ABB M2000 Product Manual
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ABB M2000 Product Manual

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

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Summary of Contents for ABB M2000

  • Page 1 Product manual (part 1 of 2), procedures Articulated robot IRB 140 M2000, M2000A, M2004...
  • Page 3 Product manual (part 1 of 2), procedures IRB 140 M2000 M2000A M2004 Document ID: 3HAC023297-001 Revision: A...
  • Page 4 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.

  • Page 5: Table Of Contents

    Product documentation, M2000/M2000A ........
  • Page 6 Table of Contents 3 Maintenance 3.1 Introduction ............... 63 3.2 Maintenance schedules .
  • Page 7 Table of Contents 5.5 Updating revolution counters ............168 5.6 Checking the calibration position .
  • Page 8 Table of Contents 3HAC023297-001 Revision: A...

  • Page 9: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 10 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. •...

  • Page 11: Product Documentation, M2000/M2000A

    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...

  • Page 12: Product Documentation, M2004

    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.
  • Page 13 Product documentation, M2004 • How to use the application • Examples of how to use the application Operator’s manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: •...

  • Page 14: How To Read The Product Manual

    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.

  • Page 15: Safety

    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.

  • Page 16: General Safety Information

    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: •...

  • Page 17: General Information

    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.

  • Page 18: 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. 3HAC023297-001 Revision: A...

  • Page 19: Related Information

    1 Safety 1.2.2.3. Related information 1.2.2.3. Related information General The list below specifies documents which contain useful information: Documents Type of information Detailed in document Section Installation of safety devices Product manual for the Installation and commissioning manipulator Changing robot modes User’s Guide Start-up Restricting the working space Product manual for the...

  • Page 20: Safety Risks

    1 Safety 1.2.3.1. Safety risks during service work on robot 1.2.3. Safety risks 1.2.3.1. Safety risks during service work on robot Overview This section includes information of general safety risks to be considered when performing service work on the robot. 3HAC023297-001 Revision: A...
  • Page 21 1 Safety 1.2.3.1. Safety risks during service work on robot 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...
  • Page 22 1 Safety 1.2.3.1. Safety risks during service work on robot 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! 3HAC023297-001 Revision: A...

  • Page 23: Safety Risks Related To Gripper

    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. 3HAC023297-001 Revision: A...

  • Page 24: Safety Risks Related To Tools/Workpieces

    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).

  • Page 25: Safety Risks Related To Pneumatic/Hydraulic Systems

    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.

  • Page 26: Safety Risks During Operational Disturbances

    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.

  • Page 27: Safety Risks During Installation And Service

    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 •...

  • Page 28: Risks Associated With Live Electric Parts

    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.

  • Page 29: Safety Actions

    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.

  • Page 30: Fire Extinguishing

    1 Safety 1.2.4.2. Fire extinguishing 1.2.4.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot (manipulator or controller)! 3HAC023297-001 Revision: A...

  • Page 31: Emergency Release Of The Robot's Arm

    1 Safety 1.2.4.3. Emergency release of the robot’s arm 1.2.4.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot or on an optional external brake release unit. How to release the brakes is detailed in section: •...

  • Page 32: Brake Testing

    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.

  • Page 33: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    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. 3HAC023297-001 Revision: A...

  • Page 34: Safe Use Of The Teach Pendant Unit

    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.

  • Page 35: Work Inside The Manipulator's Working Range

    1 Safety 1.2.4.7. Work inside the manipulator's working range 1.2.4.7. Work inside the manipulator's working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 36: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 37 1 Safety 1.3.1. Safety signals, general 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.

  • Page 38: Danger - Moving Manipulators Are Potentially Lethal

    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.

  • Page 39: Warning - The Unit Is Sensitive To Esd

    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.

  • Page 40: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.4. WARNING - Safety risks during work with gearbox oil 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...
  • Page 41 1 Safety 1.3.4. WARNING - Safety risks during work with gearbox oil Warning Description Elimination / Action Warm oil drains quicker than When changing gearbox oil, first cold oil. run the robot for a time to heat up the oil. Heat up the oil! The specified amount of oil is After refilling, check the oil level.
  • Page 42 1 Safety 1.3.4. WARNING - Safety risks during work with gearbox oil 3HAC023297-001 Revision: A...

  • Page 43: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot. 3HAC023297-001 Revision: A...

  • Page 44: Unpacking

    2 Installation and commissioning 2.2.1. Pre-installation procedure 2.2 Unpacking 2.2.1. Pre-installation procedure General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the manipulator:...
  • Page 45 2 Installation and commissioning 2.2.1. Pre-installation procedure 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.
  • Page 46 2 Installation and commissioning 2.2.1. Pre-installation procedure Protection classes The table below shows the protection class of the main parts of the robot system: Equipment Protection class Manipulator IP 67 Control cabinet IP 54 Programming unit IP 54 3HAC023297-001 Revision: A...

  • Page 47: Working Range, Irb 140

    2 Installation and commissioning 2.2.2. Working range, IRB 140 2.2.2. Working range, IRB 140 Working range axis 2 -3 The illustration below shows the unrestricted working range axis 2-3. xx0200000058 Position at wrist centre Angle (degrees) Axis 2 Axis 3 0°...
  • Page 48 2 Installation and commissioning 2.2.2. Working range, IRB 140 Working range axis 1 The illustrations below shows the unrestricted working range of axis 1. xx0200000061 3HAC023297-001 Revision: A...

  • Page 49: Risk Of Tipping/Stability

    2 Installation and commissioning 2.2.3. Risk of tipping/Stability 2.2.3. Risk of tipping/Stability General The section below details instructions for making sure the manipulator does not tip over when it has not been safely secured to the foundation. Procedure The procedure below details how to make sure the manipulator does not tip during installation while not secured to the foundation.

  • Page 50: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting manipulator with lifting slings 2.3 On-site installation 2.3.1. Lifting manipulator with lifting slings General This section details how to lift the manipulator using lifting slings. Equipment Note Sling line Length: 2 m. Load: 500 kg. Illustration The following figures shows how to lift the manipulator with lifting slings.

  • Page 51: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. Manually releasing the brakes General The section below details how to release the holding brakes of each axis' motor. This may be done in one of three ways: • using the pushbutton when the manipulator is connected to the controller. •...
  • Page 52 2 Installation and commissioning 2.3.2. Manually releasing the brakes 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 Action Info/Illustration Connect an external power supply to connector XP1.
  • Page 53 2 Installation and commissioning 2.3.2. Manually releasing the brakes Step Action Info/Illustration Locate the R1.MP4-6 connector and disconnect. Connect an external power supply to release the holding brake on all axis. 3HAC023297-001 Revision: A...

  • Page 54: Orienting And Securing The Manipulator

    2 Installation and commissioning 2.3.3. Orienting and securing the manipulator 2.3.3. Orienting and securing the manipulator General This section details how to orient and secure the manipulator to the foundation in order to safely run the robot. Bolting requirements When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts.

  • Page 55: Restricting The Working Space

    2 Installation and commissioning 2.3.4. Restricting the working space 2.3.4. Restricting the working space General When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited.

  • Page 56: Fitting Equipment On Manipulator

    2 Installation and commissioning 2.3.5. Fitting equipment on manipulator 2.3.5. Fitting equipment on manipulator General The manipulator features mounting holes for additional equipment. In addition to the stock mounting holes, extra mounting holes may be added on the manipulator under certain conditions. These special conditions are specified in the Product Specification.
  • Page 57 2 Installation and commissioning 2.3.5. Fitting equipment on manipulator 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...

  • Page 58: Loads

    Load diagrams, permitted extra loads (equipment) and their positions as specified in the Product Specification. The loads must also be defined in the software as detailed in User's Guide. Brake performance Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC023297-001 Revision: A...

  • Page 59: Suspended Mounting

    2 Installation and commissioning 2.3.7. Suspended mounting 2.3.7. Suspended mounting General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the 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...
  • Page 60 2 Installation and commissioning 2.3.7. Suspended mounting xx0200000066 Defining the parameters Following steps describes how to enter the correct gravity beta values. Step Action Info/Illustration Choose Topics: Manipulator. Choose Types: Robot. Select Master and press Enter. xx0200000073 Select the desired parameter “gravity beta” and change its value.

  • Page 61: Bolt Pattern

    2 Installation and commissioning 2.3.8. Bolt pattern 2.3.8. Bolt pattern Hole configuration The illustration below shows the hole configuration used when securing the manipulator: xx0200000085 3HAC023297-001 Revision: A...
  • Page 62 2 Installation and commissioning 2.3.8. Bolt pattern Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes: xx0200000086 3HAC023297-001 Revision: A...

  • Page 63: Electrical Connections

    2 Installation and commissioning 2.4.1. Customer connections on manipulator 2.4 Electrical connections 2.4.1. Customer connections on manipulator General For connection of extra equipment on the manipulator there are cables integrated into the manipulator's cabling. There are both air and electrical connectors on the manipulator. xx0200000074 Connections Connections...
  • Page 64 Recommended parts To connect power and signal conductors to the upper arm connector, the following parts are recommended xx0200000132 ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains: • Multipole connector 12 pin • Adapter Tin plated 12 pin •...

  • Page 65: Maintenance

    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.

  • Page 66: Maintenance Schedules

    3 Maintenance 3.2.1. Maintenance schedule, IRB 140 3.2 Maintenance schedules 3.2.1. Maintenance schedule, IRB 140 General The robot, consisting of manipulator and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below.
  • Page 67 3 Maintenance 3.2.1. Maintenance schedule, IRB 140 Battery type selection The table below shows the selection criteria for the three available battery types. Change interval, Change interval, Operation pattern 3-cell lithium 6-cell lithium Max. 4 weeks power off per year 60 mths 60 mths Weekend power off + operation pattern 1...

  • Page 68: Inspection Activities

    3 Maintenance 3.3.1. Inspection, damper axes 2-3 3.3 Inspection activities 3.3.1. Inspection, damper axes 2-3 Location of dampers, axes 2-3 The figure below shows the location of all the dampers to be inspected. xx0200000426 Damper, axis 2 xx0200000427 Damper, axis 3 3HAC023297-001 Revision: A...
  • Page 69 3 Maintenance 3.3.1. Inspection, damper axes 2-3 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: •...

  • Page 70: Inspection, Robot Cabling

    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 Product manual, reference information.

  • Page 71: Inspection, Timing Belts

    3 Maintenance 3.3.3. Inspection, timing belts 3.3.3. Inspection, timing belts Location of timing belts Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 72 3 Maintenance 3.3.3. Inspection, timing belts xx0200000453 Timing belt, axis 6 Timing belt, axis 5 Required equipment Equipment, etc. 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 These procedures include references to may be required.
  • Page 73 3 Maintenance 3.3.3. Inspection, timing belts Inspection The procedure below details how to inspect the timing belts. WARNING! Please observe the following before commencing any repair work on the manipulator: • Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! •...

  • Page 74: Cleaning Activities

    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 • Water pressure at nozzle: max. 2,500 kN/ versions only! (25 bar) Steam cleaner...

  • Page 75: Changing/ Replacing Activities

    3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6 3.5 Changing/ replacing activities 3.5.1. Oil change, gearbox, axes 5 and 6 Location of oil plugs The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
  • Page 76 3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6 WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 77 3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6 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.
  • Page 78 3 Maintenance 3.5.1. Oil change, gearbox, axes 5 and 6 3HAC023297-001 Revision: A...

  • Page 79: Repair

    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.

  • Page 80: Complete Robot

    4 Repair 4.2.1. Replacement of cable harness 4.2 Complete robot 4.2.1. Replacement of cable harness Location of cable harness The cable harness runs from the base to the motors of axes 3-6. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 81 4 Repair 4.2.1. Replacement of cable harness Removal, cable harness The procedure below details how to remove the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 82 4 Repair 4.2.1. Replacement of cable harness Step Action Note/Illustration Remove the cables from the See figure above! cable holder by unscrewing the cable securing screws. Remove the cover, arm Detailed in section Replacement of cover, arm housing. housing, IRB 140.
  • Page 83 4 Repair 4.2.1. Replacement of cable harness 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.
  • Page 84 4 Repair 4.2.1. Replacement of cable harness Refitting, cable harness The procedure below details how to refit the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! •...
  • Page 85 4 Repair 4.2.1. Replacement of cable harness Step 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 •...
  • Page 86 4 Repair 4.2.1. Replacement of cable harness Step Action Note/Illustration Cable holder in the upper arm. xx0300000094 Cables: • A: Customer signal • B: Signal • C: Pressurized air supply • D: Power cables 3HAC023297-001 Revision: A...

  • Page 87: Replacement Of Complete Upper Arm

    4 Repair 4.2.2. Replacement of complete upper arm 4.2.2. Replacement of complete upper arm Location of upper arm The upper arm is located on top of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 88 4 Repair 4.2.2. Replacement of complete upper arm Required equipment Equipment Spare part no. Art. no. Note Upper arm, spare Std/F 3HAC 10466-1 Standard and Foundry versions Includes all required sealings and gaskets. Upper arm, spare CR 3HAC 10466-3 Clean room versions Includes all required sealings and gaskets.
  • Page 89 4 Repair 4.2.2. Replacement of complete upper arm Step Action Note/Illustration Remove the rear cover armhousing by unscrewing Shown in the figure Location of its four attachment screws. upper arm on page 85! 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...
  • Page 90 4 Repair 4.2.2. Replacement of complete upper arm 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.
  • Page 91 4 Repair 4.2.2. Replacement of complete upper arm Refitting The procedure below details how to refit the complete upper arm. Step Action Note Check the sealing ring to see whether it is Shown in the figure Location of damaged. upper arm on page 85! Replace if it is damaged! Art.
  • Page 92 4 Repair 4.2.2. Replacement of complete upper arm DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that: • all the service tools and other foreign objects are removed from the manipulator! •...

  • Page 93: Replacement Of Complete Lower Arm

    4 Repair 4.2.3. Replacement of complete lower arm 4.2.3. Replacement of complete lower arm Location of lower arm The lower arm is located between upper arm and frame as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 94 4 Repair 4.2.3. Replacement of complete lower arm Required equipment Equipment Spare part no. Art. no. Note Lower arm, spare 3HAC 10468-1 Standard and Foundry versions Includes all required bearings, oil and VK cover. Lower arm, spare 3HAC 10468-4 Clean room versions Includes all required bearings, oil and VK cover.
  • Page 95 4 Repair 4.2.3. Replacement of complete lower arm Step Action Info/Illustration Remove the console. Detailed in section Replacement of console page 118. 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...
  • Page 96 4 Repair 4.2.3. Replacement of complete lower arm Refitting, lower arm The procedure below details how to refit the complete lower arm. Step Action Info/Illustration Fit the lifting device and lift the lower arm into position. Fit the lower arm to gearbox, axis 2, and secure it with its attachment screws and washers.

  • Page 97: Replacement Of Base, Spare

    4 Repair 4.2.4. Replacement of base, spare 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. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 98 4 Repair 4.2.4. Replacement of base, spare Equipment Spare part no. Art. no. Note LocTite 574 For sealing the base to the gearbox 1-2 Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit Product manual, reference information! Other tools and These procedures include procedures may be references to the tools...
  • Page 99 4 Repair 4.2.4. Replacement of base, spare Refitting The procedure below details how to refit the complete lower arm. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 100 4 Repair 4.2.4. Replacement of base, spare • 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. 3HAC023297-001 Revision: A...

  • Page 101: Upper Arm

    4 Repair 4.3.1. Replacement of wrist unit 4.3 Upper arm 4.3.1. Replacement of wrist unit Location of wrist unit The wrist unit is located in the frontmost part of the upper arm. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 102 4 Repair 4.3.1. Replacement of wrist unit Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit Product manual, reference information! 3HAC 9037-1 For adjusting the gear play, motor/pinion Other tools and These procedures include procedures may be references to the tools...
  • Page 103 4 Repair 4.3.1. Replacement of wrist unit Step Action Note 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. In order to release the brake, connect the Connect to connector R3.MP5 or 6: 24 VDC power supply to motors: •...

  • Page 104: Replacement Of Damper, Axis 3

    4 Repair 4.3.2. Replacement of damper, axis 3 4.3.2. Replacement of damper, axis 3 Location of damper, axis 3 The damper, axis 3, is shown in the figure below! A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 105 4 Repair 4.3.2. Replacement of damper, axis 3 Removal, damper axis 3 The procedure below details how to remove the damper, axis 3. Step Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Run the robot to a position that enables access to Shown in the figure Location of...

  • Page 106: Replacement Of Damper, Axis 5

    4 Repair 4.3.3. Replacement of damper, axis 5 4.3.3. Replacement of damper, axis 5 Location of damper, axis 5 The damper, axis 5, is located as shown in the figure below! xx0200000429 Damper, axis 5 Recess Required equipment Equipment, etc. Spare part no.
  • Page 107 4 Repair 4.3.3. Replacement of damper, axis 5 Removal, damper axis 5 The procedure below details how to remove the damper, axis 5. Step Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 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...

  • Page 108: Replacement Of Cover, Arm Housing

    4 Repair 4.3.4. Replacement of cover, arm housing 4.3.4. Replacement of cover, arm housing Location of cover, armhousing The cover, armhousing is located on the rear of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 109 4 Repair 4.3.4. Replacement of cover, arm housing Removal The procedure below details how to remove the cover, armhousing. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...

  • Page 110: Lower Arm

    4 Repair 4.4.1. Replacement of lower arm cover and gasket 4.4 Lower arm 4.4.1. Replacement of lower arm cover and gasket Location of lower arm cover and gasket The lower arm cover and gasket are located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
  • Page 111 4 Repair 4.4.1. Replacement of lower arm cover and gasket Required equipment Equipment, etc. Spare part no. Art. no. Note Cover l. arm, spare, Std/F 3HAC 10471-1 Standard and Foundry versions No lamp unit included Includes gasket 3HAC 7869-1 Cover l. arm, spare, CR 3HAC 10471-3 Clean room versions No lamp unit included...
  • Page 112 4 Repair 4.4.1. Replacement of lower arm cover and gasket Refitting, lower arm cover and gasket The procedure below details how to refit the lower arm cover and gasket. WARNING! Please observe the following before commencing any repair work on the manipulator: •...

  • Page 113: Replacement Of Damper, Axis 2

    4 Repair 4.4.2. Replacement of damper, axis 2 4.4.2. Replacement of damper, axis 2 Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below! A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 114 4 Repair 4.4.2. Replacement of damper, axis 2 Removal, damper axis 2 The procedure below details how to remove the damper, axis 2. Step Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Run the robot to a position that enables you to access the attachment screw of damper, axis 2.

  • Page 115: Replacement Of Indicator Lamp

    4 Repair 4.4.3. Replacement of indicator lamp 4.4.3. Replacement of indicator lamp Location of indicator lamp The indicator lamp is located on the side of the lower arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 116 4 Repair 4.4.3. Replacement of indicator lamp Removal The procedure below details how to remove the indicator lamp. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...

  • Page 117: Frame And Base

    4 Repair 4.5.1. Replacement of cover, console 4.5 Frame and base 4.5.1. Replacement of cover, console Location of cover, console The cover, console is located on top of the console as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 118 4 Repair 4.5.1. Replacement of cover, console Equipment, etc. Spare part. no. Art. no. Note Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and These procedures procedures may be include references to the required.
  • Page 119 4 Repair 4.5.1. Replacement of cover, console Step Action Note Make sure the gasket inside the cover, console Replace if damaged. has not been damaged. Shown in the figure Location of cover, console on page 115. Secure the cover, console to the console with its attachment screws.

  • Page 120: Replacement Of Console

    4 Repair 4.5.2. Replacement of console 4.5.2. Replacement of console Location of console The console is located on top of gearbox, axes 1-2 as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 121 4 Repair 4.5.2. Replacement of console Removal The procedure below details how to remove the cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 122 4 Repair 4.5.2. Replacement of console Step Action Note/Illustration Remove the bearing hub by unscrewing its attachment screws. xx0300000096 Parts: • A: Console • B: Bearing hub • C: Bearing hub attachment screws (6 pcs) • D: Console attachment screws (10 pcs) •...
  • Page 123 4 Repair 4.5.2. Replacement of console Step 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) •...

  • Page 124: Replacement Of Serial Measurement Unit And Battery Pack

    4 Repair 4.5.3. Replacement of serial measurement unit and battery pack 4.5.3. Replacement of serial measurement unit and battery pack Location of serial measurement unit and battery pack The serial measurement unit and battery pack are located inside the manipulator base as shown in the figure below.
  • Page 125 4 Repair 4.5.3. Replacement of serial measurement unit and battery pack Equipment, etc. Spare part. no. Art. no. Note Standard Toolkit, IRB 140 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and These procedures procedures may be include references to the...
  • Page 126 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.
  • Page 127 4 Repair 4.5.3. Replacement of serial measurement unit and battery pack CAUTION! This component is classified as Hazardous waste and must be disposed of accordingly! If in doubt of the correct disposal procedure, please contact your local environmental authority! CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step...

  • Page 128: Replacement Of Control Cable

    4 Repair 4.5.4. Replacement of control cable 4.5.4. Replacement of control cable Location of control cable The control cable is located on the rear of the manipulator base as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 129 4 Repair 4.5.4. Replacement of control cable Equipment, etc. Spare part. no. Art. no. Note Control cable, spare 3HAC 13089-1 30 m Standard and Foundry versions Cover gasket included Control cable, spare 3HAC 10476-4 Clean Room versions Cover gasket included Control cable, spare 3HAC 10477-2 Clean Room versions...
  • Page 130 4 Repair 4.5.4. Replacement of control cable Step Action Note/Illustration Make sure the robot system has been switched off, and that no power is supplied to the manipulator. Remove the Control cable, spareby Shown in the figure Location of control cable unscrewing its attachment screws.
  • Page 131 4 Repair 4.5.4. Replacement of control cable Refitting The procedure below details how to refit control cable. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...

  • Page 132: Motors

    4 Repair 4.6.1. Replacement of motor, axis 1 4.6 Motors 4.6.1. Replacement of motor, axis 1 Location of motor axis 1 The motor axis 1 is located on the rear of the manipulator as shown in the figure below: A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 133 4 Repair 4.6.1. Replacement of motor, axis 1 Equipment, etc. Spare part no. Art no. Note Grease 3HAB 3537-1 Used to lubricate the o-ring Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit Product manual, reference information! 3HAC 9037-1 For adjusting the gear play, motor/pinion Power supply...
  • Page 134 4 Repair 4.6.1. Replacement of motor, axis 1 Removal The procedure below details how to remove motor, axis 1. CAUTION! If the manipulator normally works in an inverted position, it must be removed from this position and placed on the floor before the work detailed in this instruction may be carried out ! WARNING! Please observe the following before commencing any repair work on the manipulator:...
  • Page 135 4 Repair 4.6.1. Replacement of motor, axis 1 Refitting The procedure below details how to refit motor, axis 1. WARNING! Please observe the following before commencing any repair work on the manipulator: • - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! •...
  • Page 136 4 Repair 4.6.1. Replacement of motor, axis 1 Step Action Note 12. Perform a leak-down test. Detailed in section . 13. Recalibrate the robot! Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the...

  • Page 137: Replacement Of Motor, Axis 2

    4 Repair 4.6.2. Replacement of motor, axis 2 4.6.2. Replacement of motor, axis 2 Location of motor axis 2 The motor axis 2 is located on the front of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
  • Page 138 4 Repair 4.6.2. Replacement of motor, axis 2 Equipment, etc. Spare part no. Art. no. Note 3HAC 9037-1 For adjusting the gear play, motor/pinion Power supply 24 VDC, 1.5 A. For releasing the brakes. Other tools and These procedures include procedures may be references to the tools required.
  • Page 139 4 Repair 4.6.2. Replacement of motor, axis 2 Step Action Note Disconnect the brake release voltage. 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.
  • Page 140 4 Repair 4.6.2. Replacement of motor, axis 2 Step Action Note Disconnect the brake release voltage. 10. Make sure the cable gland cover gasket has not Art no. is specified in section been damaged. Replace if it has. Required equipment on page 135.

  • Page 141: Replacement Of Motor And Timing Belt, Axis 3

    4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 4.6.3. Replacement of motor and timing belt, axis 3 Location of motor axis 3 The motor axis 3 is located behind the lower arm cover on the right hand side of the manipulator as shown in the figure below.
  • Page 142 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Required equipment Equipment, etc. Spare part no. Art. no. Note Rot. ac motor with 3HAC 7866-1 Includes timing belt pinion pulley. 3HAC 021756-001 Timing belt 3HAC 6793-1 Grease 3HAB 3537-1 For lubricating the o- ring.
  • Page 143 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Step Action Note/Illustration Cut the cable ties to facilitate accessing the motor. xx0200000449 • A: Cable ties • B: Pressurized air hose • C: Power cables, axes 4, 5 and 6 •...
  • Page 144 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Step 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: •...
  • Page 145 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Step Action Note/Illustration Adjust the position of the motor in such a Correct belt tension F=35 - 60 N way that the correct belt tension is achieved. DO NOT adjust the belt tension using the intermediate wheel securing screws.

  • Page 146: Replacement Of Motor, Axis 4

    4 Repair 4.6.4. Replacement of motor, axis 4 4.6.4. Replacement of motor, axis 4 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. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
  • Page 147 4 Repair 4.6.4. Replacement of motor, axis 4 Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instructions below. Circuit Diagram 3HAC 6816-3 See chapter...
  • Page 148 4 Repair 4.6.4. Replacement of motor, axis 4 Refitting The procedure below details how to refit motor, axis 4. WARNING! Please observe the following before commencing any repair work on the manipulator: • - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! •...

  • Page 149: Replacement Of Motor And Timing Belt, Axes 5 Or 6

    4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Location of motor and timing belt, axes 5 or 6 The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the figure below.
  • Page 150 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 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...
  • Page 151 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Removal The procedure below details how to remove motor, axis 5 or 6. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 152 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Step Action Note Remove the cable guide by unscrewing its Shown in the figure in section Location two attachment screws. of motor and timing belt, axes 5 or 6 page 147! 10.
  • Page 153 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Refitting The procedure below details how to refit motor, axis 5. WARNING! Please observe the following before commencing any repair work on the manipulator: • - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! •...
  • Page 154 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Step Action Note 13. Pull the pressurized air connector through Shown in the figure in section the housing and secure it into fitting in the Location of motor and timing belt, upper arm assembly.

  • Page 155: Adjustments And Measurements

    4 Repair 4.6.6.1. Measuring the gear play, axis 5 4.6.6. Adjustments and measurements 4.6.6.1. Measuring the gear play, axis 5 General After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed below.
  • Page 156 4 Repair 4.6.6.1. Measuring the gear play, axis 5 Measurement The procedure below details how to measure the gear play for axis 5. Step Action Note/Illustration Manually, turn axis 4 90°. Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure.

  • Page 157: Measuring The Gear Play, Axis 6

    4 Repair 4.6.6.2. Measuring the gear play, axis 6 4.6.6.2. Measuring the gear play, axis 6 General After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed below.
  • Page 158 4 Repair 4.6.6.2. Measuring the gear play, axis 6 Measurement The procedure below details how to measure the gear play for axis 6. Step Action Note/Illustration Manually, turn axis 4 90°. Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure.

  • Page 159: Gearboxes

    4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 4.7 Gearboxes 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Location of gearbox 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! A more detailed view of the component and its position may be found in chapter...
  • Page 160 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Lifting device, 3HAC xx gearbox 1-2 Other tools and These procedures include...
  • Page 161 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Step Action Note/Illustration 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.
  • Page 162 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Refitting, gearbox 1-2 The procedure below details how to refit gearbox, axes 1-2. WARNING! Please observe the following before commencing any repair work on the manipulator: • - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! •...
  • Page 163 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Step Action Note/Illustration Fit the lifting tool to the base/ Art. no. is specified in section Required equipment frame and turn it right side up on page 157. on top of a suitable workbench.

  • Page 164: Service Work On Gearbox, Axis 4

    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.

  • Page 165: Calibration Information

    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.

  • Page 166: Calibration Methods

    5 Calibration information 5.2. Calibration methods 5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of Description Calibration method calibration Standard The calibrated robot is positioned at home...
  • Page 167 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.

  • Page 168: Calibration Scales And Correct Axis Position

    5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales, IRB 140 The illustration below shows the calibration scale positions on IRB 140: xx0200000157 3HAC023297-001 Revision: A...

  • Page 169: Calibration Movement Directions For All Axes

    5 Calibration information 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.

  • Page 170: Updating Revolution Counters

    5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using 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;...
  • Page 171 5 Calibration information 5.5. Updating revolution counters Storing the revolution counter setting with the TPU This section details the second step when updating the revolution counter; storing the revolution counter setting with the TPU (RobotWare 4.0). Step Action Note Press the button "Miscellaneous" then ENTER to select the service window.
  • Page 172 This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Step Action On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Tap the mechanical unit in question.
  • Page 173 5 Calibration information 5.5. Updating revolution counters Step Action 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.

  • Page 174: Checking The Calibration Position

    This section describes how to create a program, which runs all the robot axes to their zero position. Step Action Note On ABB menu tap Program Editor. Create a new program. Use MoveAbsJ in the Motion&Proc menu. Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff s, v1000, z50, Tool0 Run the program in manual mode.
  • Page 175 This section describes how to jog the robot to all axes zero position. Step Action Note Tap Jogging in the ABB menu. Tap Motion mode to choose group of axes to jog. Tap axes 1-3 to jog axes 1, 2 or 3. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero.
  • Page 176 5 Calibration information 5.6. Checking the calibration position 3HAC023297-001 Revision: A...
  • Page 177 Index Calibration position calibration position, checking calibration position, jog to Connection of external safety devices direction of axes Limitation of Liability negative directions, axes positive directions, axes Revolution counters Safety, service Updating revolution counters Validity and responsibility 3HAC023297-001 Revision: A...
  • Page 180 ABB Automation Technologies AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...
  • Page 181 Product manual (part 2 of 2), reference information Articulated robot IRB 140 M2000, M2000A, M2004...
  • Page 183 Product manual (part 2 of 2), reference information IRB 140 M2000 M2000A M2004 Document ID: 3HAC023297-001 Revision: A...
  • Page 184 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.
  • Page 185 Product documentation, M2000/M2000A ........
  • Page 186 Table of Contents 3HAC023297-001 Revision: A...
  • Page 187 Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 188 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. •...
  • Page 189 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...
  • Page 190 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.
  • Page 191 Product documentation, M2004 • How to use the application • Examples of how to use the application Operator’s manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: •...
  • Page 192 Product documentation, M2004 3HAC023297-001 Revision: A...
  • Page 193 1 Reference information 1.1. Introduction 1 Reference information 1.1. Introduction General This chapter includes general information, complementing the more specific information in Product manual (part 1 of 2), procedures. 3HAC023297-001 Revision: A...
  • Page 194 1 Reference information 1.2. Applicable Safety Standards 1.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: • EN ISO10218-1 : 2005, Robots for industrial environments - Safety requirements - Part 1 Robot • ANSI/RIA 15.06-1999 •...
  • Page 195 1 Reference information 1.3. Unit conversion 1.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...
  • Page 196 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.
  • Page 197 1 Reference information 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.
  • Page 198 1 Reference information 1.4. Screw joints The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque Dimension Nm - Nominal Nm - Min. Nm - Max.
  • Page 199 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.
  • Page 200 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...
  • Page 201 1 Reference information 1.6. Document references Additional documentation Document name Document ID Note External axes 3HAC 9299-1 3HAC023297-001 Revision: A...
  • Page 202 1 Reference information 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.
  • Page 203 1 Reference information 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.
  • Page 204 1 Reference information 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.
  • Page 205 1 Reference information 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.
  • Page 206 1 Reference information 1.11. Mounting instructions for seals 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.
  • Page 207 (without sealing compund). If the flange surfaces are defective, the parts may not be used beacuse leakage could occur. Clean the surfaces properly and in accordance with ABB ROBOTICS PRODUCTS recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush.
  • Page 208 1 Reference information 1.11. Mounting instructions for seals 3HAC023297-001 Revision: A...
  • Page 209 2 Spare part / part list 2.1. Introduction 2 Spare part / part list 2.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC023297-001 Revision: A...
  • Page 210 2 Spare part / part list 2.2. Spare part / part list 2.2. Spare part / part list Spare part / part list The table below details all replacement articles on the robot. The items refer to chapter Foldouts. Item Art.
  • Page 211 2 Spare part / part list 2.2. Spare part / part list Item Art. no. Name Rem. 3HAC 10477-2 Control cable spare CR L = 7 m 3HAC 11331-1 Control cable spare Std/F L = 15 m 3HAC 11331-2 Control cable spare CR L = 15 m 3HAC 13089-1 Control cable spare Std/F...
  • Page 212 2 Spare part / part list 2.2. Spare part / part list Item Art. no. Name Rem. 3HAB 3402-15 Hex. socket head cap screw M5x20 8.8 Gleitmo 610 9ADA 312-5 Plain washer 5.3x10x1 3HAC 9258-1 Indicator lamp 3HAC 10468-4 Lower arm, spare CR 3HAC 10471-3 Cover, without lamp unit 3HAC 10474-3...
  • Page 213 2 Spare part / part list 2.2. Spare part / part list Item Art. no. Name Rem. 2125 2052-178 Distance bolt M5X55 3HAC 6598-1 Hose nipple G 1/4" 3HAB 8964-1 Damper axis 5 550 ml 3HAC 0860-1 Lubricating oil Optimol Opti- gear BM 100 3HAC 10466-3 Upper arm, spare CR...
  • Page 214 2 Spare part / part list 2.2. Spare part / part list 3HAC023297-001 Revision: A...
  • Page 215 3 Foldouts 3.1. Introduction 3 Foldouts 3.1. Introduction Overview The foldouts in this chapter refer to the part list. 3HAC023297-001 Revision: A...
  • Page 216 R1/4 Inside of cover 35 Nm Inside of base Base complete Foldout 1...
  • Page 217 A (1 : 2) 15,5 Nm ax.1 1,2 litre ax.2 1,0 litre Foldout 2...
  • Page 218 0,4 litre Do not loosen these screws Do not loosen these screws 4,1 Nm 35 Nm Lower arm complete with cables Lower arm (shown without cables) (shown without cover) Foldout 3...
  • Page 219 0,35 litre oil (at oil change). 0,30 litre oil (New wrist) 0,2 litre oil 4,1 Nm 3 Nm 28 Nm 35 Nm 6 Nm 4,1 Nm Upper arm (shown without cables) 6 Nm 4,1 Nm 4,1 Nm Foldout 4...
  • Page 220 Upper arm with cables (shown without cover) Upper arm complete Foldout 5...
  • Page 222 4 Circuit diagram 4.1. Introduction 4 Circuit diagram 4.1. Introduction Overview This chapter includes the circuit diagram for the robot. 3HAC023297-001 Revision: A...
  • Page 223 Circuit Diagram CONTENTS Page Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............101-108 IRB 140...
  • Page 224 Manipulator Circuit Diagram 3HAC 6816-3 LIST OF CONTENTS IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 225 Manipulator Circuit Diagram 3HAC 6816-3 CONNECTION POINT LOCATIONS IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 226 Manipulator Circuit Diagram 3HAC 6816-3 SERIAL MEASUREMENT BOARD IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 227 Manipulator Circuit Diagram 3HAC 6816-3 MOTOR AXIS 1 - 3 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 228 Manipulator Circuit Diagram 3HAC 6816-3 FEEDBACK AXIS 1 - 3 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 229 Manipulator Circuit Diagram 3HAC 6816-3 MOTOR AXIS 4 - 6 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 230 Manipulator Circuit Diagram 3HAC 6816-3 FEED-BACK AXIS 4 - 6 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 231 Manipulator Circuit Diagram 3HAC 6816-3 CUSTOMER CONNECTIONS IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 234 ABB Automation Technologies AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

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