Product Manual (Part 2 of 2), Reference Information: Articulated Robot

Product manual (part 2 of 2), reference information
Articulated robot
IRB 140
M2000, M2000A, M2004

Product manual (part 2 of 2), reference information

IRB 140
M2000
M2000A
M2004
Document ID: 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Reference information
11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Spare part / part list
27
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Spare part / part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Foldouts
33
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Circuit diagram
35
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3HAC 023297-001 Revision: -
Table of Contents
Overview
Overview
About this manual
This manual contains reference information for all procedures in part 1: Product manual,
procedures.
Usage
This manual should be used during:
installation
maintenance work
repair work.
Who should read this manual?

This manual is intended for:
installation personnel
maintenance personnel
repair personnel.
Prerequisites
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
Reference information
Useful information when performing installation, maintenance

or repair works. Includes lists of necessary tools, additional
documents, safety standards, etc.
Spare part / Part list
Complete spare part lists and complete lists of robot

components, shown in the foldouts.
Foldouts
Detailed illustrations of the robot with reference numbers to the

part list.
Circuit diagram
Circuit diagram for the robot.
Overview
Revisions
Revision
Description
First edition
Replaces previous manuals:
Installation and commissioning manual
Maintenance manual
Repair manual, part 1
Repair manual, part 2
Changes made in the material from the previous manuals:
Model M2004 implemented.
Section Document references added to the chapter Reference
information.
Information about the controller removed from the manual.
Additional spare part numbers for the motors.
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:
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)
10
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
11
1.2. Applicable Safety Standards
1.2. Applicable Safety Standards

Standards, general
The robot is designed in accordance with the requirements of:
ISO10218, Jan. 1992, Industrial Robot Safety
ANSI/RIA 15.06-1999
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing

systems - Basic requirements
DIN 19258 - Interbus-S, International Standard
Standards, safety fence

The following standards are applicable to the safety fence surrounding the robot cell:
ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing

systems - Basic requirements
prEN 999:1995
Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:
12
IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached
by the upper limbs.
EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human
body.
EN 811 Safety of machinery - Safety distance to prevent danger zones being reached
by the lower limbs.
Pr EN 999 Safety of machinery - The positioning of protective equipment in respect

of approach speeds of the human body.
EN 1088 Safety of machinery - Interlocking device associated with guards principles

for design and selection.
1.3. Unit conversion
1.3. Unit conversion

Converter table
Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
14.5 psi
13
1.4. Screw joints
1.4. Screw joints

General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After
this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
Tightening torque
Before tightening any screw, note the following:
14
Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
Use the correct tightening torque for each type of screw joint.
1.4. Screw joints
Only use correctly calibrated torque keys.
Always tighten the joint by hand, and never use pneumatical tools.
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm)

Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Dimension
Tightening torque
(Nm)
Class 8.8, oillubricated
Tightening torque
(Nm)
Tightening torque
(Nm)
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension

Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
15
1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
16
Dimension
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
1.5. Weight specifications
1.5. Weight specifications

Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for
each manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
17
1.6. Document references

General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot
The product specification includes generic technical data. The specification listed below is
the English version.
Document name
Document ID
Product specification
3HAC 9041-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name
Document ID
Product manual, S4Cplus M2000
3HAC 021333-001
Product manual, S4Cplus M2000A
3HAC 021128-001
Product manual, IRC5 M2004
3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name
Document ID
Note
Users guide (S4Cplus)
3HAC 7793-1
Contains instructions for daily operation

of S4Cplus based robot systems.
Operators manual (IRC5)
3HAC 16590-1
Document name
Document ID
Note
Calibration Pendulum
Instruction
3HAC 16578-1
Enclosed with the Calibration Pendulum

Toolkit.
Instructions for Levelmeter

calibration (alternative
method)
3HAC 022907-001
Enclosed with the Levelmeter 2000.
CalibWare 2.0 Users Guide
3HAC 16090-1
Calibration tool for Absolute Accuracy

calibration.
Calibration manuals
18
Additional documentation
Document name
Document ID
External axes
3HAC 9299-1
Note
19
1.7. Standard toolkit
1.7. Standard toolkit

General
All service (repair, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. All special tools, i.e. all tools that are not considered
standard as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents
Standard tool, IRB 140: 3HAC020812-001 contains:
20
Qty
Art. no.
Tool
Ring-open-end spanner 8-19mm
Socket head cap 2,5-17mm
Torx socket no:20-60
Torque wrench 10-100Nm
Small screwdriver
Ratchet head for torque wrench 1/2
Socket head cap no:5, socket 1/2"" bit L 20mm
Small cutting plier
1.8. Performing a leak-down test
1.8. Performing a leak-down test

General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc.
Art. no.
Leakdown tester
3HAC 0207-1
Leak detection spray
Note
Procedure
Step
Action
Note/Illustration
1.
Finish the refitting procedure of the motor or gear in

question.
2.
Remove the topmost oil plug on the gear in question, Art. no. is specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3.
Apply compressed air, and raise the pressure with the Recommended value: 0.2 knob until the correct value is shown on the
0.25 bar (20 - 25 kPa)
manometer.
4.
Disconnect the compressed air supply.
5.
Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is
be detected.
significantly colder or
warmer than the gearbox to
be tested, a slight pressure
increase or decrease
respectively may occur. This
is quite normal.
6.
Was any pressure drop evident?

Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7.
Spray suspected leak areas with leak detection

spray .
Bubbles indicate a leak.
8.
When the leak has been localized: take the

necessary measures to correct the leak.
Art. no. is specified above!
21
1.9. Lifting equipment and lifting instructions
1.9. Lifting equipment and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in
the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
22
1.10. Mounting instructions for bearings
1.10. Mounting instructions for bearings

General
This section details how to mount and grease different types of bearings on the manipulator.
Equipment
Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Used to grease the bearings, if not

specified otherwise.
Assembly of all bearings

Follow the instructions below when mounting a bearing on the manipulator.
1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.
2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and
other contamination. Cast components must be free from foundry sand.
3. Bearing rings, inner rings and roller elements must under no circumstances be subjected
to direct impact. Furthermore, the roller elements must not be exposed to any stresses
during the assembly work.
Assembly of tapered bearings
Follow the previous instructions for assembly of all bearings, when mounting a tapered
bearing on the manipulator.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
Note! The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.
2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the
bearing.
Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
During operation, the bearing should be filled to 70-80% of the available volume.
Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
Grooved ball bearings must be filled with grease from both sides.
Tapered roller bearings and axial needle bearings must be greased in the split
condition.
23
1.11. Mounting instructions for seals

General
This sections details how to mount different types of seals to the manipulator.
Equipment
Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Used to lubricate the seals.
Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
Protect the sealing surfaces during transport and mounting.
Keep the seal in its original wrappings or protect it well before actual mounting.
The fitting of seals and gears must be carried out on clean workbenches.
Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
Step
24
Action
Note
1.
Check the seal to ensure that:

the seal is of the correct type (provided with cutting
edge).
there is no damage to the sealing edge (feel with a
fingernail).
2.
Inspect the sealing surface before mounting. If scratches or

damage are found, the seal must be replaced, as it may
result in future leakage.
3.
Lubricate the seal with grease just before fitting. (Not too
Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page
to the seal.)
24.
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4.
Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in
leakage.
Flange seals and static seals

The procedure below details how to fit flange seals and static seals.
Step
Action
Note
1.
Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint
(without sealing compund).
If the flange surfaces are defective, the parts may not be used
beacuse leakage could occur.
2.
Clean the surfaces properly and in accordance with ABB

ROBOTICS PRODUCTS recommendations.
3.
Distribute the sealing compound evenly over the surface, preferably

with a brush.
4.
Tighten the screws evenly when fastening the flange joint.
O-rings
The procedure below details how to fit o-rings.
Step
Action
Note
1.
Ensure that the correct o-ring size is used.
2.
Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings
may not be used.
3.
Check the o-ring grooves.

Defective o-rings
The grooves must be geometrically correct and free from pores may not be used.
and contamination.
4.
Lubricate the o-ring with grease.
5.
Tighten the screws evenly when assembling.
25
26

2.1. Introduction

2.1. Introduction
Definitions
This chapter specifies all spare parts and replacement articles of the robot.
27

2.2. Spare part / part list

Spare part / part list
The table below details all replacement articles on the robot. The items refer to chapter
Foldouts.
28
Item
Qty
Art. no.
Name
Rem.
3HAC 10470-1
Base spare
3HAC 8999-1
Bottom plate
26
9ADA 629-44
Torx pan head roll. screw
3HAC 6599-1
Gasket bottom plate
3HAC 9522-1
Serial meas. board ass.
4944 026-4
Battery pack
7.2V 4Ah NiCd
2166 2055-6
Cable straps, outdoors
7.6x368
28
9ADA 618-46
Torx pan head screw
M5x20
3HAC 9030-1
Cable bracket
10
3HAC 9415-1
Clamp
11
3HAC 6755-1
Cable holder
12
9ADA 618-50
Torx pan head screw
M5x40
13
3HAC 10476-1
Control cable spare Std/F
L=3m
14
3HAC 10477-1
L=7m
15
3HAC 7527-1
Damper axis 1
16
20
3HAB 3402-52
Hex. socket head cap screw
17
3HAC 7950-1
Washer
18
3HAC 9860-1
Protecting plate
19
3HAC 8466-1
Protective earth cable
20
3HAC 9063-1
Hose clip
21
SK 615 503-2
Membrane
22
SK 616 013-F
Bracket
23
1SFA
616100R1006
Actuator black
24
3HAC 7870-1
Gasket base-cover
25
10
9ADA 290-1
Hexagon nut with flange
M5
26
2529 1920-2
Plug
R 1/8"
27
2522 2101-8
Protective hood
D=11.4-13
28
3HAC 8806-1
Clamp
29
3HAC 7370-1
Cable harness IRB 140
30
3HAC 2589-1
Instruction plate
Battery
replacement
31
10
2166 2055-3
4.8x208
32
20 ml
1234 0011-116
Flange sealing
Lotctite 574
33
3HAC 10470-3
Base, spare CR
34
3HAC 10476-4
Control cable spare CR
M5x12
M10x35 8.8
Gleitmo 610
D = 10
CBK
L=3m

Item
Qty
Art. no.
Name
Rem.
35
3HAC 10477-2
L=7m
36
3HAC 11331-1
L = 15 m
37
3HAC 11331-2
L = 15 m
38
3HAC 13089-1
L = 30 m
39
3HAC 13090-1
L = 22 m
50
3HAC 10467-1
Gearbox axes 1-2, spare Std/F
Item 67 incl.
51
3HAC 10469-1
Motor with pinion spare Std/F
3HAC 021965-001
52
24
3HAB 3409-25
Hex socket head cap screw
M6x20 12.9
Gleitmo 610
53
18
9ADA 312-6
Plain washer
6.4x12x1.6
54
2152 2012-426
O-ring
74.5x3
55
3HAC 6788-1
Bearing hub
56
3HAC 10478-1
Console spare Std/F
57
3HAC 10472-1
Cover console spare Std/F
58
3HAC 7868-1
Gasket console-cover
59
3HAC 5894-1
Cable bracket
T=1.5
60
3HAC 6965-1
Sealing ring
150x189x8.5
61
3HAC 3785-6
Parallel pin
D = 6 m6 L = 16
62
3HAB 3732-19
Sealing ring (V-ring)
85x11
63
11
9ADA 618-55
Torx pan head screw
M6x12
64
2166 2018-2
Clamp
D = 11
65
3HAC 10481-1
Connector bracket
66
25
2166 2055-1
67
3000 ml 1171 2016-604
Lubricating oil
68
3HAC 10467-3
Gearbox axes 1-2, spare CR
69
3HAC 10469-3 /
Motor with pinion, spare CR
3HAC 021966-001
70
3HAC 10478-3
Console, spare CR
71
3HAC 10472-3
Cover console, spare CR
72
3HAC 10645-1
Clamp
D = 4.7
100
3HAC 10468-1
Lower arm (axis 3), spare
Item 67, 107

and 108 incl.
101
3HAC 10471-1
Cover, without lamp unit
Item 103 incl.
102
3HAC 10474-1
Cover, with lamp unit
Item 103 incl.
103
3HAC 7869-1
Gasket lower-arm cover
104
3HAC 7866-1 /
Rot. ac motor incl. pinion
3HAC 021756-001
105
3HAC 6793-1
Timing belt
106
3HAC 6762-1
Belt shield
107
3HAB 3643-17
Groove ball bearing
80x100x10
108
3HAA 2166-13
VK-Cover
D = 100 B = 10
109
3HAC 7880-1
Damper axis 2
110
3HAA 2356-14
Washer SRKB
Item 58 incl.
2.5x101
6.4x18x1.6
29

30
Item
Qty
Art. no.
Name
Rem.
111
3HAB 3402-15
M5x20 8.8
Gleitmo 610
112
12
9ADA 312-5
Plain washer
5.3x10x1
113
3HAC 9258-1
Indicator lamp
114
3HAC 10468-4
Lower arm, spare CR
115
3HAC 10471-3
Cover, without lamp unit
116
3HAC 10474-3
Cover, with lamp unit
150
3HAC 10466-1
Upper arm compl. with wrist
Motors incl.
151
3HAC 10475-1
Wrist, spare Std/F
Item 155, 181

and 182 incl.
152
3HAC 7191-1
O-ring sealing plate
153
3HAB 3409-37
M8x25 12.9
Gleitmo 610
154
9ADA 312-7
Plain washer
8.4x16x1.6
155
2529 1920-2
Plug
R 1/8"
156
3HAC 10479-1
Axis 4 complete, spare Std/F
Item 111, 112,

180, 159, 161,
160 and 182
incl.
157
3HAB 3409-39
M8x35 12.9
Gleitmo 610
158
9ADA 334-7
Spring washer, conical
8.4x18x2
159
3HAB 3732-13
Sealing ring (V-ring)
99x10.5
160
3HAC 7842-1 /
Rot. ac motor with pinion
3HAC 021757-001
161
3HAB 3772-24
162
3HAC 7841-1 /
Rot. ac motor with pinion
3HAC 021758-001
163
3HAB 3402-18
164
3HAC 6773-1
Motor Console axes 5-6
165
9ADA 183-13
M5x12
166
3HAA 2356-15
Washer SRKB
5.3x15x1.2
167
3HAC 7367-1
Cable holder
168
3HAC 8572-1
Clamp
169
3HAC 6779-1
Timing belt
170
3HAC 6777-1
Timing Belt Pulley Z2/5
171
3HAC 6778-1
Timing Belt Pulley Z2/6
172
3HAC 7939-1
Clamping unit
173
3HAC 7391-1
Belt shield
174
3HAC 10473-1
Cover armhousing spare
175
3HAC 7867-1
Gasket upper arm cover
176
3HAC 7881-1
Damper axis 3
177
3HAC 6761-1
Cable guide
178
3HAC 7561-3
Dustcap for receptacles 12p
O-ring
29x3
M5x35 8.8
Gleitmo 610
Item 175 incl.

Item
Qty
Art. no.
Name
Rem.
179
2125 2052-178
Distance bolt
M5X55
180
3HAC 6598-1
Hose nipple
G 1/4"
181
3HAB 8964-1
Damper axis 5
182
550 ml
3HAC 0860-1
Lubricating oil
183
3HAC 10466-3
Upper arm, spare CR
184
3HAC 10475-4
Wrist, spare CR
185
3HAC 10479-3
Axis 4 complete, spare CR
186
3HAC 10439-3
Cover armhousing, spare CR
187
3HAC 11922-1
Slip strip
Optimol
Optigear BM
100
31

32
3 Foldouts
3.1. Introduction
3 Foldouts
3.1. Introduction
Overview
The foldouts in this chapter refer to the part list.
33
15
33
27
18
32
13
34
35
36
37
38
39
20
31
19
R1/4
21
22
23
28
Inside of cover
16
35 Nm
17
24
12
11
26
29
31
10
30
25
Inside of base
Base complete
Foldout 1
51
62
56
70
57
58
71
53
52
65
32
25
25
72
31
62
52
A (1 : 2)
15,5 Nm
55
31
52
53
54
52
53
51
52
69
53
54
63
64
68
50
67
61
ax.1 1,2 litre

ax.2 1,0 litre
61
60
63
31
59
31
63
63
Foldout 2
0,4 litre
67 100
104
114
105
64
103
101
115
113
102
116
Do not loosen
these screws
Do not loosen
these screws
110
109
18
66
17
16
35 Nm
108
107
112
111 4,1 Nm
Lower arm (shown without cables)
106
Lower arm complete with cables

(shown without cover)
Foldout 3
0,35 litre oil (at oil change).

0,30 litre oil (New wrist)
182 151
184
0,2 litre oil

152
180
182 156
185
159
176
162
162
164
163
4,1 Nm
112
169
153
28 Nm
154
170
171
172
3 Nm
173
181
108
157
35 Nm
158
161
Upper arm (shown without cables)
112
111
6 Nm
160
112
4,1 Nm 163
112
4,1 Nm 111
166
165
6 Nm
169
112
163
4,1 Nm
175
174
186
12
Foldout 4
177
179
168
167
150 183
20
165
3
187
Upper arm with cables

(shown without cover)
178
155
Upper arm complete
Foldout 5
4 Circuit diagram
4.1. Introduction
4 Circuit diagram
4.1. Introduction
Overview
This chapter includes the circuit diagram for the robot.
35
Circuit Diagram
CONTENTS
Page
Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............................................................101-108
IRB 140
Manipulator Circuit Diagram
3HAC 6816-3
LIST OF CONTENTS
IRB 140
No. of Sheets 8
Sheet no.
101
3HAC 6816-3
CONNECTION POINT LOCATIONS

IRB 140
No. of Sheets 8
Sheet no.
102
3HAC 6816-3
SERIAL MEASUREMENT BOARD

IRB 140
No. of Sheets 8
Sheet no.
103
3HAC 6816-3
MOTOR AXIS 1 - 3
IRB 140
No. of Sheets 8
Sheet no.
104
3HAC 6816-3
FEEDBACK AXIS 1 - 3
IRB 140
No. of Sheets 8
Sheet no.
105
3HAC 6816-3
MOTOR AXIS 4 - 6
IRB 140
No. of Sheets 8
Sheet no.
106
3HAC 6816-3
FEED-BACK AXIS 4 - 6
IRB 140
No. of Sheets 8
Sheet no.
107
3HAC 6816-3
CUSTOMER CONNECTIONS
IRB 140
No. of Sheets 8
Sheet no.
108

Product Manual (Part 2 of 2), Reference Information: Articulated Robot

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Product manual (part 2 of 2), reference information

Product manual (part 2 of 2), reference information

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

Copyright 2004 ABB All right reserved.

3HAC 023297-001 Revision: -

3HAC 023297-001 Revision: -

Who should read this manual?

be a trained maintenance/repair craftsman

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

Useful information when performing installation, maintenance

Spare part / Part list

Complete spare part lists and complete lists of robot

Detailed illustrations of the robot with reference numbers to the

Circuit diagram for the robot.

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

RAPID Overview: An overview of the RAPID programming language.

RAPID reference manual part 1: Description of all RAPID instructions.

Technical reference manual - System parameters: Description of system

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

Product documentation, M2004

How to use the application

Examples of how to use the application

Operators manual - IRC5 with FlexPendant

Operators manual - RobotStudioOnline

Trouble shooting Manual for the controller and robot

3HAC 023297-001 Revision: -

Robot fundamentals (describing the fundamental aspects, functions, concept and

Product documentation, M2004

3HAC 023297-001 Revision: -

3HAC 023297-001 Revision: -

1.2. Applicable Safety Standards

ISO10218, Jan. 1992, Industrial Robot Safety

ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing

DIN 19258 - Interbus-S, International Standard

Standards, safety fence

ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing

Standards, robot cell

Pr EN 999 Safety of machinery - The positioning of protective equipment in respect

EN 1088 Safety of machinery - Interlocking device associated with guards principles

3HAC 023297-001 Revision: -

1.3. Unit conversion

3HAC 023297-001 Revision: -