Product manual (part 2 of 2), reference information - Technology

Product manual (part 2 of 2), reference informationArticulated robotIRB 140M2000, M2000A, M2004

Product manual (part 2 of 2), reference informationIRB 140M2000M2000AM2004Document ID: 3HAC 023297-001Revision: -

The information in this manual is subject to change without notice andshould not be construed as a commitment by ABB. ABB assumes noresponsibility for any errors that may appear in this manual.Except as may be expressly stated anywhere in this manual, nothingherein shall be construed as any kind of guarantee or warranty by ABBfor losses, damages to persons or property, fitness for a specific purposeor the like.In no event shall ABB be liable for incidental or consequential damagesarising from use of this manual and products described herein.This manual and parts thereof must not be reproduced or copied withoutABB’s written permission, and contents thereof must not be imparted toa third party nor be used for any unauthorized purpose. Contraventionwill be prosecuted.Additional copies of this manual may be obtained from ABB at its thencurrent charge.© Copyright 2004 ABB All right reserved.ABB Automation Technologies ABRoboticsSE-721 68 VästeråsSweden

Table of Contents43HAC 023297-001 Revision: -

OverviewOverviewAbout this manualThis manual contains reference information for all procedures in part 1: Product manual,procedures.UsageThis manual should be used during:• installation• maintenance work• repair work.Who should read this manual?This manual is intended for:• installation personnel• maintenance personnel• repair personnel.PrerequisitesThe reader should...• be a trained maintenance/repair craftsman• have the required knowledge of mechanical and electrical installation/repair/maintenance work.Organization of chaptersThe manual is organized in the following chapters:ChapterReference informationSpare part / Part listFoldoutsCircuit diagramContentsUseful information when performing installation, maintenanceor repair works. Includes lists of necessary tools, additionaldocuments, safety standards, etc.Complete spare part lists and complete lists of robotcomponents, shown in the foldouts.Detailed illustrations of the robot with reference numbers to thepart list.Circuit diagram for the robot.3HAC 023297-001 Revision: -5

OverviewRevisionsRevisionDescription- First editionReplaces previous manuals:• Installation and commissioning manual• Maintenance manual• Repair manual, part 1• Repair manual, part 2Changes made in the material from the previous manuals:• Model M2004 implemented.• Section Document references added to the chapter Referenceinformation.• Information about the controller removed from the manual.• Additional spare part numbers for the motors.63HAC 023297-001 Revision: -

Product documentation, M2000/M2000AProduct documentation, M2000/M2000AGeneralThe complete product documentation kit for the M2000 robot system, including controller,robot and any hardware option, consists of the manuals listed below:Hardware manualsAll hardware, robots and controller cabinets, will be delivered with a Product manual whichis divided into two parts:Product manual, procedures• Safety information• Installation and commissioning (descriptions of mechanical installation, electricalconnections and loading system software)• Maintenance (descriptions of all required preventive maintenance proceduresincluding 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 Productmanual, procedures, lists of tools, safety standards)• Part list• Foldouts or exploded views• Circuit diagramsSoftware manualsThe software documentation consists of a wide range of manuals, ranging from manuals forbasic understanding of the operating system to manuals for entering parameters duringoperation.A complete listing of all available software manuals is available from ABB.Controller hardware option manualEach hardware option for the controller is supplied with its own documentation. Eachdocument set contains the types of information specified below:• Installation information• Repair information• Maintenance informationIn addition, spare part information is supplied for the entire option.3HAC 023297-001 Revision: -7

Product documentation, M2004Product documentation, M2004GeneralThe robot documentation may be divided into a number of categories. This listing is based onthe type of information contained within the documents, regardless of whether the productsare standard or optional. This means that any given delivery of robot products will not containall documents listed, only the ones pertaining to the equipment delivered.However, all documents listed may be ordered from ABB. The documents listed are valid forM2004 robot systems.Hardware manualsAll hardware, robots and controller cabinets, will be delivered with a Product manual whichis divided into two parts:Product manual, procedures• Safety information• Installation and commissioning (descriptions of mechanical installation, electricalconnections and loading system software)• Maintenance (descriptions of all required preventive maintenance proceduresincluding 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 Productmanual, procedures, lists of tools, safety standards)• Part list• Foldouts or exploded views• Circuit diagramsRobotWare manualsThe following manuals describe the robot software in general and contain relevant referenceinformation:• 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 systemparameters and configuration workflows.Application manualsSpecific applications (e.g. software or hardware options) are described in Applicationmanuals. 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)83HAC 023297-001 Revision: -

Product documentation, M2004• How to use the application• Examples of how to use the applicationOperator’s manualsThis 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 manualsinclude:• Operator’s manual - IRC5 with FlexPendant• Operator’s manual - RobotStudioOnline• Trouble shooting Manual for the controller and robotMiscellaneousA number of manuals provide generic descriptions of the robot and robot system. Theseinclude:• Robot fundamentals (describing the fundamental aspects, functions, concept andsimilar, of a robot system to provide a basic understanding of the robot system)3HAC 023297-001 Revision: -9

Product documentation, M2004103HAC 023297-001 Revision: -

1 Reference information1.1. Introduction1 Reference information1.1. IntroductionGeneralThis chapter includes general information, complementing the more specific information inthe Product manual (part 1 of 2), procedures.3HAC 023297-001 Revision: -11

1 Reference information1.3. Unit conversion1.3. Unit conversionConverter tableUse the table below to convert units used in this manual.QuantityUnitsLength 1 m 3.28 ft 39.37 inWeight 1 kg 2.21 lbPressure 1 bar 100 kPa 14.5 psiForce 1 N 0.738 lbfMoment 1 Nm 0.738 lbf-tnVolume 1 L 0.264 US gal3HAC 023297-001 Revision: -13

1 Reference information1.4. Screw joints1.4. Screw jointsGeneralThis section details how to tighten the various types of screw joints on the robot and thecontroller.The instructions and torque values are valid for screw joints comprised of metallic materialsand do not apply to soft or brittle materials.UNBRAKO screwsUNBRAKO is a special type of screw recommended by ABB for certain screw joints. Itfeatures special surface treatment (Gleitmo as described below), and is extremely resistant tofatigue.Whenever used, this is specified in the instructions, and in such cases, no other type ofreplacement screw is allowed! Using other types of screws will void any warranty and maypotentially cause serious damage or injury!Gleitmo treated screwsGleitmo is a special surface treatment to reduce the friction when tightening the screw joint.Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. Afterthis the screw must be discarded and replaced with a new one.When handling screws treated with Gleitmo, protective gloves of nitrile rubber type shouldbe used.Screws lubricated in other waysScrews lubricated with Molycote 1000 should only be used when specified in the repair,maintenance or installation procedure descriptions.In such cases, proceed as follows:1. Apply lubricant to the screw thread.2. Apply lubricant between the plain washer and screw head.3. Tighten to the torque specified in section Tightening torque below. Screw dimensionsof M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 orsmaller may be tightened without a torque wrench if this is done by trained andqualified personnel.LubricantArt. no.Molycote 1000 (molybdenum disulphide grease) 1171 2016-618Tightening torqueBefore tightening any screw, note the following:• Determine whether a standard tightening torque or special torque is to be applied. Thestandard torques are specified in the tables below. Any special torques are specified inthe Repair, Maintenance or Installation procedure description. Any special torquespecified overrides the standard value.• Use the correct tightening torque for each type of screw joint.143HAC 023297-001 Revision: -

1 Reference information1.4. Screw joints• Only use correctly calibrated torque keys.• Always tighten the joint by hand, and never use pneumatical tools.• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,flowing motion.• Maximum allowed total deviation from the specified value is 10%!The table below specifies the recommended standard tightening torque for oil-lubricatedscrews with slotted or cross-recess head screws.DimensionM2.5 0.25M3 0.5M4 1.2M5 2.5M6 5.0Tightening torque (Nm)Class 4.8, oil-lubricatedThe table below specifies the recommended standard tightening torque for oil-lubricatedscrews with Allen head screws.DimensionTightening torque(Nm)Class 8.8, oillubricatedTightening torque(Nm)Class 10.9, oillubricatedM5 6 - -M6 10 - -M8 24 34 40M10 47 67 80M12 82 115 140M16 200 290 340Tightening torque(Nm)Class 12.9, oillubricatedThe table below specifies the recommended standard tightening torque for Molycotelubricatedscrews with Allen head screws.DimensionTightening torque (Nm)Class 10.9, Molycote-lubricatedM8 28 34M10 55 66M12 96 115M16 235 280Tightening torque (Nm)Class 12.9, Molycote-lubricated3HAC 023297-001 Revision: -15

1 Reference information1.4. Screw jointsThe table below specifies the recommended standard tightening torque for water and airconnectors when one or both connectors are made of brass.DimensionTightening torqueNm - NominalTightening torqueNm - Min.1/8 12 8 151/4 15 10 203/8 20 15 251/2 40 30 503/4 70 55 90Tightening torqueNm - Max.163HAC 023297-001 Revision: -

1 Reference information1.5. Weight specifications1.5. Weight specificationsDefinitionExampleIn all repair and maintenance procedures, weights of the components handled are sometimesspecified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.To avoid injury, ABB recommends the use of lifting equipment when handling componentswith a weight exceeding 22 kg. A wide range of lifting tools and devices are available foreach manipulator model.Below is an example of how a weight specification is presented:CAUTION!Caution!The motor weighs 32 kg! All lifting equipment used must be sized accordingly!3HAC 023297-001 Revision: -17

1 Reference information1.6. Document references1.6. Document referencesGeneralThe contents of this manual may include references to additional documentation necessary toperform certain procedures. This section specifies the article numbers for the referenceddocumentation.Product specification, robotThe product specification includes generic technical data. The specification listed below isthe English version.Document nameDocument IDProduct specification 3HAC 9041-1Product manuals, controllerThe product manuals include information about installation and service activities. The tablebelow specifies the article numbers of the product manuals for all controller models. The partnumber -001 is the English version.Document nameDocument IDProduct manual, S4Cplus M2000 3HAC 021333-001Product manual, S4Cplus M2000A 3HAC 021128-001Product manual, IRC5 M2004 3HAC 021313-001Operators manualThe operators manual contains instructions for daily operation of robot systems. The tablebelow specifies the article numbers of the operators manuals for different robot systems.Document name Document ID NoteUser’s guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operationof S4Cplus based robot systems.Operator’s manual (IRC5) 3HAC 16590-1Calibration manualsDocument name Document ID NoteCalibration PendulumInstructionInstructions for Levelmetercalibration (alternativemethod)3HAC 16578-1 Enclosed with the Calibration PendulumToolkit.3HAC 022907-001 Enclosed with the Levelmeter 2000.CalibWare 2.0 Users Guide 3HAC 16090-1 Calibration tool for Absolute Accuracycalibration.183HAC 023297-001 Revision: -

1 Reference information1.6. Document referencesAdditional documentationDocument name Document ID NoteExternal axes 3HAC 9299-13HAC 023297-001 Revision: -19

1 Reference information1.7. Standard toolkit1.7. Standard toolkitGeneralContentsAll service (repair, maintenance and installation) instructions contain lists of tools requiredto perform the specified activity. All special tools, i.e. all tools that are not consideredstandard as defined below, are listed in their instructions respectively.This way, the tools required are the sum of the Standard Toolkit and any tools listed in theinstruction.Standard tool, IRB 140: 3HAC020812-001 contains:Qty Art. no. Tool1 - Ring-open-end spanner 8-19mm1 - Socket head cap 2,5-17mm1 - Torx socket no:20-601 - Torque wrench 10-100Nm1 - Small screwdriver1 - Ratchet head for torque wrench 1/21 - Socket head cap no:5, socket 1/2"" bit L 20mm1 - Socket head cap no:6, socket 1/2"" bit L 20mm1 - Socket head cap no:8, socket 1/2"" bit L 20mm1 - Small cutting plier203HAC 023297-001 Revision: -

1 Reference information1.8. Performing a leak-down test1.8. Performing a leak-down testGeneralAfter refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oilmust be tested. This is done in a leak-down test.Required equipmentEquipment, etc. Art. no. NoteLeakdown tester 3HAC 0207-1Leak detection spray -ProcedureStep Action Note/Illustration1. Finish the refitting procedure of the motor or gear inquestion.2. Remove the topmost oil plug on the gear in question,and replace it with the leakdown tester .Adapters may be required, which are included in theleakdown tester kit.3. Apply compressed air, and raise the pressure with theknob until the correct value is shown on themanometer.4. Disconnect the compressed air supply.5. Wait for approx. 8-10 minutes. No pressure loss mustbe detected.6. Was any pressure drop evident?Localize the leak as detailed below.Remove the leakdown tester, and refit the oil plug.The test is complete.7. Spray suspected leak areas with leak detectionspray .Bubbles indicate a leak.8. When the leak has been localized: take thenecessary measures to correct the leak.Art. no. is specified above!Recommended value: 0.2 -0.25 bar (20 - 25 kPa)If the compressed air issignificantly colder orwarmer than the gearbox tobe tested, a slight pressureincrease or decreaserespectively may occur. Thisis quite normal.Art. no. is specified above!3HAC 023297-001 Revision: -21

1 Reference information1.9. Lifting equipment and lifting instructions1.9. Lifting equipment and lifting instructionsGeneralMany repair and maintenance activities require different pieces of lifting equipment, whichare specified in each procedure.The use of each piece of lifting equipment is not detailed in the activity procedure, but inthe instruction delivered with each piece of lifting equipment.This implies that the instructions delivered with the lifting equipment should be stored forlater reference.223HAC 023297-001 Revision: -

1 Reference information1.10. Mounting instructions for bearings1.10. Mounting instructions for bearingsGeneralThis section details how to mount and grease different types of bearings on the manipulator.EquipmentEquipment, etc. Art. no. NoteGrease 3HAB 3537-1 Used to grease the bearings, if notspecified otherwise.Assembly of all bearingsFollow the instructions below when mounting a bearing on the manipulator.1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste andother contamination. Cast components must be free from foundry sand.3. Bearing rings, inner rings and roller elements must under no circumstances be subjectedto direct impact. Furthermore, the roller elements must not be exposed to any stressesduring the assembly work.Assembly of tapered bearingsFollow the previous instructions for assembly of all bearings, when mounting a taperedbearing on the manipulator.In addition to those instructions, the procedure below must be carried out to enable the rollerelements to adjust to the correct position against the race flange.1. Tension the bearing gradually until the recommended pre-tension is achieved.Note! The roller elements must be rotated a specified number of turns before pretensioningis carried out and also rotated during the pre-tensioning sequence.2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of thebearing.Greasing of bearingsThe bearings must be greased after assembly, according to instructions below:• The bearings must not be completely filled with grease. However, if space is availablebeside the bearing fitting, the bearing may be totally filled with grease when mounted,as excessive grease will be pressed out from the bearing when the robot is started.• During operation, the bearing should be filled to 70-80% of the available volume.• Ensure that grease is handled and stored properly, to avoid contamination.Grease the different types of bearings as detailed below:• Grooved ball bearings must be filled with grease from both sides.• Tapered roller bearings and axial needle bearings must be greased in the splitcondition.3HAC 023297-001 Revision: -23

1 Reference information1.11. Mounting instructions for seals1.11. Mounting instructions for sealsGeneralThis sections details how to mount different types of seals to the manipulator.EquipmentEquipment, etc. Art. no. NoteGrease 3HAB 3537-1 Used to lubricate the seals.Rotating sealsThe procedure below details how to fit rotating seals.CAUTION!Please observe the following before commencing any assembly of seals:• Protect the sealing surfaces during transport and mounting.• Keep the seal in its original wrappings or protect it well before actual mounting.• The fitting of seals and gears must be carried out on clean workbenches.• Use a protective sleeve for the sealing lip during mounting, when sliding over threads,keyways, etc.Step Action Note1. Check the seal to ensure that:• the seal is of the correct type (provided with cuttingedge).• there is no damage to the sealing edge (feel with afingernail).2. Inspect the sealing surface before mounting. If scratches ordamage are found, the seal must be replaced, as it mayresult in future leakage.3. Lubricate the seal with grease just before fitting. (Not tooearly as there is a risk of dirt and foreign particles adheringto the seal.)Fill the space between the dust tongue and sealing lip to 2/3 with grease. The rubber coated external diameter mustalso be greased, unless otherwise specified.4. Mount the seal correctly with a mounting tool.Never hammer directly on the seal as this may result inleakage.Art. no. is specified inEquipment on page24.243HAC 023297-001 Revision: -

1 Reference information1.11. Mounting instructions for sealsFlange seals and static sealsThe procedure below details how to fit flange seals and static seals.Step Action Note1. Check the flange surfaces. They must be even and free from pores.It is easy to check flatness using a gauge on the fastened joint(without sealing compund).If the flange surfaces are defective, the parts may not be usedbeacuse leakage could occur.2. Clean the surfaces properly and in accordance with ABBROBOTICS PRODUCTS recommendations.3. Distribute the sealing compound evenly over the surface, preferablywith a brush.4. Tighten the screws evenly when fastening the flange joint.O-ringsThe procedure below details how to fit o-rings.Step Action Note1. Ensure that the correct o-ring size is used.2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-ringsmay not be used.3. Check the o-ring grooves.The grooves must be geometrically correct and free from poresand contamination.4. Lubricate the o-ring with grease.5. Tighten the screws evenly when assembling.Defective o-ringsmay not be used.3HAC 023297-001 Revision: -25

1 Reference information1.11. Mounting instructions for seals263HAC 023297-001 Revision: -

2 Spare part / part list2.1. Introduction2 Spare part / part list2.1. IntroductionDefinitionsThis chapter specifies all spare parts and replacement articles of the robot.3HAC 023297-001 Revision: -27

2 Spare part / part list2.2. Spare part / part list2.2. Spare part / part listSpare part / part listThe table below details all replacement articles on the robot. The items refer to chapterFoldouts.Item Qty Art. no. Name Rem.1 1 3HAC 10470-1 Base spare2 1 3HAC 8999-1 Bottom plate3 26 9ADA 629-44 Torx pan head roll. screw M5x124 1 3HAC 6599-1 Gasket bottom plate5 1 3HAC 9522-1 Serial meas. board ass.6 1 4944 026-4 Battery pack 7.2V 4Ah NiCd7 2 2166 2055-6 Cable straps, outdoors 7.6x3688 28 9ADA 618-46 Torx pan head screw M5x209 1 3HAC 9030-1 Cable bracket10 1 3HAC 9415-1 Clamp11 1 3HAC 6755-1 Cable holder12 4 9ADA 618-50 Torx pan head screw M5x4013 1 3HAC 10476-1 Control cable spare Std/F L = 3 m14 1 3HAC 10477-1 Control cable spare Std/F L = 7 m15 1 3HAC 7527-1 Damper axis 116 20 3HAB 3402-52 Hex. socket head cap screw M10x35 8.8Gleitmo 61017 2 3HAC 7950-1 Washer18 2 3HAC 9860-1 Protecting plate19 1 3HAC 8466-1 Protective earth cable20 2 3HAC 9063-1 Hose clip D = 1021 1 SK 615 503-2 Membrane22 1 SK 616 013-F Bracket CBK23 1 1SFAActuator black616100R100624 1 3HAC 7870-1 Gasket base-cover25 10 9ADA 290-1 Hexagon nut with flange M526 1 2529 1920-2 Plug R 1/8"27 2 2522 2101-8 Protective hood D=11.4-1328 1 3HAC 8806-1 Clamp29 1 3HAC 7370-1 Cable harness IRB 14030 1 3HAC 2589-1 Instruction plate Batteryreplacement31 10 2166 2055-3 Cable straps, outdoors 4.8x20832 20 ml 1234 0011-116 Flange sealing Lotctite 57433 1 3HAC 10470-3 Base, spare CR34 1 3HAC 10476-4 Control cable spare CR L = 3 m283HAC 023297-001 Revision: -

2 Spare part / part list2.2. Spare part / part listItem Qty Art. no. Name Rem.35 1 3HAC 10477-2 Control cable spare CR L = 7 m36 1 3HAC 11331-1 Control cable spare Std/F L = 15 m37 1 3HAC 11331-2 Control cable spare CR L = 15 m38 1 3HAC 13089-1 Control cable spare Std/F L = 30 m39 1 3HAC 13090-1 Control cable spare Std/F L = 22 m50 1 3HAC 10467-1 Gearbox axes 1-2, spare Std/F Item 67 incl.51 2 3HAC 10469-1 Motor with pinion spare Std/F3HAC 021965-00152 24 3HAB 3409-25 Hex socket head cap screw M6x20 12.9Gleitmo 61053 18 9ADA 312-6 Plain washer 6.4x12x1.654 2 2152 2012-426 O-ring 74.5x355 1 3HAC 6788-1 Bearing hub56 1 3HAC 10478-1 Console spare Std/F57 1 3HAC 10472-1 Cover console spare Std/F Item 58 incl.58 1 3HAC 7868-1 Gasket console-cover59 1 3HAC 5894-1 Cable bracket T=1.560 1 3HAC 6965-1 Sealing ring 150x189x8.561 3 3HAC 3785-6 Parallel pin D = 6 m6 L = 1662 2 3HAB 3732-19 Sealing ring (V-ring) 85x1163 11 9ADA 618-55 Torx pan head screw M6x1264 2 2166 2018-2 Clamp D = 1165 1 3HAC 10481-1 Connector bracket66 25 2166 2055-1 Cable straps, outdoors 2.5x10167 3000 ml 1171 2016-604 Lubricating oil68 1 3HAC 10467-3 Gearbox axes 1-2, spare CR69 2 3HAC 10469-3 / Motor with pinion, spare CR3HAC 021966-00170 1 3HAC 10478-3 Console, spare CR71 1 3HAC 10472-3 Cover console, spare CR72 1 3HAC 10645-1 Clamp D = 4.7100 1 3HAC 10468-1 Lower arm (axis 3), spare Item 67, 107and 108 incl.101 1 3HAC 10471-1 Cover, without lamp unit Item 103 incl.102 1 3HAC 10474-1 Cover, with lamp unit Item 103 incl.103 1 3HAC 7869-1 Gasket lower-arm cover104 1 3HAC 7866-1 / Rot. ac motor incl. pinion3HAC 021756-001105 1 3HAC 6793-1 Timing belt106 1 3HAC 6762-1 Belt shield107 1 3HAB 3643-17 Groove ball bearing 80x100x10108 2 3HAA 2166-13 VK-Cover D = 100 B = 10109 1 3HAC 7880-1 Damper axis 2110 1 3HAA 2356-14 Washer SRKB 6.4x18x1.63HAC 023297-001 Revision: -29

2 Spare part / part list2.2. Spare part / part listItem Qty Art. no. Name Rem.111 4 3HAB 3402-15 Hex. socket head cap screw M5x20 8.8Gleitmo 610112 12 9ADA 312-5 Plain washer 5.3x10x1113 1 3HAC 9258-1 Indicator lamp114 1 3HAC 10468-4 Lower arm, spare CR115 1 3HAC 10471-3 Cover, without lamp unit116 1 3HAC 10474-3 Cover, with lamp unit150 1 3HAC 10466-1 Upper arm compl. with wrist Motors incl.151 1 3HAC 10475-1 Wrist, spare Std/F Item 155, 181and 182 incl.152 1 3HAC 7191-1 O-ring sealing plate153 3 3HAB 3409-37 Hex. socket head cap screw M8x25 12.9Gleitmo 610154 3 9ADA 312-7 Plain washer 8.4x16x1.6155 3 2529 1920-2 Plug R 1/8"156 1 3HAC 10479-1 Axis 4 complete, spare Std/F Item 111, 112,180, 159, 161,160 and 182incl.157 6 3HAB 3409-39 Hex. socket head cap screw M8x35 12.9Gleitmo 610158 6 9ADA 334-7 Spring washer, conical 8.4x18x2159 1 3HAB 3732-13 Sealing ring (V-ring) 99x10.5160 1 3HAC 7842-1 / Rot. ac motor with pinion3HAC 021757-001161 1 3HAB 3772-24 O-ring 29x3162 2 3HAC 7841-1 / Rot. ac motor with pinion3HAC 021758-001163 4 3HAB 3402-18 Hex. socket head cap screw M5x35 8.8Gleitmo 610164 1 3HAC 6773-1 Motor Console axes 5-6165 5 9ADA 183-13 Hex. socket head cap screw M5x12166 3 3HAA 2356-15 Washer SRKB 5.3x15x1.2167 1 3HAC 7367-1 Cable holder168 1 3HAC 8572-1 Clamp169 2 3HAC 6779-1 Timing belt170 1 3HAC 6777-1 Timing Belt Pulley Z2/5171 1 3HAC 6778-1 Timing Belt Pulley Z2/6172 1 3HAC 7939-1 Clamping unit173 1 3HAC 7391-1 Belt shield174 1 3HAC 10473-1 Cover armhousing spare Item 175 incl.175 1 3HAC 7867-1 Gasket upper arm cover176 1 3HAC 7881-1 Damper axis 3177 1 3HAC 6761-1 Cable guide178 1 3HAC 7561-3 Dustcap for receptacles 12p303HAC 023297-001 Revision: -

2 Spare part / part list2.2. Spare part / part listItem Qty Art. no. Name Rem.179 2 2125 2052-178 Distance bolt M5X55180 1 3HAC 6598-1 Hose nipple G 1/4"181 1 3HAB 8964-1 Damper axis 5182 550 ml 3HAC 0860-1 Lubricating oil OptimolOptigear BM100183 1 3HAC 10466-3 Upper arm, spare CR184 1 3HAC 10475-4 Wrist, spare CR185 1 3HAC 10479-3 Axis 4 complete, spare CR186 1 3HAC 10439-3 Cover armhousing, spare CR187 1 3HAC 11922-1 Slip strip3HAC 023297-001 Revision: -31

2 Spare part / part list2.2. Spare part / part list323HAC 023297-001 Revision: -

3 Foldouts3.1. Introduction3 Foldouts3.1. IntroductionOverviewThe foldouts in this chapter refer to the part list.3HAC 023297-001 Revision: -33

1 33 15 3218 27 8 13 34 35 36 37 38 393 31 20 19R1/42122 23 28 3Inside of cover4 5 7 1635 Nm17 24 6 8 12 11 9 2629 313102 3 3025Inside of baseBase completeFoldout 1

51 62 56 708 57 71 5852 5332A65 25 25 72 31625215,5 NmA (1 : 2)315552535254 53 52 516953546364685067ax.1 1,2 litreax.2 1,0 litre61 6160633159316363Foldout 2

0,4 litre67100114 104 105 64 3 103 101 115 8 113 102 116Do not loosenthese screwsDo not loosenthese screws3110109186617 16 35 Nm 108 107112 111 4,1 Nm 106Lower arm (shown without cables)Lower arm complete with cables(shown without cover)Foldout 3

0,35 litre oil (at oil change).0,30 litre oil (New wrist)182 151 1841520,2 litre oil180 182 156 185 159176162 162 164163 4,1 Nm 112169 1701711723 Nm17315328 Nm15418110835 Nm157 158 161 112 111 6 Nm160Upper arm (shown without cables)112 4,1 Nm 1631124,1 Nm 111 166 1656 Nm169112 1634,1 Nm175 8 174 186 12Foldout 4

177179168167150183201653187178Upper arm with cables(shown without cover)155Upper arm completeFoldout 5

4 Circuit diagram4.1. Introduction4 Circuit diagram4.1. IntroductionOverviewThis chapter includes the circuit diagram for the robot.3HAC 023297-001 Revision: -35

Circuit DiagramCONTENTSPageManipulator, diagram 3HAC 6816-3, Rev. 0 ..............................................................101-108IRB 140

Manipulator Circuit Diagram 3HAC 6816-3LIST OF CONTENTSIRB 140 No. of Sheets 8 Sheet no. 101

Manipulator Circuit Diagram 3HAC 6816-3CONNECTION POINT LOCATIONSIRB 140 No. of Sheets 8 Sheet no. 102

Manipulator Circuit Diagram 3HAC 6816-3SERIAL MEASUREMENT BOARDIRB 140 No. of Sheets 8 Sheet no. 103

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

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

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

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

Manipulator Circuit Diagram 3HAC 6816-3CUSTOMER CONNECTIONSIRB 140 No. of Sheets 8 Sheet no. 108