ABB M2000 Product Manual

IRB 140 M2000 M2000A M2004 Document ID: 3HAC023297-001 Revision: A

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

3 3HAC023297-001 Revision: A Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1 Safety 13 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.2.2.2 Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2 Installation and commissioning 41 2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.2.2 Working range, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.2.3 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 2.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 2.3.4 Restricting the working space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 2.3.5 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 2.3.7 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 2.3.8 Bolt pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 2.4.1 Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3HAC023297-001 Revision: A 4 3 Maintenance 63 3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 3.2.1 Maintenance schedule, IRB 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 3.3.1 Inspection, damper axes 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 3.3.2 Inspection, robot cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 3.3.3 Inspection, timing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.4.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.5 Changing/ replacing activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 3.5.1 Oil change, gearbox, axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4 Repair 77 4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 4.2 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 4.2.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 4.2.2 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 4.2.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 4.2.4 Replacement of base, spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 4.3 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4.3.1 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4.3.2 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4.3.3 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 4.3.4 Replacement of cover, arm housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 4.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 4.4.1 Replacement of lower arm cover and gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 4.4.2 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 4.4.3 Replacement of indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 4.5.1 Replacement of cover, console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 4.5.2 Replacement of console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 4.5.3 Replacement of serial measurement unit and battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 4.5.4 Replacement of control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 4.6.2 Replacement of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 4.6.3 Replacement of motor and timing belt, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 4.6.5 Replacement of motor and timing belt, axes 5 or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 4.6.6 Adjustments and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 4.6.6.1 Measuring the gear play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 4.6.6.2 Measuring the gear play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 4.7.1 Replacement of gearbox, axes 1-2 and damper, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 4.7.2 Service work on gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 5 Calibration information 163 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

5 3HAC023297-001 Revision: A 5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Overview About this manual This manual contains instructions for • mechanical and electrical installation of the robot • maintenance of the robot • mechanical and electrical repair of the robot. Usage This manual should be used during • installation, from lifting the robot to its work site and securing it to the foundation to making it ready for operation • maintenance work • repair work and calibration. Who should read this manual? This manual is intended for: • installation personnel • maintenance personnel • repair personnel. Prerequisites 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 that must be read through before performing any installation or service work on robot. Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product. Installation and commissioning Required information about lifting and installation of the robot. Maintenance Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used in the work of planning periodical maintenance. Repair Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts. Calibration information Procedures that does not require specific calibration equipment. General information about calibration. Decommissioning Environmental information about the robot and its components.

8 Revisions Revision Description - First edition. Replaces previous manuals: • Installation and commissioning manual • Maintenance manual • Repair manual, part 1 • Repair manual, part 2 Changes made in the material from the previous manuals: • Model M2004 implemented. • Chapter Calibration replaced with chapter Calibration information. • Chapter Safety, service replaced with new safety chapter. • Information about the controller removed from the manual. • Additional spare part numbers for the motors. A Changes made in: • Prerequisites in section Overview • Oil change in section Maintenance

9 3HAC023297-001 Revision: A Product documentation, M2000/M2000A General The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below: Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures • Safety information • Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) • Maintenance (descriptions of all required preventive maintenance procedures including intervals) • Repair (descriptions of all recommended repair procedures including spare parts) • Additional procedures, if any (calibration, decommissioning) Product manual, reference information • Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) • Part list • Foldouts or exploded views • Circuit diagrams Software manuals The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation. A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: • Installation information • Repair information • Maintenance information In addition, spare part information is supplied for the entire option.

3HAC023297-001 Revision: A 10 Product documentation, M2004 General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures • Safety information • Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) • Maintenance (descriptions of all required preventive maintenance procedures including intervals) • Repair (descriptions of all recommended repair procedures including spare parts) • Additional procedures, if any (calibration, decommissioning) Product manual, reference information • Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) • Part list • Foldouts or exploded views • Circuit diagrams RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: • RAPID Overview: An overview of the RAPID programming language. • RAPID reference manual part 1: Description of all RAPID instructions. • RAPID reference manual part 2: Description of all RAPID functions and data types. • Technical reference manual - System parameters: Description of system parameters and configuration workflows. Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful) • What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

11 3HAC023297-001 Revision: A • How to use the application • Examples of how to use the application Operator’s manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: • Operator’s manual - IRC5 with FlexPendant • Operator’s manual - RobotStudioOnline • Trouble shooting Manual for the controller and robot Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These include: • Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system)

3HAC023297-001 Revision: A 12 How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown. The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure. The table below shows an example of a reference to a figure from a step in an procedure. References to required equipment The procedures often include references to equipment (spare parts, tools etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, i.e. article number, dimension. The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list. The table below shows an example of a reference to a list of required equipment, from a step in an procedure. Safety information The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed. Read more in chapter Safety on page 13. Step Action Note/Illustration 8. Remove the rear attachment screws, gearbox. Shown in the figure Location of gearbox on page xx. Step Action Note/Illustration 3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required equipment on page xx.

1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page 14. • specific safety information, pointed out in the procedure at the moment of the danger. How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section Safety related instructions on page 34.

14 1.2 General safety information 1.2.1. Introduction Definitions This section details general safety information for service personnel i.e. personnel performing installation, repair and maintenance work. Sections The general safety information is divided into the following sections: 1. General information contains lists of: • Safety, service • Limitation of liability • Referenced documents 2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories: • Safety risks during service work on robot • Safety risks related to gripper/end effector • Safety risks related to tools/workpieces • Safety risks related to pneumatic/hydraulic systems • Safety risks during operational disturbances • Safety risks during installation and service • Risks associated with live electric parts 3. Safety actions details actions which may be taken to remedy or avoid dangers. • Safety fence dimensions • Fire extinguishing • Emergency release of the manipulator´s arm • Brake testing • Risk of disabling function "Reduced speed 250 mm/s" • Safe use of the Teach Pendant Unit enabling device • Work inside the manipulator´s working range • Signal lamp (optional)

15 3HAC023297-001 Revision: A 1.2.2. General information 1.2.2.1. Safety, service Validity and responsibility The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly. Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. User's Guide and Product Manual. Connection of external safety devices Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.

3HAC023297-001 Revision: A 16 1.2.2.2. Limitation of Liability General Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.

17 3HAC023297-001 Revision: A 1.2.2.3. Related information General The list below specifies documents which contain useful information: Documents Type of information Detailed in document Section Installation of safety devices Product manual for the manipulator Installation and commissioning Changing robot modes User’s Guide Start-up Restricting the working space Product manual for the manipulator Installation and commissioning

3HAC023297-001 Revision: A 18 1.2.3. Safety risks 1.2.3.1. Safety risks during service work on robot Overview This section includes information of general safety risks to be considered when performing service work on the robot.

19 3HAC023297-001 Revision: A Complete robot Cabling Gearboxes and motors 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! 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!

3HAC023297-001 Revision: A 20 Balancing device Safety risk Description Dangerous balancing device! Warning! Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!

21 3HAC023297-001 Revision: A 1.2.3.2. Safety risks related to gripper CAUTION! Ensure that a gripper is prevented from dropping a workpiece, if such is used.

3HAC023297-001 Revision: A 22 1.2.3.3. Safety risks related to tools/workpieces Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves). Safe design Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.

23 3HAC023297-001 Revision: A 1.2.3.4. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems so, after shutdown, particular care must be taken. • The pressure in pneumatic and hydraulic systems must be released before starting to repair them. 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.

3HAC023297-001 Revision: A 24 1.2.3.5. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations. • Care must be taken at all times. Qualified personnel • Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Extraordinary risks If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.

25 3HAC023297-001 Revision: A 1.2.3.6. Safety risks during installation and service General risks during installation and service • The instructions in the Product Manual - Installation and Commissioning must always be followed. • Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. • Those in charge of operations must make sure that safety instructions are available for the installation in question. • Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it. Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks • Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices. • Turntables or the like should be used to keep the operator out of the robot's working space. • The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm. • Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled. • When dismantling/assembling mechanical units, watch out for falling objects. • Be aware of stored heat energy in the controller. • Never use the robot as a ladder, i.e. do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot. To be observed by the supplier of the complete system • The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function. • The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.

3HAC023297-001 Revision: A 26 1.2.3.7. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units. • The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space. Voltage related risks, controller A danger of high voltage is associated with the following parts: • Be aware of stored electrical energy (DC link) in the controller. • Units inside the controller, e.g. I/O modules, can be supplied with power from an external source. • The mains supply/mains switch • The power unit • The power supply unit for the computer system (230 VAC) • The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!) • The drive unit (700 VDC) • The service outlets (115/230 VAC) • The power supply unit for tools, or special power supply units for the machining process • The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains. • Additional connections Voltage related risks, robot A danger of high voltage is associated with the robot in: • The power supply for the motors (up to 800 VDC) • The user connections for tools or other parts of the installation (max. 230 VAC, see Installation and Commissioning Manual) Voltage related risks, tools, material handling devices, etc Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.

27 3HAC023297-001 Revision: A 1.2.4. Safety actions 1.2.4.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification - Description, Robot Motion). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator.

3HAC023297-001 Revision: A 28 1.2.4.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator or controller)!

29 3HAC023297-001 Revision: A 1.2.4.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot or on an optional external brake release unit. How to release the brakes is detailed in section: • Manually releasing the brakes on page 49. The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar. Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!

3HAC023297-001 Revision: A 30 1.2.4.4. Brake testing When to test During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of each axis' motor holding brakes may be checked as detailed below: 1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load). 2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller. 3. Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate.

31 3HAC023297-001 Revision: A 1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.

3HAC023297-001 Revision: A 32 1.2.4.6. Safe use of the Teach Pendant Unit NOTE! The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the Teach Pendant Unit, the following must be implemented: • The enabling device must never be rendered inoperative in any way. • During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. • The programmer must always bring the Teach Pendant Unit with him/her, when entering the robot's working space. This is to prevent anyone else taking control over the robot without the programmer knowing.

33 3HAC023297-001 Revision: A 1.2.4.7. Work inside the manipulator's working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. • The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% ”full speed” may only be used by trained personnel who are aware of the risks that this entails. • Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell. • Test the motor brake on each axis, according to section Brake testing on page 30.

3HAC023297-001 Revision: A 34 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: • A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger. • A brief description of what will happen if the operator/service personnel does not eliminate the danger. • An instruction of how to eliminate the danger to facilitate performing the activity at hand. Danger levels The table below defines the captions specifying the danger levels used throughout this manual. Symbol Designation Signification danger 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.

35 3HAC023297-001 Revision: A 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

3HAC023297-001 Revision: A 36 1.3.2. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range. Elimination Step Action Info/Illustration 1. Before attempting to run the manipulator, make sure all emergency stop equipment has been correctly installed and connected. Emergency stop equipment such as gates, tread mats, light curtains, etc. 2. If possible, use the hold-to-run button whenever possible. The hold-to-run button is used in manual mode, not in automatic mode. How to use the hold-to-run control in RobotWare 5.0 is detailed in section How to use the hold-to-run switch in the Operator's Manual, IRC5. How to use the hold-to-run control in RobotWare 4.0 is detailed in section The Teach Pendant unit in the User’s Guide. 3. Make sure no personnel is present within the manipulator working range before pressing the start button.

37 3HAC023297-001 Revision: A 1.3.3. WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not connected to ground potential may transfer high static charges. This discharge may destroy sensitive electronics. Elimination Step Action Note/Illustration 1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. 2. Use an ESD protective floor mat. The mat must be grounded through a current- limiting resistor. 3. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded.

3HAC023297-001 Revision: A 38 1.3.4. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning Description Elimination / Action - 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 levels. - 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!

39 3HAC023297-001 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

2.1. Introduction 41 3HAC023297-001 Revision: A 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot.

2.2.1. Pre-installation procedure 3HAC023297-001 Revision: A 42 2.2 Unpacking 2.2.1. Pre-installation procedure General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the manipulator: Weight, manipulator The net weight of the manipulator is approximately: 100 kg. Step Action Info/Illustration 1. Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation. 2. Make sure the manipulator has not been damaged, by visually inspecting the manipulator and control cabinet exterior. 3. Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator. Specified in section Weight, manipulator on page 42. 4. If the manipulator is not to be installed directly, it must be stored. Specified in section Storage conditions, manipulator on page 43. 5. Make sure the appointed operating environment of the manipulator conforms to the specifications. Specified in section Operating conditions, manipulator on page 43. 6. Before taking the manipulator to its installation site, make sure the site conforms to applicable requirements. Specified in section : • Loads on foundation, manipulator on page 43 • Requirements on foundation, manipulator on page 43 • Protection classes on page 44 7. Before moving the manipulator, make sure it does not tip over! Described in section Risk of tipping/ Stability on page 47. 8. When these prerequisites have been met, the manipulator may be taken to its installation site. Detailed in section Lifting manipulator with lifting slings on page 48.

2.2.1. Pre-installation procedure 43 3HAC023297-001 Revision: A Loads on foundation, manipulator The table below shows the different forces and torques working on the manipulator during different kinds of operation. NOTE! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously! Requirements on foundation, manipulator Storage conditions, manipulator The table below shows the allowed storage conditions for the manipulator: Operating conditions, manipulator The table below shows the allowed operating conditions for manipulator: Force Endurance load (operation) Max. load (emergency stop) Force xy (upright/suspended) ± 1300 N ± 3200 N Force z (upright) -1000 ± 1000 N -1000 ± 2000 N Forze z (suspended) -2800 ± 1000 N +1000 ± 2000 N Torque Mxy ± 1300 Nm ± 220 Nm Mz ± 300 Nm ± 750 Nm Requirement Value Min. levelity 0.5 mm Max. tilt 5° Min. resonance frequency 22 Hz Parameter Value Max. ambient temperature +55° C Max. ambient temperature (less than 24 hrs) +70° C Min. ambient temperature -25° C Max. ambient humidity Max. 95% at constant temperature Parameter Value Max. ambient temperature +45° C Min. ambient temperature +5° C Max. ambient humidity Max. 95% at constant temperature

2.2.1. Pre-installation procedure 3HAC023297-001 Revision: A 44 Protection classes The table below shows the protection class of the main parts of the robot system: Equipment Protection class Manipulator IP 67 Control cabinet IP 54 Programming unit IP 54

2.2.2. Working range, IRB 140 45 3HAC023297-001 Revision: A 2.2.2. Working range, IRB 140 Working range axis 2 -3 The illustration below shows the unrestricted working range axis 2-3. xx0200000058 Pos Position at wrist centre Angle (degrees) X Z Axis 2 Axis 3 0 450 712 0° 0° 1 70 1092 0° -90° 2 314 421 0° +50° 3 765 99 +110° -90° 4 255 -119 +110° +4° 5 -480 23 -90° -150° 6 1 596 -90° +50° 7 218 558 +110° -230° 8 -670 352 -90° -90°

2.2.2. Working range, IRB 140 3HAC023297-001 Revision: A 46 Working range axis 1 The illustrations below shows the unrestricted working range of axis 1. xx0200000061

2.2.3. Risk of tipping/Stability 47 3HAC023297-001 Revision: A 2.2.3. Risk of tipping/Stability General The section below details instructions for making sure the manipulator does not tip over when it has not been safely secured to the foundation. Procedure The procedure below details how to make sure the manipulator does not tip during installation while not secured to the foundation. CAUTION! When the manipulator is not fastened to the floor, it will not be stable in any part of its working area. 1. DO NOT change the manipulator position before securing it to its foundation. The shipping position is the most stable. 2. If the manipulator, for some reason, must be move from its original position, ensure that the centre of gravity not is displaced.

2.3.1. Lifting manipulator with lifting slings 3HAC023297-001 Revision: A 48 2.3 On-site installation 2.3.1. Lifting manipulator with lifting slings General This section details how to lift the manipulator using lifting slings. Illustration The following figures shows how to lift the manipulator with lifting slings. xx0200000084 How to lift the manipulator 1. Adjust the manipulator to lifting position according to the picture. 2. Put one sling line around each leg on the lower arm (Pos. 1 and 2). 3. Use further one sling line to secure the lifting of the control cable (Pos. 3). Equipment Note Sling line Length: 2 m. Load: 500 kg. 1 Sling line for manipulator 2 Sling line for manipulator 3 Sling line for control cable

2.3.2. Manually releasing the brakes 49 3HAC023297-001 Revision: A 2.3.2. Manually releasing the brakes General The section below details how to release the holding brakes of each axis' motor. This may be done in one of three ways: • using the pushbutton when the manipulator is connected to the controller. • using the pushbutton on the manipulator with an external power supply. • using an external voltage supply. DANGER! When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm! Using the pushbutton when the manipulator is connected to the controller This section details how to release the holding brakes using the internal brake release unit. Step Action Info/Illustration 1. Push the "brake release button" to release the holding brakes. xx0200000069 • A: Pushbutton

2.3.2. Manually releasing the brakes 3HAC023297-001 Revision: A 50 Using the pushbutton on the manipulator with an external power supply This section details how to release the holding brakes with the pushbutton using an external voltage supply. NOTE! Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can be caused to a resistor diode and to the system board. Using External power supply This section details how to release the holding brakes using a external voltage supply. If the positions of the manipulator axes are to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable the brake release buttons on the manipulator. Step Action Info/Illustration 1. Connect an external power supply to connector XP1. xx0200000071 • A: B16 24V DC • B: B14 0V 2. Push the "brake release button" to release the holding brakes. Step Action Info/Illustration 1. Remove the screws and dismount the cover on the back of the manipulator base. xx0200000072 • A: 13 0 V • B: 15 24 V DC

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

2.3.3. Orienting and securing the manipulator 3HAC023297-001 Revision: A 52 2.3.3. Orienting and securing the manipulator General This section details how to orient and secure the manipulator to the foundation in order to safely run the robot. Bolting requirements When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in section Loads on foundation, manipulator on page 43. NOTE! When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must be used to secure the bolted joint. Attachment screws The table below specifies the type of securing screws and washers to be used for securing the manipulator to the base plate/foundation. Hole configuration and cross section The bolt pattern requirements are shown in section Bolt pattern on page 59. Guide sleeves Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re-adjusting the program. Suitable screws, lightly lubricated: M12 Quality Quality 8.8 Suitable washer: Thickness: 2.5 mm Outer diameter: 24 mm Inner diameter: 13.4 mm Tightening torque: 85 Nm Equipment Art. no. Guide sleeves 3HAC 9519-1

2.3.4. Restricting the working space 53 3HAC023297-001 Revision: A 2.3.4. Restricting the working space General When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. WARNING! The working space can only be limited using soft ware, for this reason the limited area can not be classified as a safe zone. All work within this zone is prohibited. Limiting devices Limiting devices is listed below. 1. Light curtains. 2. Tread mats. 3. Other similar devices. 4. SoftWare. Limiting the working space using software is described in the User's Guide chapter: System Parameters.

2.3.5. Fitting equipment on manipulator 3HAC023297-001 Revision: A 54 2.3.5. Fitting equipment on manipulator General The manipulator features mounting holes for additional equipment. In addition to the stock mounting holes, extra mounting holes may be added on the manipulator under certain conditions. These special conditions are specified in the Product Specification. Illustration, holes on upper arm The illustration below shows the stock holes available for fitting extra equipment on the upper arm. xx0200000062

2.3.5. Fitting equipment on manipulator 55 3HAC023297-001 Revision: A Illustration, holes on mounting flange The illustration below shows the stock holes available for fitting equipment on the mounting flange. xx0200000063 Fastener quality When fitting tools on the mounting flange (see the figures in sections Illustration, holes on upper arm on page 54 and Illustration, holes on mounting flange on page 55), use only screws with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.

2.3.6. Loads 3HAC023297-001 Revision: A 56 2.3.6. Loads General Any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operation stops may result. References Load diagrams, permitted extra loads (equipment) and their positions as specified in the Product Specification. The loads must also be defined in the software as detailed in User's Guide. Brake performance Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB.

2.3.7. Suspended mounting 57 3HAC023297-001 Revision: A 2.3.7. Suspended mounting General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the manipulator in a suspended position is basically the same as for floor mounting. NOTE! With inverted installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved. System Parameters If the robot is mounted at any other angle, the system parameter “gravity beta” must be updated. Gravity beta specifies the robot’s mounting angle expressed in radians. NOTE! It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will result in: • Overloading the mechanical structure. • Lower path performance and path accuracy. • Some S4 functions will not work properly: e.g Load Identification & Collision detection. Mounting Angles and Values The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated in the following way for a mounting angle of 45°. Gravity beta = 45° x 3.141593/180 = 0.785398 radians. Examples of Position Mounting Angle Gravity Beta Floor (pos 1) 0° 0.000000 (Default) Tilted (pos 2) 45° 0.785398 Wall (pos 3) 90° 1.570796 Ceiling (pos 4) 180° 3.141593

2.3.7. Suspended mounting 3HAC023297-001 Revision: A 58 xx0200000066 Defining the parameters Following steps describes how to enter the correct gravity beta values. Step Action Info/Illustration 1. Choose Topics: Manipulator. 2. Choose Types: Robot. 3. Select Master and press Enter. xx0200000073 4. Select the desired parameter “gravity beta” and change its value. 5. Press OK to confirm.

2.3.8. Bolt pattern 59 3HAC023297-001 Revision: A 2.3.8. Bolt pattern Hole configuration The illustration below shows the hole configuration used when securing the manipulator: xx0200000085

2.3.8. Bolt pattern 3HAC023297-001 Revision: A 60 Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes: xx0200000086

2.4.1. Customer connections on manipulator 61 3HAC023297-001 Revision: A 2.4 Electrical connections 2.4.1. Customer connections on manipulator General For connection of extra equipment on the manipulator there are cables integrated into the manipulator's cabling. There are both air and electrical connectors on the manipulator. xx0200000074 Connections Connections Description 1. For air on base / upper arm R1/4" Max. 8 bar/hose inner diameter: 6.5 mm 2. Signal connector on upper arm FCI UT 071412SH44N connector Number of signals: 12 signals, 49V, 500mA

2.4.1. Customer connections on manipulator 3HAC023297-001 Revision: A 62 Recommended parts To connect power and signal conductors to the upper arm connector, the following parts are recommended xx0200000132 ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains: • Multipole connector 12 pin • Adapter Tin plated 12 pin • Pins for cable area 0.25-0.5 mm 2 • Pins for cable area 0.5-1.5 mm 2 • Shrinking hose, bootled shaped • Shrinking hose angled The connection set is delivered in a plastic bag also containing a Technical and assembly instruction.

3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including periodicity and refers to procedures for the activities. Each procedure contains all information required to perform the activity, e.g. required tools and materials. The procedures are gathered in different sections, divided according to the maintenance activity. Safety information Before any service work is commenced, it is extremely important that all safety information is observed! There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing the procedures. Make sure to read through the chapter Safety on page 13.

3HAC023297-001 Revision: A 64 3.2 Maintenance schedules 3.2.1. Maintenance schedule, IRB 140 General The robot, consisting of manipulator and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component. Activities and intervals, standard equipment The sections referred to in the table can be found in the different chapters for every maintenance activity. The table below specifies the required maintenance activities and intervals: *) "Regularly" implies that the activity is to be performed regularly, but the actual interval may not be specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its working environment and movement pattern. Generally, the more contaminated environment, the shorter intervals. The more demanding movement pattern (sharper bending cable harness), the shorter intervals. Maintenance activity Equipment Interval Detailed in section: Inspection Damper, axes 2-3 Regularly *) Inspection, damper axes 2-3 on page 66 Inspection Cable harnesses Regularly *) Inspection, robot cabling on page 68 Inspection Timing belts 36 mths Inspection, timing belts on page 69 Change Gearbox 5, oil 36 mths Oil change, gearbox, axes 5 and 6 on page 73 Change Gearbox 6, oil 36 mths Oil change, gearbox, axes 5 and 6 on page 73 Change Measurement system, battery Depending on battery type and operation pattern as specified in section Battery type selection on page 65. Replacement of serial measurement unit and battery pack on page 122. Clean Complete manipulator Regularly *) Cleaning, complete robot on page 72

65 3HAC023297-001 Revision: A Battery type selection The table below shows the selection criteria for the three available battery types. No longer change interval than 60 months are allowed regardless of the operation pattern due to material ageing, etc. Operation pattern Change interval, 3-cell lithium Change interval, 6-cell lithium Max. 4 weeks power off per year 60 mths 60 mths Weekend power off + operation pattern 1 24 mths 48 mths Nightly power off + operation patterns 1 and 2 12 mths 24 mths

3HAC023297-001 Revision: A 66 3.3 Inspection activities 3.3.1. Inspection, damper axes 2-3 Location of dampers, axes 2-3 The figure below shows the location of all the dampers to be inspected. xx0200000426 xx0200000427 A Damper, axis 2 A Damper, axis 3

67 3HAC023297-001 Revision: A Required equipment Inspection, damper axis 2-3 The procedure below details how to inspect the dampers, axis 2-3 WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. Equipment Art. no. Note Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Step Action Note 1. Check all dampers for damage, such as cracks or existing impressions larger than 1 mm. Shown in the figure in section Location of dampers, axes 2-3 on page 66! 2. Check attachment screws for deformation. 3. If any damage is detected, the damper must be replaced with a new one! Art. no. specified in section Required equipment on page 67! Replacement is detailed in section Replacement of damper, axis 2 on page 111 and Replacement of damper, axis 3 on page 102.

3HAC023297-001 Revision: A 68 3.3.2. Inspection, robot cabling Location, robot cabling The robot cabling comprises the cabling between the manipulator and controller cabinet as well as the externally visible cabling around motors 1 and 2. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. Required equipment WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Inspection The procedure below details how to inspect the robot cabling. Equipment Art. no. Note Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and procedures may be required. See references to these procedures in the step- by-step instructions below. These procedures include references to the tools required. Circuit diagram 3HAC 6816-3 Step Action Note 1. Visually inspect the control cabling between the manipulator and control cabinet. Look for abrasions, cuts or crush damages. 2. Replace the cabling if wear or damage is detected. This is detailed in Replacement of cable harness on page 78.

69 3HAC023297-001 Revision: A 3.3.3. Inspection, timing belts Location of timing belts Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. xx0200000448 G Timing belt, axis 3

3HAC023297-001 Revision: A 70 xx0200000453 Required equipment R Timing belt, axis 6 V Timing belt, axis 5 Equipment, etc. Art. no. Note Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. These procedures include references to the tools required.

71 3HAC023297-001 Revision: A Inspection The procedure below details how to inspect the timing belts. WARNING! Please observe the following before commencing any repair work on the manipulator: • Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! • Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot! • When replacing motors/reducers, make sure that those parts of the robot which could move unexpectedly are mechanically blocked as specified in the individual procedures. Step Action Note 1. Gain access to each belt by removing covers, etc. These procedures are detailed in sections Replacement of motor and timing belt, axis 3 on page 139 and Replacement of motor and timing belt, axes 5 or 6 on page 147. 2. Check each belt for damage. Replace the timing belts if found defective as detailed in sections Replacement of motor and timing belt, axis 3 on page 139 and Replacement of motor and timing belt, axes 5 or 6 on page 147. 3. Check each belt for tension. If the belt tension is not correct, it should be adjusted. The belt tension should be: • Axis 3: F = 35-60 N • Axis 5: F = 35-60 N • Axis 6: F = 35-60 N xx0200000474 Belt tension adjustment is detailed in sections Replacement of motor and timing belt, axis 3 on page 139 and Replacement of motor and timing belt, axes 5 or 6 on page 147.

3HAC023297-001 Revision: A 72 3.4 Cleaning activities 3.4.1. Cleaning, complete robot General The protection class is IP 67, i.e. the manipulator is watertight. Required equipment Do's and don'ts! The section below specifies some special considerations when cleaning the manipulator. Always! • Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels! • Always check that all protective covers are fitted to the robot before cleaning! Never! • Never point the water jet at bearing seals, contacts, and other seals! • Never spray from a distance closer than 0.4 m! • Never remove any covers or other protective devices before cleaning the robot! • Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above! • Although the manipulator is watertight, avoid spraying connectors and similar items with a high pressure cleaner! Equipment, etc. Art. no. Note May be used on Foundry versions only! Steam cleaner - • Water pressure at nozzle: max. 2,500 kN/ m 2 (25 bar) • Type of nozzle: fan jet, min. 45° spread • Flow: max. 100 litres/min. • Water temperature: max. 80° C May be used on Foundry versions only! High pressure water cleaner - • Max. water pressure on enclosures: 50 kN/ m 2 (0.5 bar) • Fan jet nozzle should be used, min. 45° spread • Flow: max. 100 litres/min. Vacuum cleaner Cloth with mild detergent - May be used on Standard version

73 3HAC023297-001 Revision: A 3.5 Changing/ replacing activities 3.5.1. Oil change, gearbox, axes 5 and 6 Location of oil plugs The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. xx0200000475 Required equipment A Oil plug, gearbox axis 5 B Oil plug, gearbox, axis 6 Equipment, etc. Art. no. Amount Note Lubricating oil gearbox 5 and 6 3HAC0860-1 350 ml Optimol BM 100 Oil collecting vessel Capacity: 400 ml. Standard Toolkit, IRB 140 3HAC020812- 001 The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. These procedures include references to the tools required.

3HAC023297-001 Revision: A 74 WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. TIP! When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains quicker than cold oil. WARNING! When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer! WARNING! When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the manipulator from moving freely WARNING! Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure that protective gear like goggles and gloves are always worn during this activity. Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there may be pressure present in the gearbox, causing oil to spray from the opening! Draining, axes 5 and 6 The procedure below details how to drain the oil from gearboxes, axes 5 and 6. Step Action Note 1. Move the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position. 2. Remove the oil plugs. The cavity behind the plugs, containing the oil, is common to gearboxes 5 and 6, but during draining, both must be removed. Shown in the figure Location of oil plugs on page 73! 3. Move axis 4 90° to a position where the axis 6 oil plug faces downwards. 4. Drain the oil from the gearbox. Vessel capacity specified in section Required equipment on page 73! 5. Move axis 4 another 90°. This allows the remaining oil to be drained. 6. Refit the oil plug.

75 3HAC023297-001 Revision: A Refill, axes 5 and 6 The procedure below details how to refill the oil in gearboxes, axes 5 and 6. Step Action Note 1. Run the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position. 2. Remove the oil plug, axis 5.. The cavity behind the plugs, containing the oil, is common to gearboxes 5 and 6, but during draining, both must be removed. Shown in the figure Location of oil plugs on page 73! 3. Fill oil in gearbox 5 until the oil level reaches the oil plug hole on the side of the wrist. The figure shows the manipulator positions for filling and draining respectively for a standing manipulator: xx0300000161 Positions: • A: Draining position • B: Filling position The figure shows the manipulator positions for filling and draining respectively for an inverted manipulator: xx0300000162 Positions: • A: Draining position • B: Filling position The oil quality is specified in section Required equipment on page 73! 4. Refit the oil plug.

4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate units, each detailing a specific repair activity. Each unit contains all information required to perform the activity, e.g. spare parts numbers, required special tools and materials. The units are gathered in different sections, divided according to the component location on the robot. Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure. The equipment is also gathered in different lists in the Product manual, reference information. Safety information Before any service work is commenced, it is extremely important that all safety information is observed! There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing specific steps in a procedure. Make sure to read through the chapter Safety on page 13 before commencing any service work.

3HAC023297-001 Revision: A 78 4.2 Complete robot 4.2.1. Replacement of cable harness Location of cable harness The cable harness runs from the base to the motors of axes 3-6. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. Required equipment Equipment, etc. Spare part no. Art. no. Note Cable harness 3HAC 7370-1 Standard and Foundry versions Clean room version Includes cabling: • Cable harness, power axis 1-3 • Cable harness, power axis 4-6 • Cable harness, signals axis 1-3 • Cable harness, signals axis 4-6 • Cable harness, customer connections Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and procedures may be required. See references to these procedures in the step- by-step instructions below. These procedures include references to the tools required. Circuit Diagram 3HAC 6816-3 See chapter Circuit diagram in the Product manual, reference information.

79 3HAC023297-001 Revision: A Removal, cable harness The procedure below details how to remove the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step Action Note/Illustration 1. Remove the serial measurement board. Detailed in section Replacement of serial measurement unit and battery pack on page 122. 2. Disconnect connectors in the manipulator base. xx0300000090 Connectors: • A: R1.MP1-3 • B: R1.CS • C: Air hose • D: R1.MP4-6 3. Remove the cable holder by unscrewing its attachment screws. xx0300000091 • A: Cable holder • B: Attachment screws • C: Cable securing screws

3HAC023297-001 Revision: A 80 4. Remove the cables from the cable holder by unscrewing the cable securing screws. See figure above! 5. Remove the cover, arm housing. Detailed in section Replacement of cover, arm housing, IRB 140. 6. Remove the lower arm cover. Detailed in section Replacement of lower arm cover and gasket on page 108. 7. Gently knock out the VK cover. Detailed in section Removing the VK cover on page 88. 8. Disconnect connectors in the rear of the upper arm. xx0300000092 Connectors: • A: R2.CS • B: Pressurized air connection • C: R3.FB4 • D: R3.FB5 • E: R3.FB6 • F: R3.MP5 • G: R3.MP4 • H: R3.MP6 Parts: • J: Shield 9. Remove the shield by unscrewing its attachment screws. See figure above! 10. Cut any cable ties securing the cabling inside the lower arm. Step Action Note/Illustration

81 3HAC023297-001 Revision: A 11. Disconnect the connectors inside the lower arm. xx0200000449 • G: Connectors R3.MP3 and R3.FB3 12. Pull the cables out of the upper arm. 13. Remove the cover, console. Detailed in section Replacement of cover, console on page 115. 14. Disconnect the connectors inside the console and undo the cable holders. Connectors: • R3.MP1 • R3.MP2 • R3.FB1 • R3.FB2 15. Gently pull the cabling from the base up through the console. 16. Gently pull the cabling out of the lower arm. Step Action Note/Illustration

3HAC023297-001 Revision: A 82 Refitting, cable harness The procedure below details how to refit the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2. CAUTION! The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Step Action Note/Illustration 1. Refit in reverse order to what is detailed above. Detailed below are some recommendations on how to route the cables. 2. Cable distribution in the cable holder in the manipulator base. xx0300000093 Cables: • A: Signal • B: Signal • C: Customer signal • D: Power cable, axes 4-6 • E: Pressurized air supply • F: Power cable, axes 1-3

83 3HAC023297-001 Revision: A 3. Cable layout in the lower arm. xx0200000449 • A: Cable ties • B: Pressurized air hose • C: Power cables, axes 4, 5 and 6 • D: Customer cables, signal • E: Signal cables, axes 4, 5 and 6 • F: Signal cable, axis 3 • G: Connectors R3.MP3 and R3.FB3 Step Action Note/Illustration

3HAC023297-001 Revision: A 84 4. Cable holder in the upper arm. xx0300000094 Cables: • A: Customer signal • B: Signal • C: Pressurized air supply • D: Power cables Step Action Note/Illustration

85 3HAC023297-001 Revision: A 4.2.2. Replacement of complete upper arm Location of upper arm The upper arm is located on top of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. xx0200000446 A Cover, armhousing B Attachment screws, cover armhousing, (4 pcs) C CS-connector D Pressurized air connector E VK cover F Cable guide G Attachment screws, cable guide H Attachment screws, upper arm (6 pcs) J Sealing ring

3HAC023297-001 Revision: A 86 Required equipment WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. Removal, upper arm The procedure below details how to remove the complete upper arm. Equipment Spare part no. Art. no. Note Upper arm, spare Std/F 3HAC 10466-1 Standard and Foundry versions Includes all required sealings and gaskets. Upper arm, spare CR 3HAC 10466-3 Clean room versions Includes all required sealings and gaskets. Sealing ring 3HAB 3732-13 To be replaced if damaged only Included in the upper arm assembly VK cover 3HAC 2166-13 Gasket upper arm cover 3HAC 7867-1 To be replaced if damaged only Included in the upper arm assembly Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Special socket - For fitting the CS- connector Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. These procedures include references to the tools required. Step Action Note/Illustration 1. Run the manipulator arm to a horizontal position. 2. Remove all brackets securing any exterior cabling to the upper arm by unscrewing their attachment screws respectively.

87 3HAC023297-001 Revision: A 3. Remove the rear cover armhousing by unscrewing its four attachment screws. Shown in the figure Location of upper arm on page 85! 4. DO NOT under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a complete rebuild! xx0300000101 • A: DO NOT touch these screws! (NOTE! Only two screws shown!) 5. Disconnect all cables to/from motors 4-6. Connectors • R3.MP4 • R3.MP5 • R3.MP6 • R3.FB4 • R3.FB5 • R3.FB6 6. Disconnect any connector from the CS-connector. Shown in the figure Location of upper arm on page 85! 7. Use a special socket to remove the CS-connector from the housing and pull it into the upper arm assembly. Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! 8. Remove the pressurized air connector from the housing and pull it into the upper arm assembly. Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! 9. Remove the VK-cover from the upper arm/lower arm joint. Shown in the figure Location of upper arm on page 85! Detailed in section Removing the VK cover on page 88. 10. Remove the cable guide by unscrewing its two attachment screws. Shown in the figure Location of upper arm on page 85! 11. Gently pull all cables and hoses out. 12. Remove the upper arm by unscrewing its six attachment screws. Shown in the figure Location of upper arm on page 85! 13. Lift the upper arm and place it on a secure surface. Step Action Note/Illustration

3HAC023297-001 Revision: A 88 Removing the VK cover The procedure below details how to remove the VK cover from the upper arm. xx0200000433 A Lower arm B Lower arm cover gasket C Cover l. arm, spare (without lamp unit) D Cover l. arm, spare (with lamp unit) Step Action Note 1. Remove the lower arm cover by unscrewing its attachment screws. 2. Tap the VK coverwith a long blunt edged bar through the hole in the lower arm to press it out. Make sure to press the circumference of the VK cover evenly to avoid damaging it. Shown in the figure in section Location of upper arm on page 85! 3. If the VK cover is damaged, it must be replaced on refitting. Specified in section Refitting of complete upper arm.

89 3HAC023297-001 Revision: A Refitting The procedure below details how to refit the complete upper arm. Step Action Note 1. Check the sealing ring to see whether it is damaged. Replace if it is damaged! Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! 2. Lift the upper arm into position. 3. Secure the upper arm with its six attachment screws. Shown in the figure Location of upper arm on page 85! Tightening torque: 35 Nm ± 3 Nm 4. Gently pull all cables and hoses through the hole in the upper arm. 5. Reconnect all connectors to motors 4-6. Connectors • R3.MP4 • R3.MP5 • R3.MP6 • R3.FB4 • R3.FB5 • R3.FB6 6. Refit the cable guide with its two attachment screws. Shown in the figure Location of upper arm on page 85! 7. Pull the pressurized air connector through the housing and secure it into fitting in the upper arm assembly. Shown in the figure Location of upper arm on page 85! 8. Pull the CS-connector through the housing and secure it into the fitting in the upper arm assembly. Use a special socketto secure it. Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! 9. Reconnect any connector previously connected externally to the CS connector. 10. Fit a newVK-cover to the upper arm/lower arm joint. Gently knock it into position. Shown in the figure Location of upper arm on page 85! Art. no. specified in section Required equipment on page 86! Use a plastic mallet or similar. 11. Refit the rear cover armhousing with its four attachment screws. Shown in the figure Location of upper arm on page 85! 12. Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively. 13. Recalibrate the robot. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

3HAC023297-001 Revision: A 90 DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that: • all the service tools and other foreign objects are removed from the manipulator! • all normal safety equipment is installed properly, e.g. TPU enabling device. • all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. • special attention is paid to the function of the part previously serviced.

91 3HAC023297-001 Revision: A 4.2.3. Replacement of complete lower arm Location of lower arm The lower arm is located between upper arm and frame as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. xx0200000469 A Lower arm

3HAC023297-001 Revision: A 92 Required equipment Removal, lower arm The procedure below details how to remove the complete lower arm. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. Equipment Spare part no. Art. no. Note Lower arm, spare 3HAC 10468-1 Standard and Foundry versions Includes all required bearings, oil and VK cover. Lower arm, spare 3HAC 10468-4 Clean room versions Includes all required bearings, oil and VK cover. Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Lifting device for lower arm Lifting capacity xx kg Special socket - For fitting the CS- connector Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. These procedures include references to the tools required.

93 3HAC023297-001 Revision: A Step Action Info/Illustration 1. Remove the console. Detailed in section Replacement of console on page 118. 2. DO NOT under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a complete rebuild! xx0300000101 Parts: • A: DO NOT touch these screws! (Note! Only 2 screws are shown.) 3. Remove the VK cover by pressing a screwdriver, or similar, through it and pulling. xx0300000097 Parts: • A: Washer • B: Lower arm attachment screws (10 pcs) • C: VK cover 4. Unscrew thelower arm attachment screws. Also remove the washer. Shown in the figure above! 5. Raise the lifting device to remove the lower arm.

3HAC023297-001 Revision: A 94 Refitting, lower arm The procedure below details how to refit the complete lower arm. Step Action Info/Illustration 1. Fit the lifting device and lift the lower arm into position. 2. Fit the lower arm to gearbox, axis 2, and secure it with its attachment screws and washers. xx0300000097 Parts: • A: Washer • B: Lower arm attachment screws (10 pcs) • C: VK cover Tightening torque: 35 Nm ± 3 Nm 3. Fit a new VK cover by gently tapping it into position. Shown in the figure above! 4. Refit the console. Detailed in section Replacement of console on page 118. 5. Recalibrate the robot. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

95 3HAC023297-001 Revision: A 4.2.4. Replacement of base, spare Location of base The base is located at the bottom of the manipulator as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts in the Product manual, reference information. xx0200000423 Required equipment A Base B Bottom plate C Bottom plate attachment screws (26 pcs) D Gearbox/base attachment screws and washers (20 pcs each) E Joint, gearbox/base F Damper, axis 1 G Washer Equipment Spare part no. Art. no. Note Base, spare 3HAC 10470-1 Standard and Foundry versions Includes Parallel pin 3HAC 3785-2 Base, spare 3HAC 10470-3 Clean room versions Includes Parallel pin 3HAC 3785-2 Lifting slings - Min. capacity 20 kg

3HAC023297-001 Revision: A 96 Removal, base The procedure below details how to remove the base. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. LocTite 574 For sealing the base to the gearbox 1-2 Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit in the Product manual, reference information! Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. These procedures include references to the tools required. Equipment Spare part no. Art. no. Note Step Action Info 1. Remove motors 1 and 2. Detailed in sections Replacement of motor, axis 1 on page 130 and Replacement of motor, axis 2 on page 135 respectively. 2. Remove the cable harness. Detailed in section Replacement of cable harness on page 78. 3. Remove the serial measurement board. Detailed in section Replacement of serial measurement unit and battery pack on page 122. 4. Remove the complete upper arm. Detailed in section Replacement of complete upper arm on page 85. 5. Remove the complete lower arm. Detailed in section Replacement of complete lower arm on page 91. 6. Place the remaining base/gearbox axes 1- 2 assembly upside down on a work bench. Remove the bottom plate. Shown in the figure Location of base. 7. Remove the gearbox/base attachment screws. Shown in the figure Location of base. 8. Separate the base from the gearbox 1-2.

97 3HAC023297-001 Revision: A Refitting The procedure below details how to refit the complete lower arm. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! • Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! • Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2. DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that: • all the service tools and other foreign objects are removed from the manipulator! • all normal safety equipment is installed properly, e.g. TPU enabling device. Step Action Note 1. Place the gearbox 1-2 and the base on a workbench. 2. After making sure the mating surface between the base and gearbox is completely clean, apply Loctite to it. Art. no. is specified in section Required equipment on page 95. 3. Secure the gearbox to the base with the gearbox/base attachment screws and washers. Shown in the figure Location of base. Tightening torque: 35 Nm ± 3Nm 4. Refit the bottom plate and secure it with its attachment screws. Shown in the figure Location of base. 5. Turn the base into standing upright. 6. Refit the complete lower arm. Detailed in section Replacement of complete lower arm on page 91. 7. Refit the complete upper arm. Detailed in section Replacement of complete upper arm on page 85. 8. Refit motors 1 and 2. Detailed in sections Replacement of motor, axis 1 on page 130 and Replacement of motor, axis 2 on page 135 respectively. 9. Refit the serial measurement board. Detailed in section Replacement of serial measurement unit and battery pack on page 122. 10. Refit the cable harness. Detailed in section Replacement of cable harness on page 78. 11. Recalibrate the robot. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.

3HAC023297-001 Revision: A 98 • all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. • special attention is paid to the function of the part previously serviced.