ABB IRB1410 Product Manual

as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fit- ness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABB's written per- mission, and contents thereof must not be imparted to a third party nor be used for any unau- thorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge. ©Copyright 2004-2008 ABB All right reserved. ABB AB Robotics Products SE-721 68 Västerås Sweden

3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Product documentation, M2004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 1: Safety 11 1.1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1.2: General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 1.3: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 1.3.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . . . .13 1.3.2 Safety risks related to tools/workpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 1.3.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 1.3.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 1.3.5 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 1.4: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 1.4.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 1.4.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 1.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 1.4.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 1.4.5 Risk of disabling function "Reduced speed 250 mm/s". . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 1.4.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 1.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 1.4.8 Translate the information on safety and information labels. . . . . . . . . . . . . . . . . . . . . . . . . . .27 1.5: Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 1.5.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 1.5.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 1.5.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 1.5.4 WARNING - The unit is sensitive to ESD!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 1.5.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 2: Installation and commissioning 35 2.0.1 Transporting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 2.0.2 Stability / Risk of Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 2.0.3 System CD ROM and Diskette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 2.0.4 Transport Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 2.1: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 2.1.1 Lifting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 2.1.2 Assembling the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 2.1.3 Suspended Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 2.1.4 Stress Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 2.1.5 Amount of Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 2.1.6 Manually engaging the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 2.1.7 Restricting the Working Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 2.1.8 Mounting Holes for Equipment on the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 2.1.9 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 2.2: Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 2.2.1 Air supply and signals for extra equipment to upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 2.2.2 Connection of Extra Equipment to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 3: Maintenance 55 3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 3.0.2 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

4 3.1: Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3.1.1 Oil in gears 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3.1.2 Greasing axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 3.1.3 Lubricating spring brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 3.1.4 Changing the battery in the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 3.1.5 Checking the mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 4: Repair 63 4.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.1.2 Instructions for reading the following sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 4.1.3 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 4.1.4 Fitting new Bearings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 4.1.5 Instructions for tightening Screw Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 4.1.6 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 4.1.7 Checking for play in gearboxes and wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4.2: Axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.2.1 Changing the motor of axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.2.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 4.2.3 Position indicator in axis 1 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 4.2.4 Replacing the mechanical stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 4.3: Axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 4.3.1 Changing the motor of axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 4.3.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 4.3.3 Dismantling the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 4.3.4 Changing the bearings in the upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 4.3.5 Dismantling the balancing springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 4.4: Axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 4.4.1 Changing the motor of axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 4.4.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 4.4.3 Dismantling the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 4.4.4 Changing the tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 4.4.5 Dismantling the complete upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 4.5: Axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 4.5.1 Changing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 4.5.2 Changing the intermediate gear including sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 4.5.3 Dismantling the drive gear on the tubular shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4.5.4 Dismantling the tubular shaft and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 4.6: Cabling and serial measuring board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4.6.1 Changing serial measuring boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4.6.2 Changing the cabling in axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 4.6.3 Changing the cabling in axes 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 4.7: The wrist and axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 4.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 4.7.2 Dismantling the wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 4.7.3 Dismantling the complete drive mechanism of axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . 107 4.7.4 Changing the motor or driving belt of axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 4.7.5 Measuring play in axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5 4.8: Motor units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 4.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 5: Calibration information 113 5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 5.0.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 5.0.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 5.0.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 5.0.5 Updating revolution counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 5.0.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 6: Reference information, IRB 1400 123 6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 6.0.2 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 6.0.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 6.0.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 6.0.5 Weight specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 6.0.6 Document references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 6.0.7 Standard toolkit, IRB 1400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 6.0.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 6.0.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 7: Recommended Spare parts 135 7.0.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 8: Foldouts 137 8.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 9: Circuit diagram 139 9.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 9.0.2 Sheet 101 List of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 9.0.3 Sheet 102 Connection point location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 9.0.4 Sheet 103 Serial measurement board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 9.0.5 Sheet 104 Motor axes 1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 9.0.6 Sheet 105 Feedback axes 1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 9.0.7 Sheet 106 Motor axes 4 - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 9.0.8 Sheet 107 Feedback axes 4 - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 9.0.9 Sheet 108 Customer connection (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 9.0.10 Sheet 109 Integrated wirefeed cabling (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 9.0.11 Sheet 110 Position indicator axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149 9.0.12 Sheet 111 External connections (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

7 Overview About this manual This manual contains instructions for • mechanical and electrical installation of the manipulator • maintenance of the manipulator • mechanical and electrical repair of the manipulator. Usage This manual should be used during • installation, from lifting the manipulator to its work site and securing it to the foundation to making it ready for operation • maintenance work • repair work and calibration. Who should read this manual? This manual is intended for: • installation personnel • maintenance personnel • repair personnel. Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter Contents Safety, service Safety information Installation and commissioning Information about installation of the manipulator. Maintenance Information about maintenance work, including mainte- nance schedules. Repair Information about repair work. Calibration Information about calibration of the manipulator. Decommissioning Environmental information about the manipulator.

References Revisions Reference Document Id Revision Description - First edition. A Changes made in: • Prerequisites in section Overview • Oil change in section Maintenance

3HAC026320-001 Revision: A 9 Product documentation, M2004 General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any one delivery of robot products will not contain all documents listed, but only some of them. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, manipulators and controller cabinets, will be delivered with a Product manual that is divided into two parts: Product manual, procedures • Safety information • Installation and commissioning (descriptions of mechanical installation, electrical con- nections and loading system software) • Maintenance (descriptions of all required preventive maintenance procedures includ- ing periodicity) • Repair (descriptions of all recommended repair procedures including spare parts) • Additional procedures, if any (calibration, decommissioning). Product manual, reference information • Reference information (article numbers for documentation refered to in Product man- ual, procedures, lists of tools, safety standards) • Part list • Foldouts or exploded views • Circuit diagrams. Technical reference manuals The following manuals describe the robot software in general and contain reference informa- tion about it: • RAPID Overview : An overview of the RAPID programming language. • RAPID Instructions, functions and Data types. • System parameters : Description of system parameters and configuration workflows. Application manuals Specific applications (e.g. software or hardware options) are described in Application man- uals . An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what does it do and when is it useful) • What is included (e.g. cables, I/O boards, RAPID instructions, system parameters) • How to use the application

10 3HAC026320-001 Revision: A • Examples of how to use the application Operating Manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters, and include: • Operating Manual - IRC5 with FlexPendant • Operating Manual - RobotStudio Online • Operating Manual - Trouble shooting for the controller and manipulator Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These include:

11 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 12. • specific safety information, pointed out in the procedure at the moment of the danger. How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section Safety related instructions on page 28.

12 3HAC026320-001 Revision: A 1.2: General safety information 1.2.1 Safety in the robot system Validity and responsibility The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system are designed and installed correctly. Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Operating manual - IRC5 with FlexPendant (M2004) and Product manual. Connection of external safety devices Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. Limitation of liability Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information Type of information Detailed in document Section Installation of safety devices Product manual for the robot Installation and com- missioning Changing operating modes Operating manual - IRC5 with FlexPendant (RobotWare 5.0) Start-up Operating modes Restricting the working space Product manual for the robot Installation and com- missioning

3HAC026320-001 Revision: A 13 1.3: Safety risks 1.3.1 Safety risks during installation and service work on robot Overview This section includes information of general safety risks to be considered when performing installation and service work on the robot. General risks during installation and service • The instructions in the Product Manual - Installation and Commissioning must always be followed. • Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. • Those in charge of operations must make sure that safety instructions are available for the installation in question. • Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it. Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks • Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices. • Turntables or the like should be used to keep the operator out of the robot's working space. • The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm. • Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, are dismantled. • When dismantling/assembling mechanical units, watch out for falling objects. • Be aware of stored heat energy in the controller. • Never use the robot as a ladder, i.e. do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

14 3HAC026320-001 Revision: A To be observed by the supplier of the complete system • The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function. • The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function. Complete robot Cabling Safety risk Description Hot components! Caution! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! Warning! Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. 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!

3HAC026320-001 Revision: A 15 Gearboxes and motors Safety risk Description Gears may be damaged if excessive force is used! Caution! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!

16 3HAC026320-001 Revision: A 1.3.2 Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves). Safe design Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller. CAUTION! Ensure that a gripper is prevented from dropping a workpiece, if such is used.

3HAC026320-001 Revision: A 17 1.3.3 Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken. • The pressure in pneumatic and hydraulic systems must be released before starting to repair them. Safe design • Gravity may cause any parts or objects held by these systems to drop. • Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, etc., from falling due to gravity.

18 3HAC026320-001 Revision: A 1.3.4 Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations. • Care must be taken at all times. Qualified personnel • Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Extraordinary risks If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.

3HAC026320-001 Revision: A 19 1.3.5 Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units. • The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space. Voltage related risks, controller IRC5 A danger of high voltage is associated with the following parts: • Be aware of stored electrical energy (DC link, Ultra Cap unit) in the controller. • Units inside the controller, e.g. I/O modules, can be supplied with power from an external source. • The mains supply/mains switch • The transformers • The power unit • The control power supply (230 VAC) • The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!) • The drive unit (700 VDC) • The drive system power supply (230 VAC) • The service outlets (115/230 VAC) • The customer power supply (230 VAC) • The power supply unit for tools, or special power supply units for the machining process. • The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains. • Additional connections. Voltage related risks, robot A danger of high voltage is associated with the robot in: • The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC, see chapter Installation and commissioning in the Product manual). Voltage related risks, tools, material handling devices, etc Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.

20 3HAC026320-001 Revision: A 1.4: Safety actions 1.4.1 Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification IRB 1400 - Section 1.5/Description, Robot Motion). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator.

3HAC026320-001 Revision: A 21 1.4.2 Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator or controller)!

22 3HAC026320-001 Revision: A 1.4.3 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. How to release the brakes is detailed in section: • Emergency release of the robot’s arm on page 22. The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar. Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!

3HAC026320-001 Revision: A 23 1.4.4 Brake testing When to test During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as detailed below: 1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load). 2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller. 3. Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate.

24 3HAC026320-001 Revision: A 1.4.5 Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic parameters from the FlexPendant or a PC. This will affect the safety function Reduced speed 250 mm/s.

3HAC026320-001 Revision: A 25 1.4.6 Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the FlexPendant, the following must be implemented: • The enabling device must never be rendered inoperative in any way. • During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. • The programmer must always bring the FlexPendant with him/her, when entering the robot's working space. This is to prevent anyone else taking control of the robot without the programmer knowing.

26 3HAC026320-001 Revision: A 1.4.7 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. • The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position "manual mode with reduced speed". This should be the normal position when entering the working space. The position "manual mode with full speed (100%)" may only be used by trained personnel who are aware of the risks that this entails. • Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell. • Test the motor brake on each axis, according to section Brake testing on page 23.

3HAC026320-001 Revision: A 27 1.4.8 Translate the information on safety and information labels Labels on the product Both the robot and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot system, eg. during installation, service or operation. Translation possibilities The labels fitted to the product contain space for adding a fourth language underneath the three standard languages (English, German and French). Add a local language to the label by: • using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label. Example of transparent sticker The figure below shows the location of the free space on one of the labels on the robot, where the fourth language can be added. The figure also shows a transparent sticker, containing the text in Swedish. xx0500002517 A Free space for adding a fourth language

28 3HAC026320-001 Revision: A 1.5: Safety related instructions 1.5.1 Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: • A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger. • A brief description of what will happen if the operator/service personnel do not eliminate the danger. • An instruction of how to eliminate the danger to facilitate performing the activity at hand. Danger levels The table below defines the captions specifying the danger levels used throughout this manual. Symbol Designation Signification danger DANGER Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. warning WARNING Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. Electrical shock ELECTRICAL SHOCK The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death. caution CAUTION Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.

3HAC026320-001 Revision: A 29 Electrostatic discharge (ESD) ELECTROSTATIC DISCHARGE (ESD) The electrostatic discharge (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

30 3HAC026320-001 Revision: A 1.5.2 DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range. Elimination Action Note/Illustration 1. Before attempting to run the manipulator, make sure all emergency stop equipment is 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 detailed in section How to use the hold-to-run function in the Operating manual - IRC5 with Flex- Pendant. 3. Make sure no personnel are present within the manipulator working range before pressing the start button.

3HAC026320-001 Revision: A 31 1.5.3 DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance): Action 1. Remove all service tools and foreign objects from the robot and its working area! 2. Install all safety equipment properly! 3. Make sure all personnel are standing at a safe distance from the robot, i.e. out of its reach behind safety fences, etc! 4. Pay special attention to the function of the part previously serviced!

32 3HAC026320-001 Revision: A 1.5.4 WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics. Elimination Action Note 1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. 2. Use an ESD protective floor mat. The mat must be grounded through a current- limiting resistor. 3. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded.

3HAC026320-001 Revision: A 33 1.5.5 WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning Description Elimination / Action - Hot oil! 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. - 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 press out seals and gaskets • prevent the manipulator from moving freely. Make sure not to overfill the gearbox when filling with oil! After filling, check the correct oil level. - Do not mix types of oil! Mixing types of oil may cause severe damage to the gearbox! When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer!

34 3HAC026320-001 Revision: A - Heat up the oil! Warm oil drains quicker than cold oil. When changing gearbox oil, first run 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

2.0.1 Transporting and Unpacking 3HAC026320-001 Revision: A 35 2: Installation and commissioning 2.0.1 Transporting and Unpacking NB! Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. See Safety on page 11. The installation shall be made by qualified installation personnel and should conform to all national and local codes. When you have unpacked the robot, check that it has not been damaged during transport or while unpacking. Operating conditions Storage conditions If the equipment is not going to be installed straight away, it must be stored in a dry area at an ambient temperature between -25°C and +55°C. When air transport is used, the robot must be located in a pressure-equalized area. Weight The net weight of the manipulator is approximately: 225 kg Parameter Value Ambient temperature +5º to +45º Relative humidity Max. 95% at constant temperature

2.0.2 Stability / Risk of Tipping 36 3HAC026320-001 Revision: A 2.0.2 Stability / Risk of Tipping When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. When the arms are moved, care must be taken so that the centre of gravity is not displaced, as this could cause the manipu- lator to tip over.

2.0.3 System CD ROM and Diskette 3HAC026320-001 Revision: A 37 2.0.3 System CD ROM and Diskette The system CD ROM and the manipulator parameter disk are delivered with the robot system. See section RobotWare CD-ROM in the Product manual for the controller. Art. no. for the manual is detailed in section Document references in the Product manual, ref- erence information.

2.0.4 Transport Locking Device 38 3HAC026320-001 Revision: A 2.0.4 Transport Locking Device At delivery, axis 2 (= lower arm) is equipped with a transport locking device (see figure below). Remove the transport locking device before operating the robot. Figure 1: Transport Locking Device, Axis 2. Transport locking device

2.1.1 Lifting the Manipulator 3HAC026320-001 Revision: A 39 2.1: On-site installation 2.1.1 Lifting the Manipulator The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the straps to the special eye bolts on the gear boxes for axes 2 and 3 (see figure below). The lifting strap dimensions must comply with the applicable standards for lifting. Never walk under a suspended load. Figure 2: Lifting the Manipulators using a Traverse Crane. Lifting eye

2.1.2 Assembling the robot 40 3HAC026320-001 Revision: A 2.1.2 Assembling the robot Manipulator The manipulator must be mounted on a level surface with the same hole layout as shown in Figure 3. The levelness requirement of the surface is as follows: . Figure 3: Bolting down the Manipulator. The manipulator is bolted down by means of three M16 bolts. Two guide sleeves, ABB art. no. 2151 0024-169, can be fitted to the two rear bolt holes, to allow the same robot to be re-mounted without having to re-adjust the program. When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in this chapter, Section 2.1.4 Stress Forces. Suitable bolts M16 8.8 Tightening torque 190 Nm 0.5 ∅ 18,5 ∅ 35 H8 38 20 455 210 35 ∅ 18.5 H7 200 400 245

2.1.3 Suspended Mounting 3HAC026320-001 Revision: A 41 2.1.3 Suspended Mounting The method for mounting the manipulator in a suspended position is basically the same as for floor mounting. With inverted installation, make sure that the gantry or corresponding struc- ture is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved.

2.1.4 Stress Forces 42 3HAC026320-001 Revision: A 2.1.4 Stress Forces Stiffness The stiffness of the foundation must be designed to minimize the influence on the dynamic behaviour of the robot. TuneServo can be used for adapting the robot tuning to a non-optimal foundation. IRB 1400 Fxy and Mxy are vectors that can have any direction in the xy plane. Figure 4: The Directions of the Stress Forces. Force Endurance load (in operation) Max. load (emergency stop) Fxy ± 1500 N ± 2000 N Fz (upright) 2800 ± 500 N 2800 ± 700 N Fz (suspended) -2800 ± 800 N -2800 ± 1000 N Torque Endurance load (in operation) Max. load (emergency stop) Mxy ± 1800 Nm ± 2000 Nm Mz ± 400 Nm ± 500 Nm X Z

2.1.5 Amount of Space required 3HAC026320-001 Revision: A 43 2.1.5 Amount of Space required The amount of working space required to operate the manipulator is illustrated in the figures below. The working range for axis 1 is +/- 170°. NB! There are no software or mechanical limits for the working space under the base of the manipulator. Manipulator Figure 5: The Amount of working Space required for the Manipulator. 1051 150 254 1282 733 1645 770 1127 1221 150 Axis 1 ± 170o Axis 1 +145o -135o 1195 1008 1444 150 511 1793 50

2.1.6 Manually engaging the brakes 44 3HAC026320-001 Revision: A 2.1.6 Manually engaging the brakes All axes are equipped with holding brakes. If the positions of the manipulator axes are to be changed without connecting the controller, an external voltage supply (24 V d.c.) must be connected to enable engagement of the brakes. The voltage supply should be connected to the contact at the base of the manipulator (see figure below). Note! Be careful not to interchange the 24V and 0V pins! If they are mixed up, damage can be caused to electrical components. Figure 6: Connection of External Voltage to enable Engagement of the Brakes. External power must be connected according to Figure 6. Incorrectly con- nected power can release all brakes, causing simultaneously movement of all axes. When the controller or the voltage supply is connected as illustrated above, the brakes can be engaged using the push-button on the manipulator, see Figure 7. WARNING: Be very careful when engaging the brakes. The axes become acti- vated very quickly and may cause damage or injury. Figure 7: Location of the Brake Release Button. +24 V B8 0 V C10 Brake release button

2.1.7 Restricting the Working Space 3HAC026320-001 Revision: A 45 2.1.7 Restricting the Working Space When installing the manipulator, make sure that it can move freely within its entire working range. If there is a risk that it may collide with other objects, its working range should be lim- ited, both mechanically and using parameters. Installation of an optional extra stop for the main axes 1, 2 and 3 is described below. Limiting the working range using parameters is described in the section: Configuring systems in the Operating manual - IRC5 with FlexPendant. Axis 1 The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the base, see Figure 8. Instructions for necessary machining and mounting are supplied with the kit. NB! The original stop lug must never be removed. Figure 8: Mechanically limiting Axis 1. Axis 2 The working range of axis 2 can be limited mechanically by fitting extra stop lugs to the under arm (see Figure 9). The lugs limit the arm movements in intervals of 20°. (20° = 1 lug, 40° = 2 lugs, etc.) Instructions for doing this are supplied with the kit. Extra stop lug for axis 1

2.1.7 Restricting the Working Space 46 3HAC026320-001 Revision: A Figure 9: Mechanically limiting Axis 2. Axis 3 The working range of axis 3 can be limited mechanically by fitting a stop lug under the par- allel arm (see Figure 10). Axis 3 is limited upwards to 0 or -10 degrees above the horizontal plane. Under arm Extra stop lugs

2.1.7 Restricting the Working Space 3HAC026320-001 Revision: A 47 Instructions for doing this are supplied with the kit. Figure 10: Extra Stop Lug for limiting Axis 3. Extra stop lug

2.1.8 Mounting Holes for Equipment on the Manipulator 48 3HAC026320-001 Revision: A 2.1.8 Mounting Holes for Equipment on the Manipulator NB! Never drill a hole in the manipulator without first consulting ABB. Figure 11: Mounting Holes for Customer Equipment. Figure 12: The mechanical Interface (Mounting Flange). 135 Mounting holes for equipment M8 (2x) Depth 16 120 A A Mounting holes for equipment, both sides M8 (3x), R=75 Depth 16 15o 120o(3x) IRB 1400 D=25 D=50 H8 h8 45o D=6 H7 M6 (4x) R 20 A A 4 10 A - A 2 ∅ 0.05 ∅ 0.3 B C B 0.06 B (4x) 90o C D=12

2.1.9 Loads 3HAC026320-001 Revision: A 49 2.1.9 Loads Regarding load diagram, permitted extra loads (equipment) and locations of extra loads (equipment), see the Product Specification for IRB 1400. The loads must also be defined in the software, see Operating manual - IRC5 with FlexPendant.

2.2.1 Air supply and signals for extra equipment to upper arm 50 3HAC026320-001 Revision: A 2.2: Customer connections on manipulator 2.2.1 Air supply and signals for extra equipment to upper arm Option 041 Hose for compressed air is integrated into the manipulator. There is an inlet at the base and an outlet on the upper arm housing. Connections: R1/4” in the upper arm housing and at the base. Max. 8 bar. Inner hose diameter: 6.5 mm. For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling. Option 042 Control cabling to arc welding wire-feeder is integrated into the manipulator’s cabling. Number of signals 12 signals, 49V, 500 mA Connector on upper arm: FCI 12-pin UT001412SHT Connector on robot base: FCI 12-pin UT001412PHT Control signals Number of signals: 16 signals, 49V, 500 mA Connector on upper arm housing: FCI 23-pin UTG61823PN Connector on robot base: FCI 23-pin UT001823SHT Power signals Number of signals: 12 signals, 300V, 4A Connector on upper arm housing: FCI 12-pin socket UTG61412SN Connector on robot base: FCI 12-pin UT001412PHT

2.2.1 Air supply and signals for extra equipment to upper arm 3HAC026320-001 Revision: A 51 Figure 13: Location of Customer Connections. To connect power and signal conductors to the manipulator base and to the upper arm connectors, the following parts are recommended: • ABB’s recommended contact set, for connector R2.CS, has Art. No. 3HAC 12583-1. • ABB’s recommended contact set, for connector R1.CS, has Art. No. 3HAC 12493-1. The complete contact set (option) contains: • Pins for cable area 0.13 - 0.25 mm2 • Shrinking hose bottled shaped • Shrinking hose, angled, • which corresponds to item 4, 5, 6, 7, 8 and 9 according to Figure 14. Figure 14: FCI Connector R2.CS R1.CS Air (only option 041) R2.CP (only option 042) Air (only option 041) R2.CP (only option 042) 1, 3 4, 5 8 6 2 Manipulator side Customer side 7 9

2.2.2 Connection of Extra Equipment to the Manipulator 52 3HAC026320-001 Revision: A 2.2.2 Connection of Extra Equipment to the Manipulator Technical data for customer connections. Connections on Upper Arm Figure 15: Customer Connections on Upper Arm. Signals Conductor resistance < 3 ohm, 0.154 mm2 Max. voltage 50 V AC/DC Max. current 250 mA Signal Name Customer Terminal Controller (optional) Customer Contact on Upper Arm, R2 Customer Contact on Manipulator Base (Cable not supplied) CSA XT5.1 R2.CS.A R1.CS.A CSB XT5.2 R2.CS.B R1.CS.B CSC XT5.3 R2.CS.C R1.CS.C CSD XT5.4 R2.CS.D R1.CS.D CSE XT5.5 R2.CS.E R1.CS.E CSF XT5.6 R2.CS.F R1.CS.F CSG XT5.7 R2.CS.G R1.CS.G CSH XT5.8 R2.CS.H R1.CS.H CSJ XT5.9 R2.CS.J R1.CS.J CSK XT5.10 R2.CS.K R1.CS.K CSL XT5.11 R2.CS.L R1.CS.L CSM XT5.12 R2.CS.M R1.CS.M R2.CS

2.2.2 Connection of Extra Equipment to the Manipulator 3HAC026320-001 Revision: A 53 Connection of Signal Lamp on Upper Arm (Option) Figure 16: Location of Signal Lamp. Signal lamp R3.H1 + R3.H2 -

2.2.2 Connection of Extra Equipment to the Manipulator 54 3HAC026320-001 Revision: A

55 3: Maintenance 3.0.1 Introduction The robot is designed to be able to work under very demanding circumstances with a mini- mum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at given periodical intervals, see the table below. • The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with a cloth. Compressed air and harsh solvents that can damage the sealing joints, bearings, lacquer or cabling must not be used. • Check that the sealing joint and cable bushings are really airtight so that dust and dirt are not sucked into the cabinet.

56 3HAC026320-001 Revision: A 3.0.2 Maintenance Intervals 1) Check that the “mechanical stop” is not bent. 2) Inspect all visible cabling. Change if damaged. 3) See section Changing the battery in the measuring system on page 60. Equipment Check twice/ year Check once/ year Maintenance every 2000 hrs or 6 months Maintenance every 4000 hrs or 1 year Others Mechanical stop axis 1 X1 Cabling X2 Gears axis 1-4 Maintenance free Lubrication of spring brackets X Lubrication of gears axis 5-6 X Replacement of accumulator for measuring sys- tem 3 years3

3HAC026320-001 Revision: A 57 3.1: Instructions for maintenance 3.1.1 Oil in gears 1-4 The gearboxes are lubricated for life. ABB’s oil, Mobilgear 600XP 320 art. No. 1171 2016-604, corresponds to: Oil volume (BP), floor-mounted robot Oil volume (BP), suspended robot BP: Energol GR-XP 320 Castrol: Alpha SP 320 Esso: Spartan EP 320 Klüber: Lamora 320 Optimol: Optigear 320 Shell: Omala Oil 320 Texaco: Meropa 320 Statoil: Loaway EP Gearbox Volume Axis 1 2,000 ml Axis 2 and 3 1,700 ml Axis 4 30 ml Gearbox Volume Axis 1 2,700 ml Axis 2 and 3 1,700 ml Axis 4 30 ml

58 3HAC026320-001 Revision: A 3.1.2 Greasing axes 5 and 6 Grease is pressed through the 3 nipples (1), see Figure 17. The tip nozzle of the greasing gun should be of type Orion 1015063, or equivalent. Volume: 2 ml (0.00053 US gallon) Figure 17: Greasing Positions for Axes 5 and 6. Type of grease: ABB’s art. No. 3HAB 3537-1, corresponds to: Shell Alvania WR2 (1)

3HAC026320-001 Revision: A 59 3.1.3 Lubricating spring brackets There are four lubrication places, located over and under the two balancing springs. Type of grease: ABB’s art. No. 3HAA 1001-294, corresponds to: Optimol PDO

60 3HAC026320-001 Revision: A 3.1.4 Changing the battery in the measuring system The battery to be replaced is located inside the base under the flange cover (see Figure 18). The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4. The battery must never be just thrown away; it must always be handled as hazardous waste. • Set the robot to the MOTORS OFF operating mode. (This means that it will not have to be coarse-calibrated after changing the battery.) • Remove the flange cover. All connections on the flange cover, except for the sig- nal contact for the serial link, R1.SMB, can be disconnected. • Remove one of the screws and loosen the two other screws holding the serial measurement board. Push the unit to the side and remove it backwards. All cables and contacts must remain intact. Note the ESD-protection (ESD = Electro- static Discharge). • Loosen the battery terminals from the serial measuring board and cut the clasps that keep the battery unit in place. • Install a new battery with two clasps and connect the terminals to the serial mea- suring board. • Refit the serial measurement board, flange cover and connections. • The Ni-Cd battery takes 36 hours to recharge; the mains supply must be switched on during this time. Figure 18: The Battery is located Inside the Base under the Flange Cover. Alternative Battery As an alternative to the Ni-Cd battery a lithium battery of primary type can be installed. The lithium battery needs no charging and has for that reason a blocking diode which prevents charging from the serial measurement board. The benefit with a lithium 10.8 V battery is the lifetime, which can be up to 5 years in service, compare with the Ni-Cd battery’s maximum life time of 3 years in service. Two lithium batteries exists: • A 3-cell battery, art.No. 3HAB 9999-1 • A 6-cell battery, art.No. 3HAB 9999-2 The life time of the lithium battery depends on how frequently the user switches off the power. The estimated max. life time in years for the different lithium batteries and the recom- mended exchange interval is shown below: Flange cover

3HAC026320-001 Revision: A 61 1) Because of material aging, the maximum life in service is 5 years. Voltage of batteries, measured at power off: Exchange of the battery is done according to the beginning of this section. User type Exchange 3-cell Exchange 6-cell 1. Vacation (4 weeks) power off Every 5 years Every 5 years1 2. Weekend power off + user type 1 Every 2 years Every 4 years 3. Nightly power off + user type 1 and 2 Every year Every 2 years Min. Max. Ni-Cd 7.0 V 8.7 V Lithium 7.0 V -

62 3HAC026320-001 Revision: A 3.1.5 Checking the mechanical stop, axis 1 Check regularly, as follows: • That the stop pin is not bent. If the stop pin is bent, it must be replaced by a new one. See Replacing the mechanical stop on page 78. The article number of the pin is 3HAB 3258-1.

3HAC026320-001 Revision: A 63 4: Repair 4.1: General information 4.1.1 General description The industrial robot system comprises two separate units: the control cabinet and the manip- ulator. Servicing the manipulator is described in this manual. When servicing the manipulator, it is helpful to service the following parts separately: • The Electrical System • The Motor Units • The Mechanical System Electrical system The Electrical System is routed through the entire manipulator and is made up of two main cabling systems; the power cabling and signal cabling. The power cabling feeds the motor units of the manipulator axes. The signal cabling feeds the various control parameters, such as axis positions, motor revs, etc. The AC Motor Units provide the motive power for the various manipulator axes by means of gears. Mechanical brakes, electrically released, lock the motor units when the robot is inop- erative for more than 3 minutes during both automatic and manual operation. Mechanincal system The manipulator has 6 axes which makes its movements very flexible. Axis 1 rotates the manipulator. Axis 2 provides the lower arm’s reciprocating motion. The lower arm, together with the parallel arm and the parallel bracket, forms a parallelogram rel- ative to the upper arm. The parallel bracket is mounted on bearings in the parallel arm and in the upper arm. Axis 3 raises the upper arm of the manipulator. Axis 4, located on the side of the upper arm, rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes 5 and 6. These axes form a cross and their motors are located at the rear of the upper arm. Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customer tools on the tip of the wrist in the turn disc. The tool (or manipulator) can be pneumatically con- trolled by means of an external air supply (optional extra). The signals to/from the tool can be supplied via internal customer connections (optional extras). WARNING! Note that the control cabinet must be switched off during all maintenance work on the manipulator. The accumulator power supply must always be disconnected before performing any work on the manipulator measurement system (measurement boards, cabling, resolver unit). When any type of maintenance work is carried out, the calibration position of the manipulator must be checked before the robot is returned to the operational mode.

64 3HAC026320-001 Revision: A WARNING! Take special care when manually operating the brakes. Make sure also that the safety instructions described in this manual are followed when starting to operate the robot.

3HAC026320-001 Revision: A 65 4.1.2 Instructions for reading the following sections The subsequent sections describe the type of on-site maintenance that can be performed by the customer’s own maintenance staff. Some maintenance jobs require special experience or specific tools and are therefore not described in this manual. These jobs involve replacing the faulty module or component on-site. The faulty component is then transported to ABB for service. Calibration The robot must be re-calibrated when a mechanical unit or part of one is replaced, when the motor and feedback unit is disconnected, when a resolver error occurs, or when the power supply between a measurement board and resolver is interrupted. This procedure is described in detail in Calibration methods on page 115. WARNING! Any work on the robot signal cabling may cause the robot to move to the wrong positions. After performing such work, the calibration position of the robot must be checked as described in Calibration methods on page 115. Tools Two types of tools are required for the various maintenance jobs. It may be necessary to use conventional tools, such as sockets and ratchet spanners, etc., or special tools, depending on the type of servicing. Conventional tools are not discussed in this manual, since it is assumed that maintenance staff have sufficient basic technical competence. Maintenance jobs which require the use of special tools are, on the other hand, described in this manual. Foldouts The chapter on spare parts comes with a number of foldouts which illustrate the parts of the robot. These foldouts are provided in order to make it easier for you to quickly identify both the type of service required and the make-up of the various parts and components. The item numbers of the parts are also shown on the foldouts. In the subsequent sections, these numbers are referred to in angle brackets < >. If a reference is made to a foldout, other than that specified in the paragraph title, the foldout’s number is included in the numeric reference to its item number; for example: <5/19> or <10:2/5>. The digit(s) before the stroke refer to the foldout number. The foldouts also include other information such as the article number, designation and related data. NOTE! This manual is not considered as a substitute for a proper training course. The infor- mation in the following chapters should be used only after an appropriate course has been completed.

4.1.3 Caution The mechanical unit contains several parts which are too heavy to lift manually. As these parts must be moved with precision during any maintenance and repair work, it is important to have a suitable lifting device available. The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space.

3HAC026320-001 Revision: A 67 4.1.4 Fitting new Bearings and Seals Bearings Tapered Bearings Greasing Bearings Action 1. Do not unwrap new bearings until just before assembly, in order to prevent dust and grit getting into the bearing 2. Make sure that all parts of the bearing are free from burr dust, grinding dust and any other contamination. Cast parts must be free from foundry sand 3. Bearing rings, races and roller parts must not under any circumstances be subjected to direct impact. The roller parts must not be subjected to any pressure that is created during the assembly Action 1. The bearing should be tightened gradually until the recommended pre-tensioning is attained. 2. The roller parts must be rotated a specified number of turns both before pre-tensioning and during pre-tensioning. 3. The above procedure must be carried out to enable the roller parts to slot into the correct position with respect to the racer flange. 4. It is important to position the bearings correctly, because this directly affects the ser- vice life of the bearing. Action 1. Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. High quality lubricating grease, such as Shell Alvania WR2 (ABB’s art. No. 3537-1), should be used. 2. Grooved ball bearings should be greased on both sides. 3. Tapered roller bearings and axial needle bearings should be greased when they are split. 4. Normally the bearings should not be completely filled with grease. However, if there is space on both sides of the bearing, it can be filled completely with grease when it is fitted, as surplus grease will be released from the bearing on start up. 5. 70-80% of the available volume of the bearing must be filled with grease during operation.

68 3HAC026320-001 Revision: A 6. Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. High quality lubricating grease, such as Shell Alvania WR2 (ABB’s art. No. 3537-1), should be used. Action

3HAC026320-001 Revision: A 69 Seals The most common cause of leakage is incorrect mounting. Rotating Seals Flange Seals and Static Seals Action 1. The seal surfaces must be protected during transportation and assembly 2. The seals must either be kept in their original packages or be protected well. 3. The seal surfaces must be inspected before mounting. If the seal is scratched or damaged in such a way that it may cause leakage in the future, it must be replaced. 4. The seal must also be checked before it is fitted to ensure that: 1. The seal edge is not damaged (feel the edge with your finger nail), 2. The correct type of seal is used (has a cut-off edge), 3. There is no other damage. 5. Seals and gears must be fitted on clean workbenches. 6. Grease the seal just before it is fitted – not too early as otherwise dirt and foreign particles may stick to the seal. The space between the dust tongue and sealing lip should 2/3-filled with grease of type Shell Alvania WR2 (ABB’s art. No. 3537-1). 1. The rubber coated external diameter must also be greased. 7. Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumping starts. 8. Always use an assembling tool to fit the seal. Never hammer directly on the seal because this will cause it to leak. 9. Use a protective sleeve on the sealing edge during assembly, when sliding over threads, key-ways, etc. Action 1. Check the flange surfaces. The surface must be even and have no pores. The even- ness can be easily checked using a gauge on the fitted joint (without sealing com- pound). 2. The surfaces must be even and free from burr dust (caused by incorrect machining). If the flange surfaces are defective, they must not be used as they will cause leakage. 3. The surfaces must be cleaned properly in the manner recommended by ABB. 4. Distribute the sealing compound evenly over the surface, preferably using a brush. 5. Tighten the screws evenly around the flange joint. 6. Make sure that the joint is not subjected to loading until the sealing compound has attained the hardness specified in the materials specification.

70 3HAC026320-001 Revision: A O-rings Action 1. Check the O-ring grooves. The grooves must be geometrically correct, without pores and free of dust and grime. 2. Check the O-ring for surface defects and burrs, and check that it has the correct shape, etc. 3. Make sure the correct O-ring size is used. 4. Tighten the screws evenly. 5. Defective O-rings and O-ring grooves must not be used. 6. If any of the parts fitted are defective, they will cause leakage. Grease the O-ring with Shell Alvania WR2 (ABB’s art. No. 3537-1) before fitting it.

3HAC026320-001 Revision: A 71 4.1.5 Instructions for tightening Screw Joints General It is extremely important that all screw joints are tightened using the correct torque. Application The following tightening torques must be used, unless otherwise specified in the text, for all screw joints made of metallic materials. The instructions do not apply to screw joints made of soft or brittle materials. For screws with a property class higher than 8.8, the same specifications as for class 8.8. are applicable, unless otherwise stated. Screws treated with Gleitmo All screws in the manipulator that are tightened to a specified torque are treated with Gleitmo. WARNING! When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. Screws can also be treated with Molycote 1000. When screwing in new screws without Gleitmo, these should first be lubricated with Moly- cote 1000 and then tightened to the specified torque. Assembly Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote 1000 should only be used when specified in the text. Screws sized M8 or larger should be tightened with a torque wrench, if possible. Screws sized M6 or smaller may be tightened to the correct torque by personnel with suffi- cient mechanical training, without using torque measurement tools.

72 3HAC026320-001 Revision: A 4.1.6 Tightening Torques Screws with slotted or cross recessed head, property class 4.8 Screws with hexagon socket head, property class 8.8 Dimension Tightening Torque Nm Without Oil M2.5 0.25 M3 0.5 M4 1.2 M5 2.5 M6 5.0 Dimension Tightening Torque Nm Tightening Torque Nm Without Oil With Oil M3 1 1 M4 2 2 M5 5.5 4 M6 10 9 M8 24 22 M10 48 45 M12 83 78 M16 200 190 M20 410 400 M24 750 740

3HAC026320-001 Revision: A 73 4.1.7 Checking for play in gearboxes and wrist When checking for play in gearboxes the brakes must be disengaged. When trying to move an arm manually when the brakes are engaged, some play can be felt. The play that can be felt is between the brake disk and the motor shaft, not in the gearbox itself. This is because the rotating brake disk is connected to the motor shaft by splines. This is why the brakes must be disengaged before testing for play in the gearboxes and wrist. The brakes are disengaged by pressing the enable button on the teach pendant. Note! The play in the brake disk does not affect the robot motion or accuracy.

74 3HAC026320-001 Revision: A 4.2: Axis 1 4.2.1 Changing the motor of axis 1 General See foldouts 1 and 5 in chapter, Foldout. The motor and the drive gear constitute one unit. To dismantle To assemble Action Note/Illustartion 1. Remove the cover of the motor. 2. Loosen connectors R4.MP1 and R4.FB1. 3. Remove the connection box by unscrewing. See foldout/pos. <5/160> 4. Note the position of the motor before removing it. 5. Loosen the motor by unscrewing. See foldout/pos. <1/10> Action Note/Illustration 1. Check that the assembly surfaces are clean and the motor unscratched. 2. Release the brake, apply 24V DC to terminals 7 and 8 in the 4.MP1 connector. 3. Install the motor, tighten screws using a Torque, approximately 2 Nm. See foldout/pos. <1/10> NOTE! Note the position of the motor 4. Adjust the motor in relation to the gear in the gearbox. 5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. 6. Make sure there is very small play by turning axis 1 at least 45o. 7. Tighten screws using a torque of 8.3 Nm ±10%. See foldout/pos. <1/10> 8. Connect the cabling. 9. Calibrate the robot as specified in . Detailed in section: Calibration methods on page 115.

3HAC026320-001 Revision: A 75 4.2.2 Changing the gearbox General Axis 1 gearbox is of the conventional type, manufactured with a high degree of precision and, together with the gearboxes for axes 2 and 3, forms a complete unit. The gearbox is not normally serviced or adjusted. See foldout 1 in chapter, Foldout. NOTE! Note! If the gearbox on any of the axes 1, 2 or 3 is changed, the whole unit must be changed. To dismantle Action Note /Illustration 1. Remove the motors in axes 1, 2 and 3. Described in section: Changing the motor of axis 1 on page 74. Changing the motor of axis 2 on page 79. Changing the motor of axis 3 on page 86. 2. Remove the cabling and serial measuring boards. Described in section: Changing the cabling in axes 1, 2 and 3 on page 103. Changing serial measuring boards on page 102 3. Remove the tie rod. Described in section: Changing the tie rod on page 90. 4. Remove the parallel arm. Described in section: Dismantling the parallel arm on page 89. 5. Remove the balancing springs. Described in section: Dismantling the balancing springs on page 85. 6. Dismantle the upper arm. Described in section: Dismantling the complete upper arm on page 92 7. Dismantle the lower arm according to . Described in section: Dismantling the lower arm on page 82 8. Place the remaining parts of the manipulator upside-down on a table or similar surface and remove the bottom plate. See Figure 19. See foldout/pos. <1/5>.

76 3HAC026320-001 Revision: A To assemble NOTE! Make sure that the foot is stable Figure 19: 9. Undo screws. See foldout/pos. <1/4>. 10. Separate the base from the gear unit. Action Note /Illustration Action Note/Illustration 1. Place a new gear unit on the table. 2. Raise the base. 3. Screw in the screws together with their washers. See foldout/pos. <1/4> and <1/3>. Tighten using a torque of 68 Nm ±10%. 4. Replace the bottom plate using screws. See foldout/pos. <1/5> and <1/7> 5. Turn the foot. 6. Replace the lower arm. Described in section: Dismantling the lower arm on page 82. 7. Replace the parallel arm. Described in section: Dismantling the parallel arm on page 89. 8. Replace the upper arm. Described in section: Dismantling the complete upper arm on page 92. 9. Replace the cabling. Described in section: Changing the cabling in axes 1, 2 and 3 on page 103. Changing serial measuring boards on page 102. 10. Replace the tie rod. Described in section: Changing the tie rod on page 90. 11. Replace the balancingd springs. Described in section: Dismantling the balancing springs on page 85 12. Calibrate the robot. Described in section: Calibration methods on page 115

3HAC026320-001 Revision: A 77 4.2.3 Position indicator in axis 1 (optional) General See foldouts 3 and 4 in chapter, Foldout. To dismantle To assemble Action Note/Illustration 1. Remove the flange plate. See foldout/pos. <4/138> 2. Loosen the connector R1.LS. 3. Dismantle the two limit switches. See foldout/pos. <3/174> 4. Loosen the cables from the switches. 5. Remove the cabling through the base. Action Note/Illustration 1. Assemble in the reverse order.

78 3HAC026320-001 Revision: A 4.2.4 Replacing the mechanical stop General If the stop pins are bent, they must be replaced. See foldout 1 in chapter, Foldout. Replacement Action Note/Illustration 1. Remove the old stop pin. 2. Fit the new pin according to the illustration. Figure 20: Fit the new stop pin. Loctite 242 or 243 68 ± 1

3HAC026320-001 Revision: A 79 4.3: Axis 2 4.3.1 Changing the motor of axis 2 General See foldouts 1 and 5 in chapter, Foldout. The motor and the drive gear constitute one unit. To dismantle To assemble Action Note/Illustration WARNING! Lock the arm system before dismantling the motor; the brake is located in the motor. 3. Remove the cover of the motor. 4. Loosen connectors R3.MP2 and R3.FB2. 5. Remove the connection box by unscrewing the screws. See foldout/pos. <5/160> 6. Note the position of the motor before removing it. NOTE! The oil will start to run out when loosen the motor. 7. Loosen the motor by unscrewing the motor screws. See foldout/pos. <1/10> Action Note/Illustration 1. Check that the assembly surfaces are clean and the motor unscratched. 2. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP2 connector. 3. Install the motor, tighten screws. See foldout/pos. <1/10> Torque, approximately 2 Nm. NOTE! Note the position of the motor! 4. Adjust the motor in relation to the drive in the gear- box.

80 3HAC026320-001 Revision: A 5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. 6. Make sure there is no play. 7. Tighten screws. See foldout/pos. <1/10> Torque of 8.3 Nm ±10% 8. Fill with oil. Detailed in section: Oil in gears 1-4 on page 57. 9. Connect the cabling. 10. Calibrate the robot as specified in . Calibration methods on page 115 Action Note/Illustration

3HAC026320-001 Revision: A 81 4.3.2 Changing the gearbox General Axis 2 gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 3, forms a complete unit. See foldout 1 in chapter, Foldout. The gearbox is not normally serviced or adjusted. NOTE! Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed, the whole unit must be changed. To dismantle See Changing the gearbox on page 75.

82 3HAC026320-001 Revision: A 4.3.3 Dismantling the lower arm General See foldouts 1 in chapter, Foldout. To dismantle To assemble Action Note/Illustration 1. Remove the balancing springs. Described in section: Dismantling the balancing springs on page 85. 1. Remove the cabling down to axis 1. Described in section: Cabling and serial measuring board on page 102. 1. Dismantle the upper arm. Described in section: Dismantling the complete upper arm on page 92. 1. Attach a hoist with lifting slings to the lower arm. 1. Remove the parallel arm in accordance with. Described in section: Dismantling the parallel arm on page 89. 1. Loosen screws. See foldout/pos. <1/13> 1. Remove the lower arm. Action Note/Illustration 1. Transfer the damping element and calibration mark- ing to the new lower arm. 2. Lift the lower arm into position. 3. Fix the lower arm to gear 2 using screws <1/13> and tighten them to a torque of 68 Nm ±10%. WARNING! To prevent clicking during operation of the robot, grease the bearing seating of the parallel arm in the lower arm. 4. Replace the parallel arm. Detailed in section: Dismantling the parallel arm on page 89. 5. Replace the upper arm. Detailed in section: Dismantling the complete upper arm on page 92.

3HAC026320-001 Revision: A 83 6. Replace the balancing springs. Detailed in section: Dismantling the balancing springs on page 85. 7. Replace the cabling as described in . Detailed in section: Cabling and serial measur- ing board on page 102. 8. Calibrate the robot. Detailed in section: Calibration methods on page 115. Action Note/Illustration

84 3HAC026320-001 Revision: A 4.3.4 Changing the bearings in the upper arm General See foldout 1in chapter, Foldout. To dismantle To assemble Action Note/Illustration 1. Loosen the upper bracket of the tie rod. Described in section: Changing the tie rod on page 90. 2. Unscrew screws which hold the parallel arm to gear 3. See foldout/pos. <1/13> 3. Remove the bearings from the parallel arm. 1. Fit new bearings to the parallel arm. 2. Replace the parallel arm using screws and tighten. See foldout/pos. <1/13> Torque of 68 Nm ±10% 3. Attach the upper bracket of the tie rod as specified in. Described in section: Changing the tie rod on page 90. 4. Calibrate the robot. Described in section: Calibration methods on page 115

3HAC026320-001 Revision: A 85 4.3.5 Dismantling the balancing springs See foldouts 1 and 2 in chapter, Foldout. To dismantle To assemble Action Note/Illustration 1. Place the lower arm in a vertical position. 2. Loosen the locking nut. See foldout/pos. <1/76> 3. Release the spring using tool 3HAB 1214-6 and undo the screw at the same time. See foldout/pos. <1/13> WARNING! If the tool 3HAB 1214-6 is not available, but there are two persons, then the spring can be released manually. 4. Unscrew the screw in the upper bracket of the spring. See foldout/pos. <2/65> 5. Remove the springs. Action Note/Illustration 1. Before installing new springs, make sure that the distance between the attachment points is correct, see Figure 21. Lock the link heads using Loctite 242 or 243. Figure 21: Distance between the Attachment Points 2. Lubricate the link heads with grease. 3. Attach the springs to the top bracket using screws and tighten. See foldout/pos. <2/65> Torque of 68 Nm ±10%. 4. Pull the springs down using tool 3HAB 1214-6 and attach screws, together with lift- ing lug and washer. See foldout/pos. (screw) See foldout/pos. (lifting lug) See foldout/pos. (washer) 5. Attach the locking nut <1/76>. CC 377mm

86 3HAC026320-001 Revision: A 4.4: Axis 3 4.4.1 Changing the motor of axis 3 General See foldouts 1 and 5 in chapter, Foldout. The motor and the drive gear constitute one unit. To dismantle To assemble Action Note/Illustration 1. Remove the cover of the motor. 2. Loosen connectors R5.MP3 and R5.FB3. 3. Remove the connection box by unscrewing the screw.. See foldout/pos. <5/160> 4. Note the position of the motor before removing it. NOTE! The oil will start to run out when loosing the motor. 5. Loosen the motor by unscrewing the motor screws. See foldout/pos. <1/10> Action Note/Illustration 1. Check that the assembly surfaces are clean and the motor unscratched. 2. Release the brake, apply 24 V d.c. to terminals 7 and 8 on the 4.MP1 connector. 3. Install the motor, tighten screws. See foldout/pos. <1/10> Torque, approximately 2 Nm. NOTE! Note the position of the motor! 4. Adjust the motor in relation to the drive in the gearbox. 5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. 6. Make sure there is no play. 7. Tighten screws. See foldout/pos. <1/10> to a torque, 8.3 Nm ±10% 8. Fill with oil. Detailed in section: Oil in gears 1-4 on page 57.

3HAC026320-001 Revision: A 87 9. Connect the cabling. 10. Calibrate the robot. Detailed in section: Calibration methods on page 115 Action Note/Illustration

88 3HAC026320-001 Revision: A 4.4.2 Changing the gearbox General See this chapter, section Changing the gearbox on page 81.General Axis 3’s gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 2, forms a complete unit. See foldout 1 in chapter, Foldout. The gearbox is not normally serviced or adjusted. NOTE! Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed, the whole unit must be changed. To dismantle See Changing the gearbox on page 75.

3HAC026320-001 Revision: A 89 4.4.3 Dismantling the parallel arm See foldout 1 in chapter, Foldout. To dismantle To assemble Action Note/Illustration 1. Loosen the upper bracket of the tie rod. Detailed in section: Changing the tie rod on page 90. 2. Unscrew screws which fix the parallel arm to gear 3. See foldout/pos. <1/13> 3. Remove the bearings from the parallel arm. Action Note/Illustration 1. Fit the bearings on the parallel arm. 2. Replace the parallel arm using screws and tighten. See foldout/pos. <1/13> Torque, 68 Nm ±10%. 3. Attach the upper bracket of the tie rod. Detailed in section: Changing the tie rod on page 90 4. Calibrate the robot. Detailed in section: Calibration methods on page 115

90 3HAC026320-001 Revision: A 4.4.4 Changing the tie rod General See foldout 2 in chapter, Foldout. To dismantle To assemble Action Note/Illustration WARNING! Lock the upper arm in a horizontal position with the help of a hoist and lifting slings. 1. Unscrew screw. See foldout/pos. <2/74> 2. Undo the two screws for fixing the cabling bracket of the upper arm housing. 3. Fold back the cabling bracket. 4. Screw the screw back into the shaft. See foldout/pos. <2/74> and <2/71> 5. Carefully knock the shaft out. 6. Remove housing. See foldout/pos. <2/72> 7. Unscrew on the lower bracket. See foldout/pos. <2/70> 8. Carefully tap the rod off the shaft. Action Note/Illustration 1. Fit bearings on the parallel arm. 2. Make sure you replace the rod the correct way up. See foldout/pos. <1/1>. 3. Install grommets: (3 x) and (1 x). See foldout/pos. <1/68> and <1/75>. NOTE! The grommet is bevelled and must be inserted the right way up in the lower bearing. See foldout/pos. <2/75> 4. Place the lower bearing of the tie rod on the parallel arm. 5. Screw in the screw and its washer. Lock using Loc- tite 242 or 243. See foldout/pos. <1/70> and <1/69>. 6. Replace shaft. N.B! Do not forget the sleeve <72>. See foldout/pos. <1/71> 7. Mount washer <73> and tighten the shaft using a temporary screw, M8x35. 8. Replace this screw by screw <74> and mount the cable bearer <163>.

3HAC026320-001 Revision: A 91 9. Lock using Loctite 242 or 243. Action Note/Illustration

92 3HAC026320-001 Revision: A 4.4.5 Dismantling the complete upper arm General See foldout 2 in chapter, Foldout. To dismantle To assemble Action Note/Illustration WARNING! Attach a hoist with lifting slings to the upper arm. 1. Unscrew the upper bracket of the tie rod as specified in. Detailed in section: Changing the tie rod on page 90. 2. Loosen the connectors of the motors of axes 4, 5 and 6. 3. Disconnect the connection box from the motors. 4. Detach the balancing springs. Detailed in section: Dismantling the balancing springs on page 85. 5. Undo the KM nuts. See foldout/pos. <2/64> 6. Remove washers and shims on the same side as axis 3. See foldout/pos. <2/61, 2/62> and <2/63>. 7. Attach the withdrawing tool 3HAB 1259-1 and pull the axes off. Action Note/Illustration 1. Raise the upper arm into assembly position. 2. Install shaft spindles (both sides), use two tem- porary screws M10x90. See foldout/pos. <2/59> 3. Insert bearings (both sides) using tool 3HAB 1200-1 and screws. See foldout/pos. <2/60> and <2/ 65>. 4. Detach the tool and tighten the screws once more, only to prevent rotation of the axis when the KM nut is tightened. Tool no.3HAB 1259-1 NOTE! N.B! Assemble the same side as axis 2 first. 5. Mount two washers and calibration washer. See foldout/pos. <2/63> and <2/ 50> 6. Tighten using the KM nut. See foldout/pos. <2/64>

3HAC026320-001 Revision: A 93 7. Attach the measuring instrument 3HAB 1205-1 to the shaft spindle on axis 3. NOTE! If measuring instrument is not available, you can use a micrometer thickness gauge. Tool no. 3HAB 1205-1 8. Hold the tool against the shoulder of the shaft spindle and measure the dimension “A”. See Figure 22. Figure 22: Measuring the Shim Thickness when preloading the Bearing 9. (If you are not using the measuring instrument, tighten using the KM nut and, before measuring with the micrometer thickness gauge, then undo it again.) 10. Make a note of the dimension “A”. Fit one washer and shims , and using the micrometer, measure the thickness so that the total thick- ness is 0.10 - 0.20 mm more than the noted dimension “A”. This will result in a preloading of the bearing of 0.10 - 0.20 mm. See foldout/pos. <2/63>, <2/61> and <2/62> 11. Fit the shims and washer and tighten the KM nut. See foldout/pos. <2/64> 12. Replace the upper attachment of the tie rod as specified in. Detailed in section: Changing the tie rod on page 90. 13. Replace the balancing springs. Detailed in section: Dismantling the balancing springs on page 85 14. Reconnect the connection boxes and the cabling. 15. Calibrate the robot. Detailed in section: Calibration methods on page 115 16. Undo the KM-nut on the axis 2 side, just to be able to adjust the calibration washer. See foldout/pos. <2/50> Action Note/Illustration

94 3HAC026320-001 Revision: A Tools pressing tool for bearings: 3HAB 1200-1 17. If the old arm houde is mounted, adjust the cal- ibration washer according to the punch mark. If the arm house is new, adjust the washer according to Figure 24 and make new punch marks for axes 3 and 4, accordiong to Calibra- tion scales, IRB 1400 on page 117. Figure 23: Calibration Mark for Axis 3. Action Note/Illustration 105o Measuring instrument: 3HAB 1205-1 Withdrawing tool for shaft spindles: 3HAB 1259-1

3HAC026320-001 Revision: A 95 4.5: Axis 4 4.5.1 Changing the motor General See foldouts 5 and 8 in chapter, Foldout. The motor and the drive gear constitute one unit. Position the arm system in such a way that the motor of axis 4 points upwards. To dismantle To assemble Action Note/Illustration 1. Remove the cover of the motor. 2. Loosen connectors R3.MP4 and R3.FB4. 3. Remove the connection box by unscrewing the screw.. See foldout/pos. <5/160> 4. Note the position of the motor before removing it. 5. Loosen the motor by unscrewing the screw.. See foldout/pos. <8/23> Action Note/Illustration 1. Check that the assembly surfaces are clean and the motor unscratched. 2. Put O-ring on the motor. See foldout/pos. <8/21> 3. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connector. 4. Install the motor, tighten screws. See foldout/pos. <8/23> Torque, approximately 2 Nm NOTE! Note the position of the motor! 5. Adjust the position of the motor in relation to the drive in the gearbox. 6. Screw the crank tool into the end of the motor shaft. Tool no. 3HAB 1201-1 7. Make sure there is a small clearance. 8. Unscrew one screw at a time, apply Loctite 242 or 243 and tighten. Torque, 4.1 Nm ±10%. 9. Connect the cabling.

96 3HAC026320-001 Revision: A 10. Calibrate the robot. Detaild in section: Calibration methods on page 115. Action Note/Illustration

3HAC026320-001 Revision: A 97 4.5.2 Changing the intermediate gear including sealing General See foldout 8 in chapter, Foldout. To dismantle To assemble Action Note/Illustration 1. Dismantle the wrist as described in. Detailed in section: Dismantling the wrist on page 106. 2. Dismantle the drive mechanism according to. Detailed in section: Dismantling the complete drive mechanism of axes 5 and 6 on page 107. 3. Dismantle the motor of axis 4 as specified in. Detailed in section: Changing the motor on page 95. 4. Remove the cover. See foldout/pos. <8/25> 5. Undo screws fixing the large drive gear and dis- mantle it. See foldout/pos. <8/18> and <8/17>. NOTE! Put the shims in a safe place. 6. Undo screws. See foldout/pos. <8/12>. 7. Push the intermediate gear out of the arm housing. Action Note/Illustration 1. Grease the seating of the arm housing to provide radial sealing. 2. Push the gear unit down into the arm housing. 3. Screw in screws together with their washers and pull the gear down. See foldout/pos. <8/12> and <8/13> 4. Mount the drive gear <17> using screws <18> and tighten to a torque of 8.3 Nm ±10%. NOTE! Do not forget to insert shims under the drive gear. See foldout/pos. <8/14, 8/15, 8/16> 5. Tighten the screws. See foldout/pos. <8/12> Torque, approximately 5 Nm.

98 3HAC026320-001 Revision: A 6. Bend the pinion towards the large drive gear and then rotate it around the tubular shaft a couple of times so that the clearance in the gears can adjust itself in relation to the highest point of the large drive gear. 7. Then tighten the screws. See foldout/pos. <8/12> Torque, 20 Nm ±10%. 8. Check the clearance in relation to the tightening torque. 9. Replace the cover using screws. Use a drop of Loctite 242 or 243. See foldout/pos. <8/25> and <8/26>. 10. Position the manipulator so that the tubular shaft points upwards. 11. Fill (30 ml) oil into the gear of axis 4. Detailed in section: Oil in gears 1-4 on page 57. 12. Install the motor of axis 4. Detailed in section: Changing the motor on page 95 13. Install drive mechanism. See foldout/pos. <8/28> Detailed in section: Dismantling the complete drive mechanism of axes 5 and 6 on page 107. 14. Replace the wrist in accordance with. Detailed in section: Dismantling the wrist on page 106 15. Calibrate the robot as specified in . Detailed in section: Calibration methods on page 115. Action Note/Illustration