws, lower arm cover (13 pcs)
Belt shield
Motor 3
Attachment screws, belt shield (3 pcs)
Attachment screws, motor 3 (4 pcs)
Belt
139
4 Repair
Required equipment
Equipment, etc.
Spare part no.
Rot. ac motor with

pinion
3HAC 7866-1
3HAC 021756-001
Art. no.
Note
Includes timing belt
pulley.
Timing belt
3HAC 6793-1
Grease
3HAB 3537-1
For lubricating the oring.
Standard toolkit
3HAC020812-001
The contents are

defined in section
Product manual,
Other tools and

procedures may be
required. See
references to these
below.
Circuit Diagram
These procedures
the tools required.
3HAC 6816-3
See chapter Circuit

manual, reference
information.
Removal
WARNING!
result in burns!
NOTE!
used!
Step
140
Action
Note/Illustration
1.
Remove any equipment hindering

access to the lower arm cover.
Shown in the figure in section Location of

motor axis 3 on page 139.
2.
Remove the lower arm cover by


4 Repair
Step
3.
Action
Note/Illustration
Cut the cable ties to facilitate

accessing the motor.
xx0200000449
4.
Disconnect motor connectors.
A: Cable ties
Connectors:
R3.MP3
R3.FB3
R3.H1 (if Safety lamp is fitted)
R3.H2 (if Safety lamp is fitted)
141
4 Repair
Step
5.
Action
Note/Illustration
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.
7.
Remove the remaining

motorattachment screws.

8.
Remove the belt.

9.
Remove the motor.

Refitting
WARNING!
Step
142
Action
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.
4.
Tighten the two motor attachment

screws slightly, but not completely.
Note/Illustration

4 Repair
Step
Action
Note/Illustration
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

two remaining screws.
Tightening torque: 4 Nm 0.5 Nm
8.
Tighten the last motor attachment

screws.
9.
Refit the cabling as shown.
xx0200000449
A: Cable ties

Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.
143
4 Repair

Location of motor, axis 4
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0200000455
Attachment screws, motor 4 (4 pcs)
Motor, axis 4
O-ring
Required equipment
Equipment, etc.
Spare part no.
Rot. ac motor with

pinion
3HAC 7842-1
3HAC 021757-001
Art. no.
Standard, Clean Room and

Foundry versions
Does not include the o-ring!
O-ring
3HAC 3772-24

replacing motor!
Grease
3HAC 3537-1
Used to lubricate the o-ring.
Standard toolkit

the Product manual,
Power supply
Arm
144
Note
24 VDC, max. 1,5 A.

For releasing the brakes.
3HAC 9037-1
For adjusting the gear play
4 Repair
Equipment, etc.
Spare part no.
Art. no.
Other tools and

procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
Circuit Diagram
Note
required.
3HAC 6816-3
See chapter Circuit

manual, reference
information.
Removal
WARNING!
result in burns!
NOTE!
used!
Step
Action
Note
1.
Remove the motors for axes 5 and 6.
Detailed in section
Replacement of motor and
timing belt, axes 5 or 6 on page
147.
2.
Manually run the manipulator to a position where

the upper arm points straight down.
This will enable the motor 4 to

be removed without draining
the oil in the gearbox.
3.
Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of
attachment screws.
motor, axis 4 on page 144.
4.
In order to release the brake, connect the 24 VDC Connect to connector R3.MP4
power supply:
+: pin 7
-: pin 8
5.
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
6.
Remove the motor by gently lifting it straight out.
Make sure the motor pinion is

not damaged!
145
4 Repair
Refitting
WARNING!
NOTE!
used!
Step
Action
1.
Make sure the mating surfaces on the motor Shown in the figure Location of
and the gearbox are clean and free from burrs. motor, axis 4 on page 144.
2.
Make sure the o-ring on the circumference of Art. no. is specified in section
the motor is seated properly. Lightly lubricate Required equipment on page 144.
the o-ring with grease .
3.
In order to release the brake, connect the 24

VDC power supply:
Connect to connector R3.MP4

+: pin 7
-: pin 8
4.
Fit the motor with the attachment screws.
Tightening torque: approx. 2 Nm
5.

6.

gearbox.
Use the Arm tool to wiggle the motor shaft
back and forth to feel the play.
There should be a barely noticable

gear play.
7.

motor, axis 4 on page 144.
8.
Refit motors 5 and 6.

motor and timing belt, axes 5 or 6 on
page 147.
9.
Perform a leak-down test.
146
Note

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

Location of motor and timing belt, axes 5 or 6
The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the
figure below.
xx0200000453
Lower arm cover
Attachment screws, lower arm cover
Cover, armhousing
Attachment screws, cover armhousing (4 pcs)
VK cover
Pressurized air hose (on front of upper arm)
147
4 Repair
CS connector
Cable guide
Attachment screws, cable guide
Belt shield
Attachment screws, belt shield
Motor attachment screws, 4 pcs per motor
Attachment screws, motor console
Clamping unit screws
Clamping unit
Timing belt, axis 6
Pulley, axis 6
Screws securing the pulley to the axis 5 drive shaft
Timing belt, axis 5
Pulley, axis 5
Motor console, ax. 5-6
Motor, axis 4
Motor, axis 5
Motor, axis 6
Required equipment
Equipment, etc.
Spare part no.
Rot. ac motor with pinion
3HAC 7842-1
3HAC 021757-001
Axis 4
Standard, Clean room
and Foundry versions.
Rot. ac motor with pinion
3HAC 7841-1
3HAC 021758-001
Axes 5 and 6
Standard, Clean room
and Foundry versions.
Timing belt
3HAC 6779-1
VK cover
Clamping unit
Art. no.
Note
Axes 5 and 6
3HAC 2166-13
3HAC 7939-1
Standard toolkit
3HAC020812-001 The contents are

defined in section
Product manual,
Special socket xx
3HAC xx

references to these
Circuit Diagram
148
These procedures
the tools required.
3HAC 6816-3
See chapter Circuit

diagram in the
Product manual,
4 Repair
Removal
The procedure below details how to remove motor, axis 5 or 6.
WARNING!
result in burns!
NOTE!
used!
Step
Action
Note
1.
Run the robot to a position where the upper

arm is close to horizontal
2.
Remove the lower arm cover by

Shown in the figure in section Location

of motor and timing belt, axes 5 or 6 on
page 147!
3.
Remove the rear cover armhousing by

unscrewing its four attachment screws.

page 147!
4.
Disconnect all cables to/from motors 4-6.
Connectors:
R3.MP4
R3.MP5
R3.MP6
R3.FB4
R3.FB5
R3.FB6
5.
Disconnect any connector from the CSconnector.

page 147!
6.
Use a special socket to remove the CSShown in the figure in section Location
connector from the housing and pull it into of motor and timing belt, axes 5 or 6 on
the upper arm assembly.
page 147!
Art. no. specified in section Required
equipment
7.
Remove the pressurized air connector from Shown in the figure in section Location
the housing and pull it into the upper arm of motor and timing belt, axes 5 or 6 on
assembly.
page 147!
equipment!
8.
Remove the VK-cover from the upper arm/ Shown in the figure in section Location
lower arm joint.
page 147!
Detailed in section Removing the VK
cover on page 88.
149
4 Repair
Step
9.
Action
Note
Remove the cable guide by unscrewing its Shown in the figure in section Location
two attachment screws.
page 147!
10. Gently pull the cables out of the upper arm.

11. Remove the belt shield by unscrewing its
attachment screws.

page 147!
12. Unscrew the motor attachment screws.

page 147!
13. Unscrew the clamping unit screws

page 147!
14. Use the previously removed clamping unit Shown in the figure in section Location
screws to press the clamping unit apart by of motor and timing belt, axes 5 or 6 on
inserting them into the adjacent holes in the page 147!
clamping unit.
15. Remove the clamping unit.
150
16. Remove the pulley and belt from motor,

axis 6.

page 147!
17. Remove the screws securing the pulley to

the axis 5 drive shaft.

page 147!
18. Remove the pulley and belt from motor,

axis 5.

page 147!
19. Remove the motor console, ax. 5-6 by


page 147!
4 Repair
Refitting
WARNING!
NOTE!
used!
Step
Action
Note
1.
Make sure the mating surfaces on the motor

and the console are clean and free from
burrs.
2.
Fit the motors in the motor console without

tightening the attachment screws.
3.
Fit the motor console in the upper arm

housing. Secure with its attachment screws. Location of motor and timing belt,
axes 5 or 6 on page 147!
4.
Fit pulley, axis 5 and timing belt, axis 5 with

their attachment screws and washers.

Location of motor and timing belt,
5.
Tighten the motor attachment screws to

enable the motor to be shifted slightly.
This will facilitate adjustment of the

belt tension.
6.
Adjust the belt tension by xx.
Correct belt tension F=35 - 60 N
7.
Secure the motor with its attachment screws Tightening torque: 4 Nm 0.5 Nm
including the ones in the motor console.
8.
Fit pulley, axis 6 and timing belt, axis 6 with

their attachment screws and washers.

9.
Fit the clamping unit and secure it with its

clamping unit attachment screws.


10. Repeat the belt adjustment procedure

detailed above for the remaining motor.
11. Secure the motor with its attachment screws. Tightening torque: 4 Nm 0.5 Nm
12. Fit the belt shield with its attachment screws. Shown in the figure in section
151
4 Repair
Step
Action
Note
13. Pull the pressurized air connector through

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

equipment
14. Pull the CS-connector through the housing

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

equipment
15. Reconnect any connector to the CSconnector.

16. Reconnect all cables to/from motors 4-6.
Connectors
R3.MP4
R3.MP5
R3.MP6
R3.FB4
R3.FB5
R3.FB6
17. Refit the cable guide with its two attachment Shown in the figure in section
screws.
18. Fit a newVK-cover to the upper arm/lower
arm joint.
Gently knock it into position.

equipment
Use a plastic mallet or similar.
19. Refit the rear cover armhousing with its four Shown in the figure in section
attachment screws.
20. Refit any brackets securing any exterior
cabling to the upper arm with their
attachment screws respectively.
152

Art. no. for the manuals are specified
in section Document references in the
information.
4 Repair
4.6.6.1. Measuring the gear play, axis 5
4.6.6. Adjustments and measurements

General
After reassembly due to repair work or any other reason, the gear play must be checked to
ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed
below.
Certain measurement tools must be fashioned to enable measuring. The dimensions of these
are specified.
Required equipment
Equipment, etc.
Art no.
Note
Standard toolkit
3HAC020812-001

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

magnetic base
Measuring range 0-xx mm, accuracy xx
Power supply
24 VDC, max. 1,5 A


references to these

the tools required.
WARNING!
result in burns!
153
4 Repair
Measurement
The procedure below details how to measure the gear play for axis 5.
Step
Action
1.
Manually, turn axis 4 90.
2.
Fit the dial fitting arm and dial

to the manipulator turning disk
as shown in the figure.
Apply the 40 N load as shown.
3.
Remove the load and read

Value 1.
4.
Apply 40 N load as shown.
Note/Illustration
xx0200000457
xx0200000458
154
5.

Value 2.
6.
Calculate the gear play value. Gear play value = value 1 - value 2
7.
Determine whether or not the

value is OK.
OK < 0.18 mm (4.1 arc minutes)
4 Repair

General
After reassembly due to repair work or any other reason, the gear play must be checked to
ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed
below.
Certain measurement tools must be fashioned to enable measuring. The dimensions of these
are specified.
Required equipment
Equipment, etc.
Art no.
Note
Standard toolkit
3HAC020812-001

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

magnetic base
Measuring range 0-xx mm, accuracy xx
Power supply
24 VDC, max. 1,5 A

Other tools and

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

the tools required.
WARNING!
result in burns!
155
4 Repair
Measurement
The procedure below details how to measure the gear play for axis 6.
Step
Action
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.
Note/Illustration
xx0200000460
3.

Value 1.
4.
Apply 40 N load as shown.
5.

Value 2.
6.
Calculate the gear play value.
Gear play value = value 1 - value 2
7.
Determine whether or not the

value is OK.
OK < 0.30 mm (10.3 arc minutes)
xx0200000461
156
4 Repair
4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1
4.7 Gearboxes
Location of gearbox axes 1-2
The axes 1-2 gearbox is located as shown in the figure below. Note that both gearboxes, 1 and
2, are a single unit!
The damper, axis 1, is shown in the figure in the procedure!
xx0200000422
Gearbox, axis 1-2
Required equipment
Note
Gearbox, ax. 1-2

spare, Std/F
3HAC 10467-1
Standard and Foundry versions

Includes gearbox 3HAC 6603-1
Includes all required lubricant!
Includes all o-rings and sealing
rings!
Gearbox, ax. 1-2

spare, CR
3HAC 10467-3
Clean room version

Includes gearbox 3HAC 6603-1
Includes all required lubricant!
Includes all o-rings and sealing
rings!
Damper, axis 1
3HAC 7527-1
Flange sealing
1234 0011-116
2 ml
LocTite, 574
3HAC xx
For sealing gearbox/base
Sealing ring
3HAC 6965-1
Replace only when damaged!
157
4 Repair
Note
Standard toolkit
3HAC020812-001

information!
Lifting device,
gearbox 1-2
3HAC xx
Other tools and

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

references to the tools required.
Removal, gearbox 1-2

The procedure below details how to remove gearbox, axes 1-2.
WARNING!
result in burns!
NOTE!
used!
CAUTION!
Caution!
The gear box weighs 39 kg! All lifting equipment used must be dimensioned accordingly!
Step
158
Action
Note/Illustration
1.
Remove motor 1.
Detailed in section Replacement of motor, axis 1

on page 130.
2.
Remove motor 2.
Detailed in section Replacement of motor, axis 2

on page 135.
3.
Remove the cable harnesses.
Detailed in section Replacement of cable harness

on page 78.
4.
Remove the serial measurement Detailed in section Replacement of serial

board.
measurement unit and battery pack on page
122Replacement of serial measurement unit and
battery pack on page 122.
5.
Remove the upper arm.
Detailed in section Replacement of complete

upper arm on page 85.
6.
Remove the lower arm.
Detailed in section Removal of complete lower

arm.
7.
Drain the oil from gearbox 1.
4 Repair
Step
Action
Note/Illustration
8.
Fit the lifting tool to the base/

Art. no. is specified in section Required
frame and turn it upside down on equipment on page 157.
top of a suitable workbench.
9.
Remove the bottom plate by

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

Shown in the figure Location of gearbox axes 1-2
attachment screws and lift the
on page 157.
gearbox 1-2 away from the base.
Removal of damper, axis 1

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

gearbox 1-2 on page 158.
2.
Remove the damper, axis 1.
Refitting of damper, axis 1

Step
Action
Note
1.
Fit the damper, axis 1.
Shown in the illustration

Refitting, gearbox 1-2 on
page 160.
2.
Proceed with assembling the robot.
Detailed in section Refitting,

gearbox 1-2 on page 160.
159
4 Repair
Refitting, gearbox 1-2

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

suitable workbench.
2.
Fit a small amount of LocTite

574 onto the Joint, gearbox/
base.
Note/Illustration
xx0200000423
160
A: Gearbox 1-2
B: Bottom plate
C: Bottom plate attachment screws (26 pcs)
D: Gearbox/base attachment screws (20
pcs)
E: Joint, gearbox/base
F: Damper, axis 1
G: Washer
3.
Fit the base to the gearbox unit Shown in the figure Location of gearbox axes 1-2 on
and secure it with the
page 157.
attachment screws and the flat Quality Gleitmo, tightening torque: 35 Nm 3 Nm.
washer.
4.
Refit the bottom plate and

secure it with its attachment
screws.
Shown in the figure Location of gearbox axes 1-2 on

page 157.
4 Repair
Step
Action
Note/Illustration
5.
Fit the lifting tool to the base/

frame and turn it right side up
on top of a suitable
workbench.
Art. no. is specified in section Required equipment

on page 157.
6.
Refit the lower arm.
Detailed in section Refitting of complete lower arm.
7.
Refit the upper arm.
Detailed in section Refitting of complete upper arm.
8.
Refit the serial measurement

board.

9.
Refit the cable harnesses.
Detailed in section Refitting of cable harness.
10. Refit motors 1 and 2.
Detailed in section Refitting of motor 1 and Refitting

of motor 2 respectively.
12. Refill the gear box with oil.


manuals.
161
4 Repair
4.7.2. Service work on gearbox, axis 4
4.7.2. Service work on gearbox, axis 4

General
The gearbox, axis 4, is intended to run without requiring any repairs or maintenance work.
This implies that it must under no circumstances be opened or serviced.
If it requires replacement, the complete upper arm is to be replaced. This procedure is detailed
in section Replacement of complete upper arm on page 85.
162
5.1. Introduction
5.1. Introduction
General
This chapter includes general information about different calibration methods and details also
procedures that does not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 164, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.
Contents of the revolution counter memory are lost
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 168. This will occur when:
the battery is discharged
a resolver error occurs
the signal between a resolver and measurement board is interrupted
a robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are connected at
the first installation.
The robot is rebuilt
If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
References
The article numbers for the Calibration manuals are listed in section Document references in
the Product manual (part 2 of 2), reference information. Article numbers for the calibration
tools are also listed in part 2 of the Product manual.
163
5.2. Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
Types of calibration
Type of
calibration
Description
Calibration method
Standard
calibration
The calibrated robot is positioned at home

position, i.e. the axes positions (angles) are
set to 0.
Standard calibration data is found in the file
calib.cfg, supplied with the robot at delivery.
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Calibration Pendulum
(standard method)
or
Levelmeter calibration
(alternative method)
Absolute Accuracy
calibration
(optional)
Based on standard calibration, but besides

CalibWare
positioning the robot at home position, the
Absolute Accuracy calibration also
compensates for:
mechanical tolerances in the robot
structure
deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
motor positions as well as absacccompensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy
performance, the robot must be recalibrated
for Absolute Accuracy!
xx0400001197
164
Calibration methods
Each calibration method is detailed in separate manuals. Below is a brief description of the
methods available.
Calibration Pendulum - standard method
Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the manual Calibration Pendulum Instruction.
Levelmeter Calibration - alternative method
Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots,
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but has not as good mechanical tolerances to the toolkit
parts as the standard method with Calibration Pendulum.
This method may, after calibration, require modifications in the robot program, and is
therefore not recommended.
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter
2000.
CalibWare - Absolute Accuracy calibration
In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the manual CalibWare 2.0
Users Guide.
If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.
165
5.3. Calibration scales and correct axis position
5.3. Calibration scales and correct axis position

Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
Calibration scales, IRB 140
The illustration below shows the calibration scale positions on IRB 140:
xx0200000157
166
5.4. Calibration movement directions for all axes
5.4. Calibration movement directions for all axes

Calibration movement directions
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
Note! The figure shows an IRB 7600, but the positive direction is the same for all robots,
except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!
xx0200000089
167
5.5. Updating revolution counters

General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using either the TPU or the FlexPendant.
Manually running the robot to the calibration position
This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.
Step
Action
Note
1.
Select axis-by-axis motion mode.
2.
Jog the robot so that the calibration marks lie Shown in section Calibration scales
within the tolerance zone.
and correct axis position on page
166.
3.
When all axes are positioned, store the

revolution counter settings.
Detailed in sections:
Storing the revolution counter setting
with the TPU on page 169
(RobotWare 4.0).
Storing the revolution counter setting
with the FlexPendant on page 170
(RobotWare 5.0).
Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have
any mechanical stops and can therefore be calibrated at the wrong turn.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the exact calibration position will be lost due to
uneven gear ratio. This affects the following robots:
168
Robot variant
Axis 4
Axis 6
IRB 140
Yes
Yes
Storing the revolution counter setting with the TPU

This section details the second step when updating the revolution counter; storing the
revolution counter setting with the TPU (RobotWare 4.0).
Step
1.
Action
Note
Press the button "Miscellaneous" then ENTER to select the

service window.
xx0100000194
2.
Select Calibration from the View menu.

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

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

with an x.
CANCEL returns to the Calibration window.
169
Step
Action
Note
6.
Press OK again to confirm and start the update.

CANCEL returns to the Revolution Counter Update window.
7.
At this point, it is recommended that the revolution counter

values are saved to a diskette.
Not required.
8.
Caution!
If a revolution counter is incorrectly updated, it will cause
incorrect robot positioning, which in turn may cause damage or
injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the
calibration position on page 172.
Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).
Step
Action
1.
On the ABB menu, tap Calibration.

All mechanical units connected to the system are shown along with their calibration
status.
2.
Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.
en0400000771
170
Step
Action
3.
Tap Update revolution counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
Tap Yes to update the revolution counters.
Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4.
Select the axis to have its revolution counter updated by:

Ticking in the box to the left
Tapping Select all to update all axes.
Then tap Update.
5.
A dialog box is displayed, warning that the updating operation cannot be undone:
Tap Update to proceed with updating the revolution counters.
Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from
the list of axes.
6.
Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 172.
171
5.6. Checking the calibration position

General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
Using a MoveAbsJ instruction with argument zero on all axes
Using the Jogging window on the teach pendant
Using a MoveAbsJ instruction on the TPU, S4Cplus

This section describes how to create a program, which runs all the robot axes to their zero
position
Step
Action
1.
Crate a new program
2.
Use MoveAbsJ
3.
Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs
, v1000, z50, Tool0
4.
Run the program in manual mode
5.
Check that the calibration marks for the axes align

correctly. If they do not, update the revolution
counters!
Note
The calibration marks are

shown in section Calibration
scales and correct axis
position on page 166.
How to update the revolution
counters is detailed in section
Updating revolution counters
on page 168
Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero
position.
Step
172
Action
1.
On ABB menu tap Program Editor.
2.
Create a new program.
3.
Use MoveAbsJ in the Motion&Proc menu.
4.
Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff
s, v1000, z50, Tool0
5.
Run the program in manual mode.
6.

counters!
Note

How to update the revolution
counters is detailed in section
on page 168.
Using the Jogging window on the TPU, S4Cplus

This section describes how to jog the robot to all axes zero position.
Step
Action
Illustration/information
1.
Open the Jogging window.
2.
Choose running axes-by-axes.
3.
Manually run the robot axes to a position where the

axis position value read on the TPU, is equal to
zero.
4.
Check that the calibration marks for the axes align The calibration marks are
counters!
Detailed in section Updating
revolution counters on page
168.
xx0100000195
xx0100000196
Using the Jogging window on the FlexPendant, IRC5

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

counters!
Note

How to update the counters
is detailed in section
on page 168.
173
174
Index
C
Calibration position 168
calibration position, checking 172
calibration position, jog to 173
Connection of external safety devices 15
D
direction of axes 167
L
Limitation of Liability 16
N
negative directions, axes 167
P
positive directions, axes 167
R
Revolution counters 168
S
Safety, service 15
U
Updating revolution counters 168
V
Validity and responsibility 15
175
176

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Product manual (part 1 of 2), procedures

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The information in this manual is subject to change without notice and

Copyright 2004 ABB All right reserved.

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

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

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

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

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

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

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

3HAC 023297-001 Revision: -

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

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

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

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

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

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

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

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

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

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

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

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

3HAC 023297-001 Revision: -

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

3HAC 023297-001 Revision: -

3HAC 023297-001 Revision: -

mechanical and electrical installation of the robot

maintenance of the robot

mechanical and electrical repair of the robot.

repair work and calibration.

Who should read this manual?

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/

Safety information that must be read through before performing

Required information about lifting and installation of the robot.

Step-by-step procedures that describe how to perform

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

Procedures that does not require specific calibration equipment.

Environmental information about the robot and its components.

3HAC 023297-001 Revision: -

3HAC 023297-001 Revision: -

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views

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

3HAC 023297-001 Revision: -

Product documentation, M2004

Product documentation, M2004

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views