ABB M2000 Product Manual Download Page 83

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4 Repair

4.2.1. Replacement of cable harness

3HAC023297-001 Revision: A

11. Disconnect the connectors

inside the lower arm.

xx0200000449

•

G: Connectors R3.MP3 and R3.FB3

12. Pull the cables out of the upper

arm.

13. Remove the cover, console.

Detailed in section

Replacement of cover, console

on page 115.

14. Disconnect the connectors

inside the console and undo
the cable holders.

Connectors:

•

R3.MP1

•

R3.MP2

•

R3.FB1

•

R3.FB2

15. Gently pull the cabling from the

base up through the console.

16. Gently pull the cabling out of

the lower arm.

Step

Action

Note/Illustration

Summary of Contents for M2000

Page 1: ... Product manual part 1 of 2 procedures Articulated robot IRB 140 M2000 M2000A M2004 ...

Page 2: ......

Page 3: ...Product manual part 1 of 2 procedures IRB 140 M2000 M2000A M2004 Document ID 3HAC023297 001 Revision A ...

Page 4: ... specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be prosecuted Additio...

Page 5: ...xtinguishing 28 1 2 4 3 Emergency release of the robot s arm 29 1 2 4 4 Brake testing 30 1 2 4 5 Risk of disabling function Reduced speed 250 mm s 31 1 2 4 6 Safe use of the Teach Pendant Unit 32 1 2 4 7 Work inside the manipulator s working range 33 1 3 Safety related instructions 34 1 3 1 Safety signals general 34 1 3 2 DANGER Moving manipulators are potentially lethal 36 1 3 3 WARNING The unit ...

Page 6: ...wer arm 108 4 4 1 Replacement of lower arm cover and gasket 108 4 4 2 Replacement of damper axis 2 111 4 4 3 Replacement of indicator lamp 113 4 5 Frame and base 115 4 5 1 Replacement of cover console 115 4 5 2 Replacement of console 118 4 5 3 Replacement of serial measurement unit and battery pack 122 4 5 4 Replacement of control cable 126 4 6 Motors 130 4 6 1 Replacement of motor axis 1 130 4 6 ...

Page 7: ...Table of Contents 5 3HAC023297 001 Revision A 5 5 Updating revolution counters 168 5 6 Checking the calibration position 172 ...

Page 8: ...Table of Contents 3HAC023297 001 Revision A 6 ...

Page 9: ...k Organization of chapters The manual is organized in the following chapters Chapter Contents Safety service Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product Installation and commissioning Required information ab...

Page 10: ...al part 2 Changes made in the material from the previous manuals Model M2004 implemented Chapter Calibration replaced with chapter Calibration information Chapter Safety service replaced with new safety chapter Information about the controller removed from the manual Additional spare part numbers for the motors A Changes made in Prerequisites in section Overview Oil change in section Maintenance ...

Page 11: ...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 fr...

Page 12: ...criptions 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 r...

Page 13: ...rators programmers and trouble shooters The group of manuals include Operator s manual IRC5 with FlexPendant Operator s 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 ...

Page 14: ... spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information i e article number dimension The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list The table...

Page 15: ...erforming any service work on the robot These are applicable for all service work and are found in section General safety information on page 14 specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section Safety related instructio...

Page 16: ... The dangers are split into different categories Safety risks during service work on robot Safety risks related to gripper end effector Safety risks related to tools workpieces Safety risks related to pneumatic hydraulic systems Safety risks during operational disturbances Safety risks during installation and service Risks associated with live electric parts 3 Safety actions details actions which ...

Page 17: ...rved and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly Personnel working with robots must be familiar with the operation and handling of the industrial robot described in the applicable documents e g User s Guide and Product Manual Connection of external safety devices Apart from the built in safety functions the robot ...

Page 18: ...ision A 16 1 2 2 2 Limitation of Liability General Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions have been complied with ...

Page 19: ...ments which contain useful information Documents Type of information Detailed in document Section Installation of safety devices Product manual for the manipulator Installation and commissioning Changing robot modes User s Guide Start up Restricting the working space Product manual for the manipulator Installation and commissioning ...

Page 20: ...vice work on robot 3HAC023297 001 Revision A 18 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 ...

Page 21: ...y necessary measures to ensure that the robot does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage Caution The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Safety risk Description Gears ma...

Page 22: ...n A 20 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 ...

Page 23: ...1 Safety 1 2 3 2 Safety risks related to gripper 21 3HAC023297 001 Revision A 1 2 3 2 Safety risks related to gripper CAUTION Ensure that a gripper is prevented from dropping a workpiece if such is used ...

Page 24: ... must be possible to turn off tools such as milling cutters etc safely Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller ...

Page 25: ...lic systems Residual energy Residual energy may be present in these systems so after shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from...

Page 26: ...nally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than tho...

Page 27: ...ve mats are suitable devices Turntables or the like should be used to keep the operator out of the robot s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by the parallel arm Energy stored in the robot for the purpose of counterbalancing certain axes may be released...

Page 28: ... with power from an external source The mains supply mains switch The power unit The power supply unit for the computer system 230 VAC The rectifier unit 400 480 VAC and 700 VDC Note Capacitors The drive unit 700 VDC The service outlets 115 230 VAC The power supply unit for tools or special power supply units for the machining process The external voltage connected to the control cabinet remains l...

Page 29: ...osure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification Description Robot Motion Also consider the maximum possible impact caused by a breaking or malfunction...

Page 30: ...1 Safety 1 2 4 2 Fire extinguishing 3HAC023297 001 Revision A 28 1 2 4 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot manipulator or controller ...

Page 31: ...uttons on the robot or on an optional external brake release unit How to release the brakes is detailed in section Manually releasing the brakes on page 49 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on th...

Page 32: ...he function of each axis motor holding brakes may be checked as detailed below 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 Check that the axis maintains its position If the manipulator does not change position as...

Page 33: ... 250 mm s 31 3HAC023297 001 Revision A 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 ...

Page 34: ...d all the way in the robot is taken to the MOTORS OFF state To ensure safe use of the Teach Pendant Unit the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the Teach Pendant Unit with him her when ent...

Page 35: ...rol panel The robot s speed is limited to max 250 mm s when the operating mode selector is in position 250 mm s This should be the normal position when entering the working space The position 100 full speed may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance to the axes in order not to get entangle...

Page 36: ...mple contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage elect...

Page 37: ...harge ESD symbol indicates electrostatic hazards which could result in severe damage to the product Note NOTE Note symbols alert you to important facts and conditions Tip TIP Tip symbols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way Symbol Designation Signification ...

Page 38: ...on Info Illustration 1 Before attempting to run the manipulator make sure all emergency stop equipment has been correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run button whenever possible The hold to run button is used in manual mode not in automatic mode How to use the hold to run control in RobotWare 5 0 is det...

Page 39: ...ling parts or their containers personnel not connected to ground potential may transfer high static charges This discharge may destroy sensitive electronics Elimination Step Action Note Illustration 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly 2 Use an ESD protective floor mat The mat must be grounded through a current l...

Page 40: ...vity Possible pressure build up in gearbox When opening the oil plug there may be pressure present in the gearbox causing oil to spray from the opening Open oil plug carefully and keep away from the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely p...

Page 41: ...the robot for a time to heat up the oil Specified amount depends on drained volume The specified amount of oil is based on the total volume of the gearbox When changing the oil the amount of refilled oil may differ from the specified amount depending on how much oil has previously been drained from the gearbox After refilling check the oil level Warning Description Elimination Action ...

Page 42: ...1 Safety 1 3 4 WARNING Safety risks during work with gearbox oil 3HAC023297 001 Revision A 40 ...

Page 43: ...nd 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 ...

Page 44: ...ator and control cabinet exterior 3 Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator Specified in section Weight manipulator on page 42 4 If the manipulator is not to be installed directly it must be stored Specified in section Storage conditions manipulator on page 43 5 Make sure the appointed operating environment of the manipulator conforms to the s...

Page 45: ...for the manipulator Operating conditions manipulator The table below shows the allowed operating conditions for manipulator Force Endurance load operation Max load emergency stop Force xy upright suspended 1300 N 3200 N Force z upright 1000 1000 N 1000 2000 N Forze z suspended 2800 1000 N 1000 2000 N Torque Mxy 1300 Nm 220 Nm Mz 300 Nm 750 Nm Requirement Value Min levelity 0 5 mm Max tilt 5 Min re...

Page 46: ...e installation procedure 3HAC023297 001 Revision A 44 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 ...

Page 47: ...RB 140 Working range axis 2 3 The illustration below shows the unrestricted working range axis 2 3 xx0200000058 Pos Position at wrist centre Angle degrees X Z Axis 2 Axis 3 0 450 712 0 0 1 70 1092 0 90 2 314 421 0 50 3 765 99 110 90 4 255 119 110 4 5 480 23 90 150 6 1 596 90 50 7 218 558 110 230 8 670 352 90 90 ...

Page 48: ...2 Installation and commissioning 2 2 2 Working range IRB 140 3HAC023297 001 Revision A 46 Working range axis 1 The illustrations below shows the unrestricted working range of axis 1 xx0200000061 ...

Page 49: ...The procedure below details how to make sure the manipulator does not tip during installation while not secured to the foundation CAUTION When the manipulator is not fastened to the floor it will not be stable in any part of its working area 1 DO NOT change the manipulator position before securing it to its foundation The shipping position is the most stable 2 If the manipulator for some reason mu...

Page 50: ...n The following figures shows how to lift the manipulator with lifting slings xx0200000084 How to lift the manipulator 1 Adjust the manipulator to lifting position according to the picture 2 Put one sling line around each leg on the lower arm Pos 1 and 2 3 Use further one sling line to secure the lifting of the control cable Pos 3 Equipment Note Sling line Length 2 m Load 500 kg 1 Sling line for m...

Page 51: ...pushbutton on the manipulator with an external power supply using an external voltage supply DANGER When releasing the holding brakes the manipulator axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near the manipulator arm Using the pushbutton when the manipulator is connected to the controller This section details how to release the holding brakes using the i...

Page 52: ...External power supply This section details how to release the holding brakes using a external voltage supply If the positions of the manipulator axes are to be changed without connecting the controller an external voltage supply 24 V DC must be connected to enable the brake release buttons on the manipulator Step Action Info Illustration 1 Connect an external power supply to connector XP1 xx020000...

Page 53: ...ssioning 2 3 2 Manually releasing the brakes 51 3HAC023297 001 Revision A 2 Locate the R1 MP4 6 connector and disconnect 3 Connect an external power supply to release the holding brake on all axis Step Action Info Illustration ...

Page 54: ...When the robot is to be mounted in a tilted or a suspended position the guide sleeves must be used to secure the bolted joint Attachment screws The table below specifies the type of securing screws and washers to be used for securing the manipulator to the base plate foundation Hole configuration and cross section The bolt pattern requirements are shown in section Bolt pattern on page 59 Guide sle...

Page 55: ...hat it may collide with other objects its working space should be limited WARNING The working space can only be limited using soft ware for this reason the limited area can not be classified as a safe zone All work within this zone is prohibited Limiting devices Limiting devices is listed below 1 Light curtains 2 Tread mats 3 Other similar devices 4 SoftWare Limiting the working space using softwa...

Page 56: ...s mounting holes for additional equipment In addition to the stock mounting holes extra mounting holes may be added on the manipulator under certain conditions These special conditions are specified in the Product Specification Illustration holes on upper arm The illustration below shows the stock holes available for fitting extra equipment on the upper arm xx0200000062 ...

Page 57: ...e stock holes available for fitting equipment on the mounting flange xx0200000063 Fastener quality When fitting tools on the mounting flange see the figures in sections Illustration holes on upper arm on page 54 and Illustration holes on mounting flange on page 55 use only screws with quality 12 9 When fitting other equipment standard screws with quality 8 8 can be used ...

Page 58: ...avoid jolting movements and overloading the motors If this is not done correctly operation stops may result References Load diagrams permitted extra loads equipment and their positions as specified in the Product Specification The loads must also be defined in the software as detailed in User s Guide Brake performance Manipulator motor brake performance depends on any loads attached For further in...

Page 59: ...ed Gravity beta specifies the robot s mounting angle expressed in radians NOTE It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way Incorrect definition of mounting angle gravity beta will result in Overloading the mechanical structure Lower path performance and path accuracy Some S4 functions will not work properly e ...

Page 60: ...fining the parameters Following steps describes how to enter the correct gravity beta values Step Action Info Illustration 1 Choose Topics Manipulator 2 Choose Types Robot 3 Select Master and press Enter xx0200000073 4 Select the desired parameter gravity beta and change its value 5 Press OK to confirm ...

Page 61: ...lation and commissioning 2 3 8 Bolt pattern 59 3HAC023297 001 Revision A 2 3 8 Bolt pattern Hole configuration The illustration below shows the hole configuration used when securing the manipulator xx0200000085 ...

Page 62: ...2 Installation and commissioning 2 3 8 Bolt pattern 3HAC023297 001 Revision A 60 Cross section guide sleeve hole The illustration below shows the cross section of the guide sleeve holes xx0200000086 ...

Page 63: ...nnection of extra equipment on the manipulator there are cables integrated into the manipulator s cabling There are both air and electrical connectors on the manipulator xx0200000074 Connections Connections Description 1 For air on base upper arm R1 4 Max 8 bar hose inner diameter 6 5 mm 2 Signal connector on upper arm FCI UT 071412SH44N connector Number of signals 12 signals 49V 500mA ...

Page 64: ...e following parts are recommended xx0200000132 ABB s recommended contact set for connector R2 CS 3HAC 12497 1 contains Multipole connector 12 pin Adapter Tin plated 12 pin Pins for cable area 0 25 0 5 mm 2 Pins for cable area 0 5 1 5 mm 2 Shrinking hose bootled shaped Shrinking hose angled The connection set is delivered in a plastic bag also containing a Technical and assembly instruction ...

Page 65: ...ity and refers to procedures for the activities Each procedure contains all information required to perform the activity e g required tools and materials The procedures are gathered in different sections divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are general safety asp...

Page 66: ...but the actual interval may not be specified by the robot manufacturer The interval depends on the operation cycle of the robot its working environment and movement pattern Generally the more contaminated environment the shorter intervals The more demanding movement pattern sharper bending cable harness the shorter intervals Maintenance activity Equipment Interval Detailed in section Inspection Da...

Page 67: ...battery types No longer change interval than 60 months are allowed regardless of the operation pattern due to material ageing etc Operation pattern Change interval 3 cell lithium Change interval 6 cell lithium Max 4 weeks power off per year 60 mths 60 mths Weekend power off operation pattern 1 24 mths 48 mths Nightly power off operation patterns 1 and 2 12 mths 24 mths ...

Page 68: ...3 3HAC023297 001 Revision A 66 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 xx0200000427 A Damper axis 2 A Damper axis 3 ...

Page 69: ...oes not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Equipment Art no Note Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Step Action Note 1 Check all dampers for damage such as cracks or existing impressions larger than 1 mm Shown in the figure in section Location of ...

Page 70: ... the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Inspection The procedure below details how to inspect the robot cabling Equipment Art no Note Standard toolkit 3HAC020812 001 The co...

Page 71: ...ming 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 in the Product manual reference information xx0200000448 G Timing belt axis 3 ...

Page 72: ...lt axis 5 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 may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required ...

Page 73: ...ep Action Note 1 Gain access to each belt by removing covers etc These procedures are detailed in sections Replacement of motor and timing belt axis 3 on page 139 and Replacement of motor and timing belt axes 5 or 6 on page 147 2 Check each belt for damage Replace the timing belts if found defective as detailed in sections Replacement of motor and timing belt axis 3 on page 139 and Replacement of ...

Page 74: ... other seals Never spray from a distance closer than 0 4 m Never remove any covers or other protective devices before cleaning the robot Never use any cleaning agents e g compressed air or solvents other than those specified above Although the manipulator is watertight avoid spraying connectors and similar items with a high pressure cleaner Equipment etc Art no Note May be used on Foundry versions...

Page 75: ...duct manual reference information xx0200000475 Required equipment A Oil plug gearbox axis 5 B Oil plug gearbox axis 6 Equipment etc Art no Amount Note Lubricating oil gearbox 5 and 6 3HAC0860 1 350 ml Optimol BM 100 Oil collecting vessel Capacity 400 ml Standard Toolkit IRB 140 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other too...

Page 76: ...age seals and gaskets completely press out seals and gaskets prevent the manipulator from moving freely WARNING Changing and draining gearbox oil may require handling hot oil of up to 90 C Make sure that protective gear like goggles and gloves are always worn during this activity Also be aware of possible pressure build up in gearbox When opening the oil plug there may be pressure present in the g...

Page 77: ... during draining both must be removed Shown in the figure Location of oil plugs on page 73 3 Fill oil in gearbox 5 until the oil level reaches the oil plug hole on the side of the wrist The figure shows the manipulator positions for filling and draining respectively for a standing manipulator xx0300000161 Positions A Draining position B Filling position The figure shows the manipulator positions f...

Page 78: ...3 Maintenance 3 5 1 Oil change gearbox axes 5 and 6 3HAC023297 001 Revision A 76 ...

Page 79: ... according to the component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the Product manual reference information Safety information Before any service work is commenced it is extremely important that all safety information is observed There ar...

Page 80: ...70 1 Standard and Foundry versions Clean room version Includes cabling Cable harness power axis 1 3 Cable harness power axis 4 6 Cable harness signals axis 1 3 Cable harness signals axis 4 6 Cable harness customer connections Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be required Se...

Page 81: ... the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Step Action Note Illustration 1 Remove the serial measurement board Detailed in section Replacement of serial measurement unit and b...

Page 82: ...d in section Replacement of lower arm cover and gasket on page 108 7 Gently knock out the VK cover Detailed in section Removing the VK cover on page 88 8 Disconnect connectors in the rear of the upper arm xx0300000092 Connectors A R2 CS B Pressurized air connection C R3 FB4 D R3 FB5 E R3 FB6 F R3 MP5 G R3 MP4 H R3 MP6 Parts J Shield 9 Remove the shield by unscrewing its attachment screws See figur...

Page 83: ...the cables out of the upper arm 13 Remove the cover console Detailed in section Replacement of cover console on page 115 14 Disconnect the connectors inside the console and undo the cable holders Connectors R3 MP1 R3 MP2 R3 FB1 R3 FB2 15 Gently pull the cabling from the base up through the console 16 Gently pull the cabling out of the lower arm Step Action Note Illustration ...

Page 84: ...cessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Step Action Note Illustration 1 Refit in reverse order to what is detailed above Detailed below ar...

Page 85: ...1 Revision A 3 Cable layout in the lower arm xx0200000449 A Cable ties B Pressurized air hose C Power cables axes 4 5 and 6 D Customer cables signal E Signal cables axes 4 5 and 6 F Signal cable axis 3 G Connectors R3 MP3 and R3 FB3 Step Action Note Illustration ...

Page 86: ... 2 1 Replacement of cable harness 3HAC023297 001 Revision A 84 4 Cable holder in the upper arm xx0300000094 Cables A Customer signal B Signal C Pressurized air supply D Power cables Step Action Note Illustration ...

Page 87: ...or as shown in the figure below A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual reference information xx0200000446 A Cover armhousing B Attachment screws cover armhousing 4 pcs C CS connector D Pressurized air connector E VK cover F Cable guide G Attachment screws cable guide H Attachment screws upper arm 6 pcs J Sealing ring ...

Page 88: ...ersions Includes all required sealings and gaskets Upper arm spare CR 3HAC 10466 3 Clean room versions Includes all required sealings and gaskets Sealing ring 3HAB 3732 13 To be replaced if damaged only Included in the upper arm assembly VK cover 3HAC 2166 13 Gasket upper arm cover 3HAC 7867 1 To be replaced if damaged only Included in the upper arm assembly Standard toolkit 3HAC020812 001 The con...

Page 89: ...ng and pull it into the upper arm assembly Shown in the figure Location of upper arm on page 85 Art no specified in section Required equipment on page 86 8 Remove the pressurized air connector from the housing and pull it into the upper arm assembly Shown in the figure Location of upper arm on page 85 Art no specified in section Required equipment on page 86 9 Remove the VK cover from the upper ar...

Page 90: ...ver l arm spare with lamp unit Step Action Note 1 Remove the lower arm cover by unscrewing its attachment screws 2 Tap the VK coverwith a long blunt edged bar through the hole in the lower arm to press it out Make sure to press the circumference of the VK cover evenly to avoid damaging it Shown in the figure in section Location of upper arm on page 85 3 If the VK cover is damaged it must be replac...

Page 91: ... it into fitting in the upper arm assembly Shown in the figure Location of upper arm on page 85 8 Pull the CS connector through the housing and secure it into the fitting in the upper arm assembly Use a special socketto secure it Shown in the figure Location of upper arm on page 85 Art no specified in section Required equipment on page 86 9 Reconnect any connector previously connected externally t...

Page 92: ...intenance it is vital that all the service tools and other foreign objects are removed from the manipulator all normal safety equipment is installed properly e g TPU enabling device all personnel are standing at a safe distance from the manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced ...

Page 93: ...acement 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 in the Product manual reference information xx0200000469 A Lower arm ...

Page 94: ...se as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Equipment Spare part no Art no Note Lower arm spare 3HAC 10468 1 Standard and Foundry versions Includes all required bearings oil and VK cover Lower arm spare 3HAC 10468 4 Clean room versions Includes all required bearings oil and VK cover Standard toolkit 3HAC020812 001 The contents are defined in section Stan...

Page 95: ...e lower arm Doing so will cause the manipulator to require a complete rebuild xx0300000101 Parts A DO NOT touch these screws Note Only 2 screws are shown 3 Remove the VK cover by pressing a screwdriver or similar through it and pulling xx0300000097 Parts A Washer B Lower arm attachment screws 10 pcs C VK cover 4 Unscrew thelower arm attachment screws Also remove the washer Shown in the figure abov...

Page 96: ...cure it with its attachment screws and washers xx0300000097 Parts A Washer B Lower arm attachment screws 10 pcs C VK cover Tightening torque 35 Nm 3 Nm 3 Fit a new VK cover by gently tapping it into position Shown in the figure above 4 Refit the console Detailed in section Replacement of console on page 118 5 Recalibrate the robot Calibration is detailed in separate calibration manuals Art no for ...

Page 97: ...ldouts in the Product manual reference information xx0200000423 Required equipment A Base B Bottom plate C Bottom plate attachment screws 26 pcs D Gearbox base attachment screws and washers 20 pcs each E Joint gearbox base F Damper axis 1 G Washer Equipment Spare part no Art no Note Base spare 3HAC 10470 1 Standard and Foundry versions Includes Parallel pin 3HAC 3785 2 Base spare 3HAC 10470 3 Clea...

Page 98: ...e references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment Spare part no Art no Note Step Action Info 1 Remove motors 1 and 2 Detailed in sections Replacement of motor axis 1 on page 130 and Replacement of motor axis 2 on page 135 respectively 2 Remove the cable harness Detailed in section Replacement of cable harness...

Page 99: ...e between the base and gearbox is completely clean apply Loctite to it Art no is specified in section Required equipment on page 95 3 Secure the gearbox to the base with the gearbox base attachment screws and washers Shown in the figure Location of base Tightening torque 35 Nm 3Nm 4 Refit the bottom plate and secure it with its attachment screws Shown in the figure Location of base 5 Turn the base...

Page 100: ... base spare 3HAC023297 001 Revision A 98 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 ...

Page 101: ...r Foldouts in the Product manual reference information xx0200000438 Required equipment A Wrist unit attachment screws 3 pcs B Oil plug one shown C Wrist unit Equipment etc Spare part no Art no Note Wrist unit Std F 3HAC 10475 1 Standard and Foundry versions O ring sealing plate not included Wrist unit CR 3HAC 10475 4 Clean room versions O ring sealing plate not included O ring sealing plate 3HAC 7...

Page 102: ...ures include references to the tools required Equipment etc Spare part no Art no Note Step Action Note 1 Danger Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Drain the oil from the wrist unit Detailed in section Oil change gearbox axes 5 and 6 on page 73 3 Remove the wrist unit by unscrewing its three attachment screws Shown in the figure in section Location ...

Page 103: ...ly to motors Connect to connector R3 MP5 or 6 pin 7 pin 8 6 Fit the Arm to the rear of the motor Art no is specified in section Required equipment on page 99 7 Manually push the motor to adjust the motor in relation to the gear in the gearbox Minimize the gear play as shown in the figure xx0200000445 A Wrist unit axes 5 and 6 gears B Drive shafts from motors axes 5 and 6 gears C Adjustment directi...

Page 104: ...outs in the Product manual reference information xx0200000427 Required equipment A Damper axis 3 Equipment etc Spare part no Art no Note Damper axis 3 3HAC 7881 1 Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be required See references to these procedures in the step by step instructio...

Page 105: ...manipulator i e out of its reach behind any safety fences etc special attention is paid to the function of the part previously serviced Step Action Note 1 Danger Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Run the robot to a position that enables access to damper axis 3 Shown in the figure Location of damper axis 3 on page 102 3 Remove the damper by gently ...

Page 106: ...uired equipment A Damper axis 5 B Recess Equipment etc Spare part no Art no Note Damper axis 5 3HAC 8964 1 Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tool...

Page 107: ...is paid to the function of the part previously serviced Step Action Note 1 Danger Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Run the robot to a position that enables the end of the damper to be pushed into the recess in the wrist unit Shown in the figure in section Location of damper axis 5 on page 104 3 Unhook the end of the damper and push it into the re...

Page 108: ...ousing B Attachment screws cover armhousing C Gasket upper arm cover Equipment etc Spare part no Art no Note Cover arm housing 3HAC 10473 1 Standard and Foundry version Includes gasket 3HAC 7867 1 Cover arm housing 3HAC 10473 3 Clean Room versions Includes gasket 3HAC 7867 1 Gasket upper arm cover 3HAC 7867 1 Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in t...

Page 109: ...g the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Step Action Note 1 Manually run the robot to a position that enables access to the rear of th...

Page 110: ...n 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 in the Product manual reference information xx0200000433 A Lower arm B Gasket lower arm cover C Cover l arm spare without lamp unit D Cover l arm spare with lamp unit ...

Page 111: ...t included Includesgasket3HAC 7869 1 Cover l arm spare CR 3HAC 10471 3 Clean room versions No lamp unit included Includesgasket3HAC 7869 1 Gasket lower arm cover 3HAC 7869 1 Isopropanol 1177 1012 208 For cleaning sealing surfaces Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be require...

Page 112: ...ssure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Step Action Note 1 If the Gasket lower arm cover is to be replaced proceed below If not see further down Shown in the figure Location of lower arm cover and gasket on page 108 2 Remove the protective backing...

Page 113: ...er Foldouts in the Product manual reference information xx0200000426 Required equipment A Damper axis 2 Equipment etc Spare part no Art no Note Damper ax 2 3HAC 7880 1 Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be required See references to these procedures in the step by step instr...

Page 114: ... 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 Step Action Note 1 Danger Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Run the robot to a position that enables you to access the attachment screw of damper axis 2 3 Remove the damper by...

Page 115: ...chapter Foldouts in the Product manual reference information xx0200000472 Required equipment A Indication lamp B Lower arm cover Equipment etc Spare part no Art no Note Indicator lamp 3HAC 9258 1 Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be required See references to these procedur...

Page 116: ... power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 DANGER 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 remov...

Page 117: ... the component and its position may be found in chapter Foldouts in the Product manual reference information xx0200000462 Required equipment A Cover console B Attachment screws cover console 4 pcs C Gasket D Console Equipment etc Spare part no Art no Note Cover console spare 3HAC 10472 1 Standard and Foundry version Includes gasket 3HAC 7868 1 Cover console spare 3HAC 10472 3 Clean Room versions I...

Page 118: ...burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and proc...

Page 119: ...023297 001 Revision A 2 Make sure the gasket inside the cover console has not been damaged Replace if damaged Shown in the figure Location of cover console on page 115 3 Secure the cover console to the console with its attachment screws Step Action Note ...

Page 120: ... Required equipment A Cover console B Attachment screws cover console 4 pcs C Gasket D Console Equipment etc Spare part no Art no Note Console spare 3HAC 10478 1 Standard and Foundry version Console spare 3HAC 10478 3 Clean Room versions Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be...

Page 121: ...xtures if removing motor axis 2 Step Action Note Illustration 1 Remove the cable harness Detailed in section Replacement of cable harness on page 78 2 Remove the serial measurement board Detailed in section Replacement of serial measurement unit and battery pack on page 122 3 Remove the complete upper arm Detailed in section Replacement of complete upper arm on page 85 4 DO NOT under any circumsta...

Page 122: ...lectric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 7 Remove the bearing hub by unscrewing its attachment screws xx0300000096 Parts A Console B Bearing hub C Bearing hub attachment screws 6 pcs D Console attachment screws...

Page 123: ...ening torque 15 Nm 1 Nm 3 Refit the complete upper arm Detailed in section Replacement of complete upper arm on page 85 4 Refit motor 3 and timing belt Detailed in section Replacement of motor and timing belt axis 3 on page 139 5 Refit the serial measurement board Detailed in section Replacement of serial measurement unit and battery pack on page 122 6 Refit the cable harness Detailed in section R...

Page 124: ...view of the component and its position may be found in chapter Foldouts in the Product manual reference information xx0200000432 Required equipment A Rear cable cover B Battery pack C Serial measurement board SMB D SMB attachment screws 4 pcs E Manipulator base bottom plate Equipment etc Spare part no Art no Note Serial measurement unit 3HAC 9522 1 Battery pack 4944 026 4 NiCd type Battery pack 3H...

Page 125: ...t the unit to be damaged from ESD The unit is sensitive to electrostatic discharge It will be destroyed if subjected to electrostatic voltages Before handling make sure you are grounded through a special ESD wrist bracelet or similar CAUTION This component is classified as Hazardous waste and must be disposed of accordingly If in doubt of the correct disposal procedure please contact your local en...

Page 126: ...earth through a special ESD wrist bracelet or similar Step Action Note 1 Set the robot system to MOTORS OFF state This will simplify calibration of the robot after replacement since no coarse calibration will be required 2 Remove the rear cable cover from the base of the robot by unscrewing its attachment screws Shown in the figure Location of serial measurement unit and battery pack on page 122 3...

Page 127: ...ling the rear cable cover has not been damaged Replace the gasket if required Shown in the figure Location of serial measurement unit and battery pack on page 122 Art no specified in section Required equipment on page 122 5 Making sure all cables are correctly located behind the rear cable cover refit it into position Make sure no cables or other equipment fitted behind the cover get pinched by th...

Page 128: ...ence information xx0200000467 Required equipment A Gasket base cover B Attachment screws and washers 9 pcs each control cable C Control cable spare Equipment etc Spare part no Art no Note Control cable spare 3HAC 10476 1 3 m Standard and Foundry versions Cover gasket included Control cable spare 3HAC 10477 1 7 m Standard and Foundry versions Cover gasket included Control cable spare 3HAC 11331 1 1...

Page 129: ...089 1 30 m Standard and Foundry versions Cover gasket included Control cable spare 3HAC 10476 4 3 m Clean Room versions Cover gasket included Control cable spare 3HAC 10477 2 7 m Clean Room versions Cover gasket included Control cable spare 3HAC 11331 2 15 m Clean Room versions Cover gasket included Control cable spare 3HAC 13090 2 22 m Clean Room versions Cover gasket included Control cable spare...

Page 130: ...manipulator 2 Remove the Control cable spareby unscrewing its attachment screws Shown in the figure Location of control cable on page 126 Make sure the gasket does not get damaged 3 Disconnect connectors inside the manipulator base xx0300000090 Connectors A R1 MP1 3 B R1 CS C Air hose D R1 MP4 6 4 Pull the cable out of the manipulator base 5 Disconnect the connectors from the control cabinet ...

Page 131: ...nsure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Step Action Note Illustration 1 Place the control cable on the floor with the manipulator base cover close to the manipulator Shown in the figure Location of control cable on page 126 2 Connect the connectors inside the manipulators base xx0300000090 Connectors A R1 MP1...

Page 132: ...407 Required equipment A Motor axis 1 B Cover for connector access C Motor attachment screws 4 pcs D Cable gland attachment screws 4 pcs E Console Equipment etc Spare part no Art no Note Rot ac motor with pinion 3HAC 10469 3 3HAC 021966 001 Clean room versions Rot ac motor with pinion 3HAC 10469 1 3HAC 021965 001 Standard and Foundry versions Rot ac motor w pinion TStd TF 3HAC 10469 4 High perform...

Page 133: ... information Arm 3HAC 9037 1 For adjusting the gear play motor pinion Power supply 24 VDC max 1 5 A For releasing the brakes Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram 3HAC 6816 3 See chapter Circuit diagram in the Product manual reference information ...

Page 134: ...otor and gearbox the gears may be damaged if excessive force is used Step Action Note 1 Remove the Cover for connector access on top of the motor by unscrewing its four attachment screws Shown in the figure Location of motor axis 1 on page 130 Detailed in section Replacement of cover console on page 115 2 Disconnect the motor 1 connectors inside the console Connectors R3 MP1 R3 FB1 3 Cut any cable...

Page 135: ... with grease Art no is specified in section Required equipment on page 130 3 In order to release the brake connect the 24 VDC power supply Connect to connector R2 MP1 pin 7 pin 8 4 Fit the motor making sure the motor pinion is properly mated to gearbox 1 Make sure the motor is turned the right way i e connections rearwards Make sure the motor pinion does not get damaged 5 Fit the motor with four a...

Page 136: ...on A 134 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 Product manual reference information Step Action Note ...

Page 137: ...nt screws 4 pcs D Cable gland attachment screws 4 pcs E Console Equipment etc Spare part no Art no Note Rot ac motor with pinion spare 3HAC 10469 3 3HAC 021966 001 Clean room versions Rot ac motor with pinion spare 3HAC 10469 1 3HAC 021965 001 Standard and Foundry versions Rot ac motor with pinion spare TStd TF 3HAC 10469 4 High performance version O ring 2152 2012 426 Must be replaced when replac...

Page 138: ... procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram 3HAC 6816 3 See chapter Circuit diagram in the Product manual reference information Equipment etc Spare part no Art no Note Step Action Note 1 Remove the Cover for connector access on top of the motor by unscrewing its four attachment screws Shown in the figure in section Lo...

Page 139: ...e any remaining oil from the gearbox by siphoning it out Step Action Note Step Action Note 1 Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs 2 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is specified in section Required equipment on page 135 3 In order to release the brake connect...

Page 140: ... Required equipment on page 135 11 Push the cables into the console and refit the cable gland with its attachment screws 12 Perform a leak down test Detailed in section Leak down test 13 Refill the gearbox with oil 14 Recalibrate the robot Calibration is detailed in separate calibration manuals Art no for the manuals are specified in section Document references in the Product manual reference info...

Page 141: ... the lower arm cover on the right hand side 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 in the Product manual reference information xx0200000448 A Lower arm cover B Attachment screws lower arm cover 13 pcs C Belt shield D Motor 3 E Attachment screws belt shield 3 pcs F Attachment screws motor 3 4 pcs G Belt...

Page 142: ... is used Equipment etc Spare part no Art no Note Rot ac motor with pinion 3HAC 7866 1 3HAC 021756 001 Includes timing belt pulley Timing belt 3HAC 6793 1 Grease 3HAB 3537 1 For lubricating the o ring Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Other tools and procedures may be required See references to these proc...

Page 143: ...motor xx0200000449 A Cable ties B Pressurized air hose C Power cables axes 4 5 and 6 D Customer cables signal E Signal cables axes 4 5 and 6 F Signal cable axis 3 G Connectors R3 MP3 and R3 FB3 4 Disconnect motor connectors Connectors R3 MP3 R3 FB3 R3 H1 if Safety lamp is fitted R3 H2 if Safety lamp is fitted Step Action Note Illustration ...

Page 144: ...Doing so will cause the manipulator to require a complete rebuild xx0300000102 Parts DO NOT touch these screws 3 pcs 6 Remove the belt shield by unscrewing its twoattachment screws Shown in the figure in section Location of motor axis 3 on page 139 7 Remove the remaining motorattachment screws Shown in the figure in section Location of motor axis 3 on page 139 8 Remove the belt Shown in the figure...

Page 145: ...e two remaining screws Tightening torque 4 Nm 0 5 Nm 8 Tighten the last motor attachment screws Tightening torque 4 Nm 0 5 Nm 9 Refit the cabling as shown xx0200000449 A Cable ties B Pressurized air hose C Power cables axes 4 5 and 6 D Customer cables signal E Signal cables axes 4 5 and 6 F Signal cable axis 3 10 Recalibrate the robot Calibration is detailed in separate calibration manuals Art no ...

Page 146: ... Required equipment A Attachment screws motor 4 4 pcs B Motor axis 4 C O ring Equipment etc Spare part no Art no Note Rot ac motor with pinion 3HAC 7842 1 3HAC 021757 001 Standard Clean Room and Foundry versions Does not include the o ring O ring 3HAC 3772 24 Must be replaced when replacing motor Grease 3HAC 3537 1 Used to lubricate the o ring Standard toolkit 3HAC020812 001 The contents are defin...

Page 147: ...e step by step instructions below These procedures include references to the tools required Circuit Diagram 3HAC 6816 3 See chapter Circuit diagram in the Product manual reference information Equipment etc Spare part no Art no Note Step Action Note 1 Remove the motors for axes 5 and 6 Detailed in section Replacement of motor and timing belt axes 5 or 6 on page 147 2 Manually run the manipulator to...

Page 148: ...ce of the motor is seated properly Lightly lubricate the o ring with grease Art no is specified in section Required equipment on page 144 3 In order to release the brake connect the 24 VDC power supply Connect to connector R3 MP4 pin 7 pin 8 4 Fit the motor with the attachment screws Tightening torque approx 2 Nm 5 Fit the Arm to the end of the motor shaft Art no is specified in section Required e...

Page 149: ...timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the figure below A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual reference information xx0200000453 A Lower arm cover B Attachment screws lower arm cover C Cover armhousing D Attachment screws cover armhousing 4 pcs E VK cover F Pressurized air hose on front of...

Page 150: ...rt no Note Rot ac motor with pinion 3HAC 7842 1 3HAC 021757 001 Axis 4 Standard Clean room and Foundry versions Rot ac motor with pinion 3HAC 7841 1 3HAC 021758 001 Axes 5 and 6 Standard Clean room and Foundry versions Timing belt 3HAC 6779 1 Axes 5 and 6 VK cover 3HAC 2166 13 Clamping unit 3HAC 7939 1 Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Prod...

Page 151: ...ming belt axes 5 or 6 on page 147 3 Remove the rear cover armhousing by unscrewing its four attachment screws Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 147 4 Disconnect all cables to from motors 4 6 Connectors R3 MP4 R3 MP5 R3 MP6 R3 FB4 R3 FB5 R3 FB6 5 Disconnect any connector from the CS connector Shown in the figure in section Location of motor and tim...

Page 152: ... 6 on page 147 14 Use the previously removed clamping unit screws to press the clamping unit apart by inserting them into the adjacent holes in the clamping unit Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 147 15 Remove the clamping unit 16 Remove the pulley and belt from motor axis 6 Shown in the figure in section Location of motor and timing belt axes 5 o...

Page 153: ... timing belt axes 5 or 6 on page 147 Tightening torque 4 Nm 0 5 Nm 4 Fit pulley axis 5 and timing belt axis 5 with their attachment screws and washers Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 147 Tightening torque 6 Nm 0 5 Nm 5 Tighten the motor attachment screws to enable the motor to be shifted slightly This will facilitate adjustment of the belt tensi...

Page 154: ...ct all cables to from motors 4 6 Connectors R3 MP4 R3 MP5 R3 MP6 R3 FB4 R3 FB5 R3 FB6 17 Refit the cable guide with its two attachment screws Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 147 18 Fit a newVK cover to the upper arm lower arm joint Gently knock it into position Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page ...

Page 155: ... Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Equipment etc Art no Note Standard toolkit 3HAC020812 001 The contents are defined in section Standard t...

Page 156: ...ally turn axis 4 90 2 Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure Apply the 40 N load as shown xx0200000457 3 Remove the load and read Value 1 4 Apply 40 N load as shown xx0200000458 5 Remove the load and read Value 2 6 Calculate the gear play value Gear play value value 1 value 2 7 Determine whether or not the value is OK OK 0 18 mm 4 1 arc minutes ...

Page 157: ...rs and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Equipment etc Art no Note Standard toolkit 3HAC020812 001 The contents are defined in section Standard toolkit in the Prod...

Page 158: ...lly turn axis 4 90 2 Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure Apply the 40 N load as shown xx0200000460 3 Remove the load and read Value 1 4 Apply 40 N load as shown xx0200000461 5 Remove the load and read Value 2 6 Calculate the gear play value Gear play value value 1 value 2 7 Determine whether or not the value is OK OK 0 30 mm 10 3 arc minutes ...

Page 159: ...n chapter Foldouts in the Product manual reference information xx0200000422 Required equipment A Gearbox axis 1 2 Equipment etc Spare part no Art no Note Gearbox ax 1 2 spare Std F 3HAC 10467 1 Standard and Foundry versions Includes gearbox 3HAC 6603 1 Includes all required lubricant Includes all o rings and sealing rings Gearbox ax 1 2 spare CR 3HAC 10467 3 Clean room version Includes gearbox 3HA...

Page 160: ...kit 3HAC020812 001 The contents are defined in section Standard toolkit in the Product manual reference information Lifting device gearbox 1 2 3HAC xx Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Step Action Note Illustration 1 Re...

Page 161: ...attachment screws xx0200000423 A Gearbox 1 2 B Bottom plate C Bottom plate attachment screws 26 pcs D Gearbox base attachment screws 20 pcs E Joint gearbox base F Damper axis 1 10 Remove the gearbox base attachment screws and lift the gearbox 1 2 away from the base Shown in the figure Location of gearbox axes 1 2 on page 157 Step Action Note Illustration Step Action Note 1 Open the base of the rob...

Page 162: ...enever parting mating motor and gearbox the gears may be damaged if excessive force is used CAUTION The gearbox weighs 39 kg All lifting equipment used must be dimensioned accordingly Step Action Note Illustration 1 Place the gearbox 1 2 on a suitable workbench 2 Fit a small amount of LocTite 574 onto the Joint gearbox base xx0200000423 A Gearbox 1 2 B Bottom plate C Bottom plate attachment screws...

Page 163: ...the serial measurement board Detailed in section Replacement of serial measurement unit and battery pack on page 122 9 Refit the cable harnesses Detailed in section Refitting of cable harness 10 Refit motors 1 and 2 Detailed in section Refitting of motor 1 and Refitting of motor 2 respectively 11 Perform a leak down test Detailed in section Leak down test 12 Refill the gear box with oil 13 Recalib...

Page 164: ...eneral The gearbox axis 4 is intended to run without requiring any repairs or maintenance work This implies that it must under no circumstances be opened or serviced If it requires replacement the complete upper arm is to be replaced This procedure is detailed in section Replacement of complete upper arm on page 85 ...

Page 165: ...es will change when parts affecting the calibration position are replaced on the robot e g motors wrist or part of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must be updated as detailed in section Updating revolution counters on page 168 This will occur when the battery is discharged a resolver error occurs...

Page 166: ... standard method or Levelmeter calibration alternative method Absolute Accuracy calibration optional Based on standard calibration but besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate syste...

Page 167: ...bration Pendulum but has not as good mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum This method may after calibration require modifications in the robot program and is therefore not recommended The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the manual Instruction for Levelmeter Calibration is enclose...

Page 168: ...evision A 166 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 ...

Page 169: ...ly be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Note The figure shows an IRB 7600 but the positive direction is the same for all robots except the positive direction of axis 3 for IRB 6400R which is in the op...

Page 170: ...calibration values not only according to the calibration marks The correct values are found on a label located either on the lower arm or underneath the flange plate on the base At delivery the robot is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution counters are updated If one of the below mentioned axes are rotated one or more turns from its calibration positi...

Page 171: ...service window xx0100000194 2 Select Calibration from the View menu The Calibration window appears If there is more than one unit connected to the robot they will be listed in the window xx0100000201 3 Select the desired unit and choose Rev Counter Update from the Calib menu The Revolution Counter Update window appears xx0100000202 4 Select the desired axis and press Incl to include it it will be ...

Page 172: ... recommended that the revolution counter values are saved to a diskette Not required 8 Caution If a revolution counter is incorrectly updated it will cause incorrect robot positioning which in turn may cause damage or injury Check the calibration position very carefully after each update How to perform the check is detailed in section Checking the calibration position on page 172 Step Action Note ...

Page 173: ...n the box to the left Tapping Select all to update all axes Then tap Update 5 A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and removes the tick from the list of axes 6 Caution If a revolution counte...

Page 174: ...0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 4 Run the program in manual mode 5 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 166 How to update the revolution counters is detailed in section Updating revolution counters on page...

Page 175: ...rks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 166 Detailed in section Updating revolution counters on page 168 Step Action Note 1 Tap Jogging in the ABB menu 2 Tap Motion mode to choose group of axes to jog 3 Tap axes 1 3 to jog axes 1 2 or 3 4 Manually run the robots ax...

Page 176: ...5 Calibration information 5 6 Checking the calibration position 3HAC023297 001 Revision A 174 ...

Page 177: ...alibration position jog to 173 Connection of external safety devices 15 D direction of axes 167 L Limitation of Liability 16 N negative directions axes 167 P positive directions axes 167 R Revolution counters 168 S Safety service 15 U Updating revolution counters 168 V Validity and responsibility 15 ...

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Page 180: ... ABB Automation Technologies AB Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC 023297 001 part 1 Revision A en ...

Page 181: ... Product manual part 2 of 2 reference information Articulated robot IRB 140 M2000 M2000A M2004 ...

Page 182: ......

Page 183: ...Product manual part 2 of 2 reference information IRB 140 M2000 M2000A M2004 Document ID 3HAC023297 001 Revision A ...

Page 184: ... specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be prosecuted Additio...

Page 185: ...ion 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...

Page 186: ...Table of Contents 3HAC023297 001 Revision A 4 ...

Page 187: ... ABB Robot must be trained by ABB and have the required knowledge of mechanical and electrical installation repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Reference information Useful information when performing installation maintenance or repair works Includes lists of necessary tools additional documents safety standards etc Sp...

Page 188: ... 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 A Changes made in Prerequisites in section Overview Oil change in section Maintenance ...

Page 189: ...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 fr...

Page 190: ...riptions 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 ro...

Page 191: ...rators programmers and trouble shooters The group of manuals include Operator s manual IRC5 with FlexPendant Operator s 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 ...

Page 192: ...Product documentation M2004 3HAC023297 001 Revision A 10 ...

Page 193: ...1 1 Introduction 11 3HAC023297 001 Revision A 1 Reference information 1 1 Introduction General This chapter includes general information complementing the more specific information in the Product manual part 1 of 2 procedures ...

Page 194: ...g 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 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 pa...

Page 195: ...vision A 1 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 196: ...ed 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 p...

Page 197: ...pecifies the recommended standard tightening torque for oil lubricated screws with Allen head screws The table below specifies the recommended standard tightening torque for Molycote lubricated screws with Allen 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 Dimension Tightening torque Nm Class 8 8 oil lubricated Tightening torque Nm Class...

Page 198: ...low specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 1 4 15 10 20 3 8 20 15 25 1 2 40 30 50 3 4 70 55 90 ...

Page 199: ...omponents 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 mus...

Page 200: ...e 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 Calibration manuals Document name Document ID Product specification 3HAC 9041 1 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 19 3HAC023297 001 Revision A Additional documentation Document name Document ID Note External axes 3HAC 9299 1 ...

Page 202: ... 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 Qty Art no Tool 1 Ring open end spanner 8 19mm 1 Socket head cap 2 5 17mm 1 Torx socket no 20 60 1 Torque wrench 10 100Nm 1 Small screwdriver 1 Ratchet head for torque wrench 1 2 1 Socket head cap no 5 socket...

Page 203: ...d in the leakdown tester kit Art no is specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is significantly colder or warmer than the gearbox to be tested a sl...

Page 204: ... 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 ...

Page 205: ...e roller elements to adjust to the correct position against the race flange 1 Tension the bearing gradually until the recommended pre tension is achieved Note The roller elements must be rotated a specified number of turns before pre tensioning is carried out and also rotated during the pre tensioning sequence 2 Make sure the bearing is properly aligned as this will directly affect the lifespan of...

Page 206: ...over threads keyways etc Equipment etc Art no Note Grease 3HAB 3537 1 Used to lubricate the seals Step 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 ...

Page 207: ...rts 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 Step Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accur...

Page 208: ...1 Reference information 1 11 Mounting instructions for seals 3HAC023297 001 Revision A 26 ...

Page 209: ...2 Spare part part list 2 1 Introduction 27 3HAC023297 001 Revision A 2 Spare part part list 2 1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot ...

Page 210: ...w M5x40 13 1 3HAC 10476 1 Control cable spare Std F L 3 m 14 1 3HAC 10477 1 Control cable spare Std F L 7 m 15 1 3HAC 7527 1 Damper axis 1 16 20 3HAB 3402 52 Hex socket head cap screw M10x35 8 8 Gleitmo 610 17 2 3HAC 7950 1 Washer 18 2 3HAC 9860 1 Protecting plate 19 1 3HAC 8466 1 Protective earth cable 20 2 3HAC 9063 1 Hose clip D 10 21 1 SK 615 503 2 Membrane 22 1 SK 616 013 F Bracket CBK 23 1 1...

Page 211: ...189x8 5 61 3 3HAC 3785 6 Parallel pin D 6 m6 L 16 62 2 3HAB 3732 19 Sealing ring V ring 85x11 63 11 9ADA 618 55 Torx pan head screw M6x12 64 2 2166 2018 2 Clamp D 11 65 1 3HAC 10481 1 Connector bracket 66 25 2166 2055 1 Cable straps outdoors 2 5x101 67 3000 ml 1171 2016 604 Lubricating oil 68 1 3HAC 10467 3 Gearbox axes 1 2 spare CR 69 2 3HAC 10469 3 3HAC 021966 001 Motor with pinion spare CR 70 1...

Page 212: ...socket head cap screw M8x35 12 9 Gleitmo 610 158 6 9ADA 334 7 Spring washer conical 8 4x18x2 159 1 3HAB 3732 13 Sealing ring V ring 99x10 5 160 1 3HAC 7842 1 3HAC 021757 001 Rot ac motor with pinion 161 1 3HAB 3772 24 O ring 29x3 162 2 3HAC 7841 1 3HAC 021758 001 Rot ac motor with pinion 163 4 3HAB 3402 18 Hex socket head cap screw M5x35 8 8 Gleitmo 610 164 1 3HAC 6773 1 Motor Console axes 5 6 165...

Page 213: ...8 1 Hose nipple G 1 4 181 1 3HAB 8964 1 Damper axis 5 182 550 ml 3HAC 0860 1 Lubricating oil Optimol Opti gear BM 100 183 1 3HAC 10466 3 Upper arm spare CR 184 1 3HAC 10475 4 Wrist spare CR 185 1 3HAC 10479 3 Axis 4 complete spare CR 186 1 3HAC 10439 3 Cover armhousing spare CR 187 1 3HAC 11922 1 Slip strip Item Qty Art no Name Rem ...

Page 214: ...2 Spare part part list 2 2 Spare part part list 3HAC023297 001 Revision A 32 ...

Page 215: ...3 Foldouts 3 1 Introduction 33 3HAC023297 001 Revision A 3 Foldouts 3 1 Introduction Overview The foldouts in this chapter refer to the part list ...

Page 216: ...1 15 18 27 8 13 21 R1 4 4 5 7 16 17 24 6 8 11 9 26 2 3 25 12 10 3 30 32 35 Nm Base complete 29 31 Inside of base 22 23 28 3 3 31 20 19 Inside of cover Foldout 1 33 34 36 35 37 38 39 ...

Page 217: ...Foldout 2 51 62 56 8 57 58 52 53 62 52 55 54 53 52 51 63 31 59 31 63 63 64 60 61 61 50 54 53 52 31 32 15 5 Nm 52 53 67 63 70 68 69 71 ax 1 1 2 litre ax 2 1 0 litre A 65 25 31 72 25 A 1 2 ...

Page 218: ...03 101 102 64 3 105 104 112 111 106 8 18 113 4 1 Nm 35 Nm Lower arm shown without cables Do not loosen these screws 0 4 litre 67 66 Lower arm complete with cables shown without cover Do not loosen these screws Foldout 3 114 115 116 ...

Page 219: ...108 157 158 173 162 164 162 160 163 112 112 163 111 112 161 112 111 181 152 151 153 154 180 159 Upper arm shown without cables 4 1 Nm 35 Nm 6 Nm 4 1 Nm 4 1 Nm 6 Nm 4 1 Nm 3 Nm 182 28 Nm 0 30 litre oil New wrist 182 0 2 litre oil 184 185 186 0 35 litre oil at oil change ...

Page 220: ...Upper arm with cables shown without cover 178 155 Upper arm complete Foldout 5 177 3 20 168 165 179 167 150 187 183 ...

Page 221: ......

Page 222: ...4 Circuit diagram 4 1 Introduction 35 3HAC023297 001 Revision A 4 Circuit diagram 4 1 Introduction Overview This chapter includes the circuit diagram for the robot ...

Page 223: ...Circuit Diagram CONTENTS Page IRB 140 Manipulator diagram 3HAC 6816 3 Rev 0 101 108 ...

Page 224: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 101 LIST OF CONTENTS ...

Page 225: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 102 CONNECTION POINT LOCATIONS ...

Page 226: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 103 SERIAL MEASUREMENT BOARD ...

Page 227: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 104 MOTOR AXIS 1 3 ...

Page 228: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 105 FEEDBACK AXIS 1 3 ...

Page 229: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 106 MOTOR AXIS 4 6 ...

Page 230: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 107 FEED BACK AXIS 4 6 ...

Page 231: ...Manipulator Circuit Diagram 3HAC 6816 3 IRB 140 No of Sheets 8 Sheet no 108 CUSTOMER CONNECTIONS ...

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Page 234: ... ABB Automation Technologies AB Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC 023297 001 part 2 Revision A en ...

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