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Product manual (part 2 of 2), reference information

Articulated robot
IRB 140 M2000, M2000A, M2004

Product manual (part 2 of 2), reference information IRB 140


M2000 M2000A M2004 Document ID: 3HAC 023297-001 Revision: -

The information in this manual is subject to change without notice and 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 ABBs 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 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1 Reference information 11

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2 Spare part / part list 27

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.2 Spare part / part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3 Foldouts 33

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4 Circuit diagram 35

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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Table of Contents

3HAC 023297-001 Revision: -

Overview

Overview
About this manual This manual contains reference information for all procedures in part 1: Product manual, procedures. Usage This manual should be used during: installation maintenance work repair work.

Who should read this manual? This manual is intended for: Prerequisites The reader should... be a trained maintenance/repair craftsman have the required knowledge of mechanical and electrical installation/repair/ maintenance work. installation personnel maintenance personnel repair personnel.

Organization of chapters The manual is organized in the following chapters: Chapter


Reference information

Contents
Useful information when performing installation, maintenance or repair works. Includes lists of necessary tools, additional documents, safety standards, etc. Complete spare part lists and complete lists of robot components, shown in the foldouts. Detailed illustrations of the robot with reference numbers to the part list. Circuit diagram for the robot.

Spare part / Part list Foldouts Circuit diagram

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Overview

Revisions Revision
-

Description
First edition Replaces previous manuals: Installation and commissioning manual Maintenance manual Repair manual, part 1 Repair manual, part 2 Changes made in the material from the previous manuals: Model M2004 implemented. Section Document references added to the chapter Reference information. Information about the controller removed from the manual. Additional spare part numbers for the motors.

3HAC 023297-001 Revision: -

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A


General The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below: Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which 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 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 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

In addition, spare part information is supplied for the entire option.

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Product documentation, M2004

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 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. 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

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:
8

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)
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Product documentation, M2004

Operators manuals

How to use the application Examples of how to use the application

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: 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) Operators manual - IRC5 with FlexPendant Operators manual - RobotStudioOnline Trouble shooting Manual for the controller and robot

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Product documentation, M2004

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1 Reference information
1.1. Introduction

1 Reference information
1.1. Introduction
General This chapter includes general information, complementing the more specific information in the Product manual (part 1 of 2), procedures.

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1 Reference information
1.2. Applicable Safety Standards

1.2. Applicable Safety Standards


Standards, general The robot is designed in accordance with the requirements of: Standards, safety fence The following standards are applicable to the safety fence surrounding the robot cell: Standards, robot cell The following standards are applicable when the robot is part of a robot cell: IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs. EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body. EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs. Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body. EN 1088 Safety of machinery - Interlocking device associated with guards principles for design and selection. ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing systems - Basic requirements prEN 999:1995 ISO10218, Jan. 1992, Industrial Robot Safety ANSI/RIA 15.06-1999 ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing systems - Basic requirements DIN 19258 - Interbus-S, International Standard

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1 Reference information
1.3. Unit conversion

1.3. Unit conversion


Converter table Use the table below to convert units used in this manual.

Quantity
Length Weight Pressure Force Moment Volume

Units
1m 1 kg 1 bar 1N 1 Nm 1L 3.28 ft 2.21 lb 100 kPa 0.738 lbf 0.738 lbf-tn 0.264 US gal 14.5 psi 39.37 in

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1 Reference information
1.4. Screw joints

1.4. Screw joints


General This section details how to tighten the various types of screw joints on the robot and the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue. Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury! Gleitmo treated screws Gleitmo 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. After this the screw must be discarded and replaced with a new one. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions. In such cases, proceed as follows: 1. Apply lubricant to the screw thread. 2. Apply lubricant between the plain washer and screw head. 3. Tighten to the torque specified in section Tightening torque below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

Lubricant
Molycote 1000 (molybdenum disulphide grease)

Art. no.
1171 2016-618

Tightening torque Before tightening any screw, note the following: Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value. Use the correct tightening torque for each type of screw joint.
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1 Reference information
1.4. Screw joints

Only use correctly calibrated torque keys. Always tighten the joint by hand, and never use pneumatical tools. Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion. Maximum allowed total deviation from the specified value is 10%!

The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Dimension
M2.5 M3 M4 M5 M6

Tightening torque (Nm) Class 4.8, oil-lubricated


0.25 0.5 1.2 2.5 5.0

The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws.

Dimension

Tightening torque (Nm) Class 8.8, oillubricated


6 10 24 47 82 200

Tightening torque (Nm) Class 10.9, oillubricated


34 67 115 290

Tightening torque (Nm) Class 12.9, oillubricated


40 80 140 340

M5 M6 M8 M10 M12 M16

The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.

Dimension
M8 M10 M12 M16

Tightening torque (Nm) Tightening torque (Nm) Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
28 55 96 235 34 66 115 280

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1 Reference information
1.4. Screw joints

The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.

Dimension
1/8 1/4 3/8 1/2 3/4

Tightening torque Nm - Nominal


12 15 20 40 70

Tightening torque Nm - Min.


8 10 15 30 55

Tightening torque Nm - Max.


15 20 25 50 90

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1 Reference information
1.5. Weight specifications

1.5. Weight specifications


Definition In all repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model. Example 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!

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1 Reference information
1.6. Document references

1.6. Document references


General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentation. Product specification, robot The product specification includes generic technical data. The specification listed below is the English version.

Document name
Product specification

Document ID
3HAC 9041-1

Product manuals, controller The product manuals include information about installation and service activities. The table below specifies the article numbers of the product manuals for all controller models. The part number -001 is the English version.

Document name
Product manual, S4Cplus M2000 Product manual, S4Cplus M2000A Product manual, IRC5 M2004

Document ID
3HAC 021333-001 3HAC 021128-001 3HAC 021313-001

Operators manual The operators manual contains instructions for daily operation of robot systems. The table below specifies the article numbers of the operators manuals for different robot systems.

Document name
Users guide (S4Cplus) Operators manual (IRC5)

Document ID
3HAC 7793-1 3HAC 16590-1

Note
Contains instructions for daily operation of S4Cplus based robot systems.

Calibration manuals Document name


Calibration Pendulum Instruction Instructions for Levelmeter calibration (alternative method) CalibWare 2.0 Users Guide

Document ID
3HAC 16578-1 3HAC 022907-001

Note
Enclosed with the Calibration Pendulum Toolkit. Enclosed with the Levelmeter 2000.

3HAC 16090-1

Calibration tool for Absolute Accuracy calibration.

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1 Reference information
1.6. Document references

Additional documentation Document name


External axes

Document ID
3HAC 9299-1

Note

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1 Reference information
1.7. Standard toolkit

1.7. Standard toolkit


General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents Standard tool, IRB 140: 3HAC020812-001 contains:

Qty
1 1 1 1 1 1 1 1 1 1

Art. no.
-

Tool
Ring-open-end spanner 8-19mm Socket head cap 2,5-17mm Torx socket no:20-60 Torque wrench 10-100Nm Small screwdriver Ratchet head for torque wrench 1/2 Socket head cap no:5, socket 1/2"" bit L 20mm Socket head cap no:6, socket 1/2"" bit L 20mm Socket head cap no:8, socket 1/2"" bit L 20mm Small cutting plier

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1 Reference information
1.8. Performing a leak-down test

1.8. Performing a leak-down test


General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.
Leakdown tester Leak detection spray

Art. no.
3HAC 0207-1 -

Note

Procedure Step
1. 2.

Action
Finish the refitting procedure of the motor or gear in question.

Note/Illustration

Remove the topmost oil plug on the gear in question, Art. no. is specified above! and replace it with the leakdown tester . Adapters may be required, which are included in the leakdown tester kit. Apply compressed air, and raise the pressure with the Recommended value: 0.2 knob until the correct value is shown on the 0.25 bar (20 - 25 kPa) manometer. Disconnect the compressed air supply. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is be detected. significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal. Was any pressure drop evident? Localize the leak as detailed below. Remove the leakdown tester, and refit the oil plug. The test is complete. Spray suspected leak areas with leak detection spray . Bubbles indicate a leak. When the leak has been localized: take the necessary measures to correct the leak. Art. no. is specified above!

3.

4. 5.

6.

7.

8.

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1 Reference information
1.9. Lifting equipment and lifting instructions

1.9. Lifting equipment and lifting instructions


General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.

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1 Reference information
1.10. Mounting instructions for bearings

1.10. Mounting instructions for bearings


General This section details how to mount and grease different types of bearings on the manipulator. Equipment Equipment, etc.
Grease

Art. no.
3HAB 3537-1

Note
Used to grease the bearings, if not specified otherwise.

Assembly of all bearings Follow 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 and other contamination. Cast components must be free from foundry sand. 3. Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Furthermore, the roller elements must not be exposed to any stresses during the assembly work. Assembly of tapered bearings Follow the previous instructions for assembly of all bearings, when mounting a tapered bearing on the manipulator. In addition to those instructions, the procedure below must be carried out to enable the roller elements to adjust to the correct position against the race flange. 1. Tension the bearing gradually until the recommended pre-tension is achieved. Note! The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence. 2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the bearing. Greasing of bearings The bearings must be greased after assembly, according to instructions below: The bearings must not be completely filled with grease. However, if space is available beside 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 split condition.

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1 Reference information
1.11. Mounting instructions for seals

1.11. Mounting instructions for seals


General This sections details how to mount different types of seals to the manipulator. Equipment Equipment, etc.
Grease

Art. no.
3HAB 3537-1

Note
Used to lubricate the seals.

Rotating seals The 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. Action
Check the seal to ensure that: the seal is of the correct type (provided with cutting edge). there is no damage to the sealing edge (feel with a fingernail). Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in early as there is a risk of dirt and foreign particles adhering Equipment on page to the seal.) 24. Fill the space between the dust tongue and sealing lip to 2/ 3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified. Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage.

Step
1.

Note

2.

3.

4.

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1 Reference information
1.11. Mounting instructions for seals

Flange seals and static seals The procedure below details how to fit flange seals and static seals. Step
1.

Action
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 used beacuse leakage could occur. Clean the surfaces properly and in accordance with ABB ROBOTICS PRODUCTS recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

Note

2. 3. 4.

O-rings The procedure below details how to fit o-rings. Step


1. 2. 3.

Action
Ensure that the correct o-ring size is used.

Note

Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may not be used. Check the o-ring grooves. Defective o-rings The grooves must be geometrically correct and free from pores may not be used. and contamination. Lubricate the o-ring with grease. Tighten the screws evenly when assembling.

4. 5.

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1 Reference information
1.11. Mounting instructions for seals

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2 Spare part / part list


2.1. Introduction

2 Spare part / part list


2.1. Introduction
Definitions This chapter specifies all spare parts and replacement articles of the robot.

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2 Spare part / part list


2.2. Spare part / part list

2.2. Spare part / part list


Spare part / part list The table below details all replacement articles on the robot. The items refer to chapter Foldouts.

Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Qty
1 1 26 1 1 1 2 28 1 1 1 4 1 1 1 20 2 2 1 2 1 1 1 1 10 1 2 1 1 1 10 20 ml 1 1

Art. no.
3HAC 10470-1 3HAC 8999-1 9ADA 629-44 3HAC 6599-1 3HAC 9522-1 4944 026-4 2166 2055-6 9ADA 618-46 3HAC 9030-1 3HAC 9415-1 3HAC 6755-1 9ADA 618-50 3HAC 10476-1 3HAC 10477-1 3HAC 7527-1 3HAB 3402-52 3HAC 7950-1 3HAC 9860-1 3HAC 8466-1 3HAC 9063-1 SK 615 503-2 SK 616 013-F 1SFA 616100R1006 3HAC 7870-1 9ADA 290-1 2529 1920-2 2522 2101-8 3HAC 8806-1 3HAC 7370-1 3HAC 2589-1 2166 2055-3 1234 0011-116 3HAC 10470-3 3HAC 10476-4

Name
Base spare Bottom plate Torx pan head roll. screw Gasket bottom plate Serial meas. board ass. Battery pack Cable straps, outdoors Torx pan head screw Cable bracket Clamp Cable holder Torx pan head screw Control cable spare Std/F Control cable spare Std/F Damper axis 1 Hex. socket head cap screw Washer Protecting plate Protective earth cable Hose clip Membrane Bracket Actuator black Gasket base-cover Hexagon nut with flange Plug Protective hood Clamp Cable harness IRB 140 Instruction plate Cable straps, outdoors Flange sealing Base, spare CR Control cable spare CR

Rem.

M5x12

7.2V 4Ah NiCd 7.6x368 M5x20

M5x40 L=3m L=7m M10x35 8.8 Gleitmo 610

D = 10 CBK

M5 R 1/8" D=11.4-13

Battery replacement 4.8x208 Lotctite 574 L=3m

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2 Spare part / part list


2.2. Spare part / part list

Item
35 36 37 38 39 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 100 101 102 103 104 105 106 107 108 109 110 3HAC 023297-001 Revision: -

Qty
1 1 1 1 1 1 2 24 18 2 1 1 1 1 1 1 3 2 11 2 1 25 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1

Art. no.
3HAC 10477-2 3HAC 11331-1 3HAC 11331-2 3HAC 13089-1 3HAC 13090-1 3HAC 10467-1

Name
Control cable spare CR Control cable spare Std/F Control cable spare CR Control cable spare Std/F Control cable spare Std/F Gearbox axes 1-2, spare Std/F

Rem.
L=7m L = 15 m L = 15 m L = 30 m L = 22 m Item 67 incl.

3HAC 10469-1 Motor with pinion spare Std/F 3HAC 021965-001 3HAB 3409-25 9ADA 312-6 2152 2012-426 3HAC 6788-1 3HAC 10478-1 3HAC 10472-1 3HAC 7868-1 3HAC 5894-1 3HAC 6965-1 3HAC 3785-6 3HAB 3732-19 9ADA 618-55 2166 2018-2 3HAC 10481-1 2166 2055-1 3HAC 10467-3 Hex socket head cap screw Plain washer O-ring Bearing hub Console spare Std/F Cover console spare Std/F Gasket console-cover Cable bracket Sealing ring Parallel pin Sealing ring (V-ring) Torx pan head screw Clamp Connector bracket Cable straps, outdoors Lubricating oil Gearbox axes 1-2, spare CR 2.5x101 T=1.5 150x189x8.5 D = 6 m6 L = 16 85x11 M6x12 D = 11 Item 58 incl. M6x20 12.9 Gleitmo 610 6.4x12x1.6 74.5x3

3000 ml 1171 2016-604

3HAC 10469-3 / Motor with pinion, spare CR 3HAC 021966-001 3HAC 10478-3 3HAC 10472-3 3HAC 10645-1 3HAC 10468-1 3HAC 10471-1 3HAC 10474-1 3HAC 7869-1 Console, spare CR Cover console, spare CR Clamp Lower arm (axis 3), spare Cover, without lamp unit Cover, with lamp unit Gasket lower-arm cover D = 4.7 Item 67, 107 and 108 incl. Item 103 incl. Item 103 incl.

3HAC 7866-1 / Rot. ac motor incl. pinion 3HAC 021756-001 3HAC 6793-1 3HAC 6762-1 3HAB 3643-17 3HAA 2166-13 3HAC 7880-1 3HAA 2356-14 Timing belt Belt shield Groove ball bearing VK-Cover Damper axis 2 Washer SRKB 6.4x18x1.6 29 80x100x10 D = 100 B = 10

2 Spare part / part list


2.2. Spare part / part list

Item
111 112 113 114 115 116 150 151 152 153 154 155 156

Qty
4 12 1 1 1 1 1 1 1 3 3 3 1

Art. no.
3HAB 3402-15 9ADA 312-5 3HAC 9258-1 3HAC 10468-4 3HAC 10471-3 3HAC 10474-3 3HAC 10466-1 3HAC 10475-1 3HAC 7191-1 3HAB 3409-37 9ADA 312-7 2529 1920-2 3HAC 10479-1

Name
Hex. socket head cap screw Plain washer Indicator lamp Lower arm, spare CR Cover, without lamp unit Cover, with lamp unit Upper arm compl. with wrist Wrist, spare Std/F O-ring sealing plate Hex. socket head cap screw Plain washer Plug Axis 4 complete, spare Std/F

Rem.
M5x20 8.8 Gleitmo 610 5.3x10x1

Motors incl. Item 155, 181 and 182 incl. M8x25 12.9 Gleitmo 610 8.4x16x1.6 R 1/8" Item 111, 112, 180, 159, 161, 160 and 182 incl. M8x35 12.9 Gleitmo 610 8.4x18x2 99x10.5

157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178

6 6 1 1 1 2 4 1 5 3 1 1 2 1 1 1 1 1 1 1 1 1

3HAB 3409-39 9ADA 334-7 3HAB 3732-13

Hex. socket head cap screw Spring washer, conical Sealing ring (V-ring)

3HAC 7842-1 / Rot. ac motor with pinion 3HAC 021757-001 3HAB 3772-24 O-ring 29x3 3HAC 7841-1 / Rot. ac motor with pinion 3HAC 021758-001 3HAB 3402-18 3HAC 6773-1 9ADA 183-13 3HAA 2356-15 3HAC 7367-1 3HAC 8572-1 3HAC 6779-1 3HAC 6777-1 3HAC 6778-1 3HAC 7939-1 3HAC 7391-1 3HAC 10473-1 3HAC 7867-1 3HAC 7881-1 3HAC 6761-1 3HAC 7561-3 Hex. socket head cap screw Motor Console axes 5-6 Hex. socket head cap screw Washer SRKB Cable holder Clamp Timing belt Timing Belt Pulley Z2/5 Timing Belt Pulley Z2/6 Clamping unit Belt shield Cover armhousing spare Gasket upper arm cover Damper axis 3 Cable guide Dustcap for receptacles 12p Item 175 incl. M5x12 5.3x15x1.2 M5x35 8.8 Gleitmo 610

30

3HAC 023297-001 Revision: -

2 Spare part / part list


2.2. Spare part / part list

Item
179 180 181 182

Qty
2 1 1 550 ml

Art. no.
2125 2052-178 3HAC 6598-1 3HAB 8964-1 3HAC 0860-1

Name
Distance bolt Hose nipple Damper axis 5 Lubricating oil

Rem.
M5X55 G 1/4" Optimol Optigear BM 100

183 184 185 186 187

1 1 1 1 1

3HAC 10466-3 3HAC 10475-4 3HAC 10479-3 3HAC 10439-3 3HAC 11922-1

Upper arm, spare CR Wrist, spare CR Axis 4 complete, spare CR Cover armhousing, spare CR Slip strip

3HAC 023297-001 Revision: -

31

2 Spare part / part list


2.2. Spare part / part list

32

3HAC 023297-001 Revision: -

3 Foldouts
3.1. Introduction

3 Foldouts
3.1. Introduction
Overview The foldouts in this chapter refer to the part list.

3HAC 023297-001 Revision: -

33

33

15

32

18

27

13

34

35

36

37

38

39

31

20

19

R1/4

21

22

23

28

Inside of cover

16

35 Nm

17

24

12

11

26

29

31

10

30

25

Inside of base

Base complete

Foldout 1

51

62

56

70

57

71

58

52

53

32

65

25

25

72

31

62

52

15,5 Nm

A (1 : 2)

31 52 53 52 53 54 54 53

55

52

51

69

63 64

68

50 67

ax.1 1,2 litre ax.2 1,0 litre

61

61

60

63

31

59

31

63

63

Foldout 2

0,4 litre

67 100

114

104

105

64

103

101

115

113

102

116 Do not loosen these screws

Do not loosen these screws

110

109

18

66

17

16

35 Nm

108

107

112

111 4,1 Nm

106

Lower 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) 182 151 184 152 180 0,2 litre oil 182 156 185 159 176

162

162

164

163

4,1 Nm

112

169

170

171

172

3 Nm

173

153

28 Nm

154

181

108

157

35 Nm

158

161

112

111

6 Nm

160

Upper arm (shown without cables)

112

4,1 Nm 163

112

4,1 Nm 111

166

165

6 Nm

169

112

163

4,1 Nm

175

174

186

12

Foldout 4

177

179

168

167

150 183

20

165

3 187

178

Upper arm with cables (shown without cover)

155

Upper arm complete

Foldout 5

4 Circuit diagram
4.1. Introduction

4 Circuit diagram
4.1. Introduction
Overview This chapter includes the circuit diagram for the robot.

3HAC 023297-001 Revision: -

35

Circuit Diagram
CONTENTS
Page

Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............................................................101-108

IRB 140

Manipulator Circuit Diagram

3HAC 6816-3

LIST OF CONTENTS IRB 140


No. of Sheets 8

Sheet no.

101

Manipulator Circuit Diagram

3HAC 6816-3

CONNECTION POINT LOCATIONS IRB 140


No. of Sheets 8

Sheet no.

102

Manipulator Circuit Diagram

3HAC 6816-3

SERIAL MEASUREMENT BOARD IRB 140


No. of Sheets 8

Sheet no.

103

Manipulator Circuit Diagram

3HAC 6816-3

MOTOR AXIS 1 - 3 IRB 140


No. of Sheets 8

Sheet no.

104

Manipulator Circuit Diagram

3HAC 6816-3

FEEDBACK AXIS 1 - 3 IRB 140


No. of Sheets 8

Sheet no.

105

Manipulator Circuit Diagram

3HAC 6816-3

MOTOR AXIS 4 - 6 IRB 140


No. of Sheets 8

Sheet no.

106

Manipulator Circuit Diagram

3HAC 6816-3

FEED-BACK AXIS 4 - 6 IRB 140


No. of Sheets 8

Sheet no.

107

Manipulator Circuit Diagram

3HAC 6816-3

CUSTOMER CONNECTIONS IRB 140


No. of Sheets 8

Sheet no.

108