ABB IRB 140 Product Manual
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ABB IRB 140 Product Manual

Irb 140 series type c
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Summary of Contents for ABB IRB 140

  • Page 1 ABB Robotics Product manual IRB 140...
  • Page 2 Trace back information: Workspace R13-1 version a7 Checked in 2013-04-02 Skribenta version 1184...
  • Page 3 Product manual IRB 140 type C IRB 140T type C IRB 140-6/0.8 type C IRB 140T-6/0.8 type C M2004 Document ID: 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 4 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.

  • Page 5: Table Of Contents

    Bolt pattern .................... 2.3.9 Installation of signal lamp (option) .............. Restricting the working range ................2.4.1 Restricting the working range ..............Electrical connections ..................2.5.1 Customer connections on manipulator ............3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 6 Service work on gearbox, axis 4 ..............4.8.3 Amount of oil ..................Calibration information Introduction ..................... Calibration methods ................... Calibration scale and correct axis position ............. Calibration movement directions for all axes ............3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 7 Special tools ....................Performing a leak-down test ................Lifting accessories and lifting instructions .............. Spare part lists Introduction ...................... Spare parts - robot IRB 140 ................. 10 Circuit diagram 10.1 About circuit diagrams ..................Index 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    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...
  • Page 10 Circuit diagram References to the circuit diagrams for the robot. References Reference Document ID Circuit diagram - IRB 140 type C 3HAC6816-3 Product manual - IRC5 3HAC021313-001 Product specification - IRB 140 3HAC041346-001 Operating manual - IRC5 with FlexPendant...
  • Page 11 • Corrected article number for battery pack, see Spare parts - robot IRB 140 on page 220. • A new SMB unit and battery is introduced, with longer battery lifetime. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 12: Product Documentation, M2004

    All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
  • Page 13 Operating manual - Introduction to RAPID • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Trouble shooting IRC5, for the controller and manipulator. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 14: How To Read The Product Manual

    Likewise certain work methods or general information, that is valid for several robot models, can be illustrated with pictures that show a different robot model that the one described in the current manual. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 15: Safety

    Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section Safety related instructions on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 16: General Safety Information

    • stopping functions Safety stops describes different types of • description of emergency stop stops. • description of safety stop • description of safeguarding 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 17: Safety In The Manipulator System

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 18: Safety Risks

    ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the manipulator system.
  • Page 19 Removed cables to the measurement sys- WARNING If the internal cables for the measurement system have been disconnected during repair or maintenance, then the revolution counters must be updated. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 20 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 balan- cing device is potentially lethal! 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 21: Caution - Hot Parts May Cause Burns

    Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 22: Safety Risks Related To Tools/Work Pieces

    Unauthorized modifications of the originally delivered manipulator are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.

  • Page 23: Safety Risks Related To Pneumatic/Hydraulic Systems

    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. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 24: Safety Risks During Operational Disturbances

    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. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 25: Risks Associated With Live Electric Parts

    The power supply unit for additional tools, or special power supply units for the machining process. • The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 26 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. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 27: Safety Actions

    (see the section Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 28: Fire Extinguishing

    1 Safety 1.2.4.2 Fire extinguishing 1.2.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 29: Emergency Release Of The Manipulator's Arm

    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! 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 30: Brake Testing

    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. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 31: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" Note Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 32: Safe Use Of The Flexpendant

    The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 33: Work Inside The Manipulator's Working Range

    NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is always a risk that the manipulator will move unexpectedly when manipulator axes are moved using the enabling device or during other work inside the manipulator’s working range. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 34: Safety Stops

    Emergency stop should not be used for normal program stops as this causes extra, unnecessary wear on the manipulator. For how to perform normal program stops, see section Stopping programs in Operating manual - IRC5 with FlexPendant. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 35 Dual Cabinet Controller). There can also be other types of emergency stops on your manipulator. Consult your plant or cell documentation to see how your manipulator system is configured. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 36: Safety Related Instructions

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 37 1.3.1 Safety signals in the manual Continued Symbol Designation Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 38: Safety Symbols On Manipulator Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 39 Pressing this button will release the brakes. This means that the manipulator arm can fall down. xx0900000808 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened. xx0900000810 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 40 Risk of crush injuries. xx0900000817 Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 41 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 42 Symbol Description Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 43: Danger - Moving Manipulators Are Potentially Lethal

    The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the manipulator be- fore pressing the start button. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 44: Danger - First Test Run May Cause Injury Or Damage

    Pay special attention to the function of the part previously serviced Collision risks CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 45: Danger - Make Sure That The Main Power Has Been Switched Off

    Switch off the main switch for the controller. xx0600003255 Elimination, Single Cabinet Controller Action Note/illustration Switch off the main switch on the controller cabinet. xx0600002782 A: Main switch Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 46 Note/illustration Switch off the main switch on the Drive Module. xx0600002783 K: Main switch, Drive Module Switch off the main switch on the Control A: Main switch, Control Module Module. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 47: Warning - The Unit Is Sensitive To Esd

    The location of the wrist strap button is shown in the following illustration. IRC5 The wrist strap button is located in the top right corner. xx0500002171 Wrist strap button Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 48 Panel Mounted Controller xx0600003249 Panel Mounted Control Module Panel Mounted Drive Module Wrist strap button NOTE! When not used, the wrist strap must always be attached to the wrist strap button. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 49: Warning - Safety Risks During Handling Of Batteries

    Risk of fire or explosion. page Use safety glasses when handling the batteries. In the event of leakage, wear gloves and chemical apron. In the event of fire, use self-contained breathing apparatus. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 50: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    Do not present in the gearbox, causing overfill the gearbox when filling. lubricant to spray from the xx0100000002 opening. Possible pressure build-up in gearbox Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 51 Specified amount de- been drained from the gearbox. pends on drained volume 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 52 This page is intentionally left blank...

  • Page 53: Installation And Commissioning

    Safety on page 15 before performing any installation work. Note If the IRB 140 type C is connected to power, always make sure that the robot is connected to protective earth before starting any installation work! For more information see: •...

  • Page 54: Unpacking

    It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation Installation craftsmen working with an ABB robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 55 Wall mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ± 1750 N ± 2800 N Force z ± 850 N ± 1600 N Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 56 Maximum tilt 5° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Minimum resonance 22 Hz frequency Storage conditions, robot...
  • Page 57 The table shows the protection class of the robot: Equipment Protection class Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 Manipulator, protection type Clean Room IP 67 Manipulator, protection type Wash IP 67 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 58: Working Range, Irb 140

    Axis 2 Axis 3 0° 0° 1092 0° -90° 0° +50° +110° -90° -119 +110° +4° -480 -90° -150° -90° +50° +110° -230° -670 -90° -90° Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 59 2 Installation and commissioning 2.2.2 Working range, IRB 140 Continued Working range axis 1 The illustrations below shows the unrestricted working range of axis 1. xx0200000061 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 60: Risk Of Tipping/Stability

    The shipping position is the most stable position. Do not change the robot position before securing it to the foundation! WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 61: On-Site Installation

    2 Put one sling line around each leg on the lower arm (positions 1 and 2). 3 Use another sling line to secure the lifting of the control cable (position 3). 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 62: Lifting And Turning The Manipulator

    2.3.2 Lifting and turning the manipulator 2.3.2 Lifting and turning the manipulator Recommendation Use lifting slings to lift the manipulator. See Lifting the manipulator with lifting slings on page For more information contact ABB. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 63: Manually Releasing The Brakes

    Make sure no personnel is near or beneath the robot arm! Release the holding brakes by pushing the brake re- lease button. The brake will function again as soon as the button is released. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 64 Supply: • A: B16 24V DC • B: B14 0V Push the brake release button to release the holding brakes, according to the previous procedure. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 65 • A: 13 0V • B: 15 24V DC Locate the R1.MP4-6 connector and discon- nect. Connect an external power supply to re- lease the holding brake on all axis. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 66: Orienting And Securing The Manipulator

    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. Equipment Art. no. Guide sleeves 3HAC 9519-1 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 67: Fitting Equipment On Manipulator

    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 - IRB 140. Illustration, holes on upper arm The illustration below shows the stock holes available for fitting extra equipment on the upper arm.
  • Page 68 Fastener quality When fitting tools on the turning disk, use only screws with quality 12.9. When fitting equipment on other places, standard screws with quality 8.8 can be used. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 69: Loads

    The loads must also be defined in the software as detailed in Operating manual - IRC5 with FlexPendant. Brake performance Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 70: Setting The System Parameters For A Suspended Robot

    B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor (A) 0° 0.000000 (Default) Wall (C) 90° 1.570796 Suspended (D) 180° 3.141593 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 71 The parameter can be edited either with the FlexPendant or in RobotStudio. See Operating manual - IRC5 with FlexPendant or Operating manual - RobotStudio. Article numbers for the manuals are specified in References on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 72: Bolt Pattern

    The illustration below shows the hole configuration used when securing the manipulator: Ø 25H8 (2x) Ø 25H8 (2x) Ø 0,25 Ø 0,25 Ø13 Ø13 B - B B - B xx0200000085 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 73 2 Installation and commissioning 2.3.8 Bolt pattern Continued Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes: xx0200000086 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 74: Installation Of Signal Lamp (Option)

    2.3.9 Installation of signal lamp (option) 2.3.9 Installation of signal lamp (option) Note Do not use the signal lamp in a Clean Room environment. Signal lamp See the assembly instruction delivered with the signal lamp. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 75: Restricting The Working Range

    Technical reference manual - System parameters. Limiting devices Examples of limiting devices are listed below. 1 Light curtains. 2 Tread mats. 3 Other similar devices. 4 Software. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 76: Electrical Connections

    For air on base / upper arm R1/4" Max. 8 bar/hose inner diameter: 6.5 mm Signal connector on upper arm FCI UT 071412SH44N connector Number of signals: 12 signals, 49V, 500mA Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 77 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 •...
  • Page 78 This page is intentionally left blank...

  • Page 79: Maintenance

    Note If the IRB 140 type C is connected to power, always make sure that the IRB 140 type C is connected to protective earth before starting any maintenance work! For more information see: •...

  • Page 80: Maintenance Schedules

    Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 140 type C: • Calendar time: specified in months regardless of whether the system is running or not.

  • Page 81: Maintenance Schedule

    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. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 82 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 83: Inspection Activities

    3.3.1 Inspection, damper axes 2, 3 and 5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0200000426 Damper, axis 2 xx0200000427 Damper, axis 3 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 84 • Replacing the damper, axis 2 on page 139 • Replacing the damper, axis 3 on page 128 • Replacement of damper, axis 5 on page 130. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 85 1 and 2. Look for abrasions, cuts or crush damages. Replace the cabling if wear or damage is detected. This is detailed in section Replace- ment of cable harness on page 102. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 86: Inspection, Timing Belts

    A more detailed view of the components and its position may be found in chapter Spare part lists on page 219. xx0200000448 Timing belt, axis 3 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 87 Other tools and procedures These procedures include references to may be required. See refer- the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 88 Belt tension adjustment is detailed in sections Replacement of motor and timing belt, axis 3 on page 166 Replacement of motor and timing belt, axes 5 or 6 on page 176. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 89: Cleaning Activities

    Clean room Yes. With light cleaning deter- gent, spirit or isopropyl alco- hol. Perform according to section Cleaning with water and steam on page Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 90 Never point the water jet at connectors, joints, sealings, or gaskets! • Never use compressed air to clean the robot! • Never use solvents that are not approved by ABB to clean the robot! • Never spray from a distance closer than 0.4 meters! •...

  • Page 91: Changing/ Replacing Activities

    10. In order to always get the latest information of updates about lubrication in gearboxes, always check on ABB Library for the latest revision of the manual. A new revision will be published on ABB Library immediatly after any updates.

  • Page 92: Changing The Oil In Axes 5 And 6 Gearboxes

    Other tools and procedures may be These procedures include references to the tools required. See references to these pro- required. cedures in the step-by-step instruc- tions below. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 93 Location of oil Both oil plugs must be removed in order to drain plugs on page the wrist unit properly. Refit the oil plug, vent hole. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 94 Fill oil in the wrist unit through the oil plug. xx0500001435 • A: Oil plug, draining and filling The position for an inverted robot is the opposite. Refit the oil plug. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 95: Repair

    Safety on page 15 before commencing any service work. Note If the IRB 140 type C is connected to power, always make sure that the IRB 140 type C is connected to earth before starting any repair work. For more information see: •...

  • Page 96: General Procedures

    Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 97 Grease the different types of bearings as following description: • 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. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 98: Mounting Instructions For Seals

    Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 99 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

  • Page 100: Replacing Parts On Clean Room Robots

    Before the parts are refitted, clean the joint Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 101 Always read the instruction in the product data sheet in the paint repair kit for Clean Room. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 102: Complete Robot

    See references to quired. these procedures in the step-by-step in- structions below. Circuit Diagram 3HAC 6816-3 See chapter Circuit dia- gram on page 229. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 103 148. Disconnect connectors in the ma- nipulator base. xx0300000090 Connectors: • A: R1.MP1-3 • B: R1.CS • C: Air hose • D: R1.MP4-6 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 104 Replacement of lower arm cover and gasket on page 135. Gently knock out the VK cover. Detailed in section Removing the VK cover on page 113. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 105 Parts: • J: Shield Remove the shield by unscrewing See figure above! its attachment screws. Cut any cable ties securing the cabling inside the lower arm. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 106 • R3.MP2 • R3.FB1 • R3.FB2 Gently pull the cabling from the base up through the console. Gently pull the cabling out of the lower arm. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 107 A: Signal • B: Signal • C: Customer signal • D: Power cable, axes 4-6 • E: Pressurized air supply • F: Power cable, axes 1-3 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 108 • D: Customer cables, signal • E: Signal cables, axes 4, 5 and 6 • F: Signal cable, axis 3 • G: Connectors R3.MP3 and R3.FB3 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 109 Replacing parts on Clean Room robots on page 100 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 110: Replacement Of Complete Upper Arm

    Attachment screws, cover armhousing, (4 pcs) CS-connector Pressurized air connector VK cover Cable guide Attachment screws, cable guide Attachment screws, upper arm (6 pcs) Sealing ring Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 111 Always cut the paint with a knife and grind the paint edge when disassembling parts of a Clean Room robot! See Replacing parts on Clean Room robots on page 100 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 112 Remove the cable guide by unscrewing its two at- Shown in the figure Location of tachment screws. upper arm on page 110! Gently pull all cables and hoses out. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 113 VK cover evenly to avoid dam- aging it. Shown in the figure in section Location of upper arm on page 110! Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 114 Shown in the figure Location of upper attachment screws. arm on page 110! Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 115 • special attention is paid to the function of the part that has been serviced. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 116: Replacement Of Complete Lower Arm

    Lower arm Required equipment Equipment Spare part no. Art. no. Note Lower arm, spare 3HAC034935-001 Standard and Foundry versions Includes all required bearings, oil and VK cov- Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 117 Clean Room robot! See Replacing parts on Clean Room robots on page 100 Remove the console. Detailed in section Replacement of console on page 144. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 118 See Repla- cing parts on Clean Room robots on page 100 Fit the lifting device and lift the lower arm into position. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 119 Recalibrate the robot. Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General Calibration information is included in section, Calibration information on page 195 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 120: Replacement Of Base

    Note Base, spare 3HAC10470-1 Standard and Foundry versions. Includes parallel pin 3HAC 3785-2. Base, spare 3HAC10470-3 Clean room versions. Includes parallel pin 3HAC 3785-2. Lifting slings Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 121 Detailed in section Replacement of complete upper arm on page 110. Remove the complete lower arm. Detailed in section Replacement of complete lower arm on page 116. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 122 Detailed in section Replacement of complete lower arm on page 116. Refit the complete upper arm. Detailed in section Replacement of complete upper arm on page 110. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 123 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 124: Upper Arm

    Note! The wrist, stand- ard/Foundry is not interchange- able with art. no. 3HAC 10475-1! Wrist unit (CR) 3HAC 026569-003 Clean room versions O-ring sealing plate not in- cluded! Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 125 Clean Room robots: clean the joints that have been opened. See Replacing parts on Clean Room robots on page 100 Move the robot to a position where the upper arm is vertical. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 126 Performing a leak-down test on page 217. Refill the wrist unit with oil. Detailed in section Changing the oil in axes 5 and 6 gearboxes on page Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 127 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause in- jury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 128: Replacing The Damper, Axis 3

    DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 129 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 130: Replacement Of Damper, Axis 5

    Unhook the end of the damper, and push it into the recess. Manually move the wrist (robot axis 5) away from the damper to pull it out. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 131 Make sure all safety requirements are met when perform- ing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 132: Replacement Of Cover, Arm Housing

    Other tools and proced- These procedures in- ures may be required. clude references to the See references to these tools required. procedures in the step- by-step instructions be- low. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 133 Manually, run the robot to a position that enables Shown in the figure Location of access to the rear of the upper arm. cover, armhousing on page 132. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 134 See Replacing parts on Clean Room robots on page 100 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 135: Lower Arm

    A more detailed view of the components and its position may be found in section Spare part lists on page 219. xx0200000433 Lower arm Gasket lower-arm cover Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 136 Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, for example secure the lower arm with fixtures if removing motor, axis 2. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 137 Refit the lower arm cover with its attachment screws. Shown in the figure Location of lower arm cover and gasket on page 135. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 138 See Replacing parts on Clean Room robots on page 100 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 139: Replacing The Damper, Axis 2

    Clean Room robots on page 100 Run the robot to a position where it is best to enable access to the attachment screw of the damper. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 140 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 141: Frame And Base

    3HAC 10472-1 Standard and Foundry version Includes gasket 3HAC 7868-1 Cover, console, spare 3HAC 10472-3 Clean Room versions Includes gasket 3HAC 7868-1 Gasket, cover console 3HAC 7868-1 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 142 141. Remove the cover, console by unscrewing its attach- NOTE! Do not damage the gas- ment screws. ket inside the cover! Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 143 See Replacing parts on Clean Room robots on page 100 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 144: Replacement Of Console

    Other tools and procedures These procedures in- may be required. See refer- clude references to the ences to these procedures tools required. in the step-by-step instruc- tions below. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 145 Remove the motor of axis 3. Detailed in section Replacement of motor and timing belt, axis 3 on page 166. Attach the lifting device to the lower arm. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 146 2. Action Note/Illustration Clean Room robots: clean the joints that have been opened. See Repla- cing parts on Clean Room robots on page 100 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 147 Recalibrate the robot! Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 195. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 148: Replacing The Serial Measurement Unit And The Battery Pack

    (different layouts are shown). DSQC 633A xx1200000831 Battery pack with 2-pole battery contact Serial measurement board (SMB), DSQC 633A SMB attachment screws (2 pcs) Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 149 It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact! Equipment, etc. Note Serial measurement unit Spare parts - robot IRB 140 on page 220 Battery pack Spare parts - robot IRB 140 on page 220 Cable tie Indoors...
  • Page 150 100 Set the robot system to MOTORS OFF state. This will simplify calibration of the robot after replacement since no coarse calibration will be required. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 151 Battery includes protection circuits. Replace it only with the specified spare part in the refitting instruction or with an ABB approved eqvivalent. Refitting The procedure below details how to refit the serial measurement unit and battery pack.
  • Page 152 Secure the rear cable cover to the base of the robot Shown in the figure Location of with its attachment screws. serial measurement unit and bat- tery pack on page 148! Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 153 Recalibrate the robot! Calibration is detailed in a separ- ate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 195. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 154: Replacement Of Control Cable

    Control cable, spare 3HAC 11331-1 15 m Standard and Foundry versions Cover gasket included Control cable, spare 3HAC 13090-1 22 m Standard and Foundry versions Cover gasket included Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 155 Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, for example secure the lower arm with fixtures if removing motor, axis 2. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 156 Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, for example secure the lower arm with fixtures if removing motor, axis 2. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 157 See Repla- cing parts on Clean Room robots on page 100 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 158: Motors

    Used to lubricate the o-ring Standard toolkit 3HAC020812-001 Content is defined in section Stand- ard tools on page 215. 3HAC 9037-1 For adjusting the gear play, motor/pin- Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 159 Shown in the figure Location of motor by unscrewing its four attachment screws. motor axis 1 on page 158. Detailed in section Replacement of cover, console on page 141. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 160 In order to release the brake, connect the 24 VDC Connect to connector R2.MP1 power supply: • +: pin 7 • -: pin 8 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 161 Recalibrate the robot! Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration in- formation on page 195. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 162: Replacement Of Motor, Axis 2

    Standard tools on page 215. Rotation tool, motor 3HAC 9037-1 For adjusting the gear play, motor/pinion Power supply 24 VDC, 1.5 A. For releasing the brakes. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 163 In order to release the brakes, connect the 24 VDC Connect to connector R3.MP2 power supply to the motor. • +: pin 7 • -: pin 8 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 164 Tap with a plastic mallet. Refit the motor cover to the top of the motor. Be careful not to damage the cables! Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 165 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 166: Replacement Of Motor And Timing Belt, Axis 3

    Lower arm cover Attachment screws, lower arm cover (13 pcs) Belt shield Motor 3 Attachment screws, belt shield (3 pcs) Attachment screws, motor 3 (4 pcs) Belt Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 167 166. Remove the lower arm cover by un- Shown in the figure in section Location of motor screwing its attachment screws. axis 3 on page 166. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 168 G: Connectors R3.MP3 and R3.FB3 Disconnect motor connectors. Connectors: • R3.MP3 • R3.FB3 • R3.H1 (if Safety lamp is fitted) • R3.H2 (if Safety lamp is fitted) Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 169 Replacing parts on Clean Room robots on page 100 Make sure the mating surfaces on the motor and the lower arm are clean and free from burrs. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 170 • D: Customer cables, signal • E: Signal cables, axes 4, 5 and 6 • F: Signal cable, axis 3 • G: Connectors R3.MP3 and R3.FB3 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 171 Recalibrate the robot! Calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 195. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 172: Replacement Of Motor, Axis 4

    Content is defined in section Standard tools on page 215. Power supply 24 VDC, max. 1,5 A. For releasing the brakes. Rotation tool, motor 3HAC9037-1 For adjusting the gear play. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 173 Remove the motor by gently lifting it out. Make sure the motor pinion is not damaged! Remove the o-ring from the arm housing. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 174 5 or 6 on page 176. Perform a leak-down test. Detailed in section Performing a leak- down test on page 217. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 175 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 176: Replacement Of Motor And Timing Belt, Axes 5 Or 6

    Cover, armhousing Attachment screws, cover armhousing (4 pcs) VK cover Pressurized air hose (on front of upper arm) CS connector Cable guide Attachment screws, cable guide Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 177 Circuit Diagram 3HAC6816-3 See chapter Circuit dia- gram on page 229. Sonic Tension Meter Model 505C Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 178 5 or 6 on the upper arm assembly. page 176! Art. no. specified in section Required equipment on page 177 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 179 2. Note Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 180 177 Reconnect any connector to the CS-connect- Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 176! Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 181 Recalibrate the robot. Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is in- cluded in section Calibration informa- tion on page 195. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 182: Adjustments And Measurements

    2. Measurement The procedure below details how to measure the gear play for axis 5. Action Note Manually, turn axis 4 90°. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 183 Value 2. Calculate the gear play value. Gear play value = value 1 - value 2 Determine whether or not the OK < 0.18 mm (4.1 arc minutes) value is OK. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 184: Measuring The Gear Play, Axis 6

    2. Measurement The procedure below details how to measure the gear play for axis 6. Action Note Manually, turn axis 4 90°. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 185 Value 2. Calculate the gear play value. Gear play value = value 1 - value 2 Determine whether or not the OK < 0.30 mm (10.3 arc minutes) value is OK. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 186: Gearboxes

    2 ml Locking liquid Loctite 574 Sealing ring 3HAC6965-1 Replace only when damaged! Lifting slings Standard toolkit Content is defined in section Standard tools on page 215. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 187 Illustration, base xx0200000423 Base Bottom plate Attachment screws, bottom plate (26 pcs) Attachment screws and washers, gearbox/base (10 pcs each) Damper, axis 1 Washer Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 188 Fit the lifting slings to the base/gearbox unit and place it with the lower arm side downwards, on top of a suitable workbench. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 189 See Replacing parts on Clean Room robots on page 100 Place the gearbox unit with the lower arm side downwards on a suitable workbench. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 190 Clean Room robots on page 100 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 191 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 192: Service Work On Gearbox, Axis 4

    This implies that it must under no circumstances be opened or serviced. If it requires replacement, the complete upper arm is to be replaced. This procedure is detailed in section Replacement of complete upper arm on page 110. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 193: Amount Of Oil

    200 ml Axis 5-6 Optimol BM 100 3HAC0860-1 300 ml Axis 5-6 Optimol BM 100 3HAC0860-1 300 ml (new wrist) At oil change, refill the same volume as is drained. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 194 This page is intentionally left blank...

  • Page 195: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in the section Calibration methods on page 196 , and further detailed in separate calibration manuals.

  • Page 196: Calibration Methods

    To regain 100% absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy! xx0400001197 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 197 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

  • Page 198: Calibration Scale And Correct Axis Position

    This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales, IRB 140 The illustration below shows the calibration scale positions on IRB 140. xx0200000157 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 199: Calibration Movement Directions For All Axes

    Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 200: Updating Revolution Counters

    Calibration scale and correct axis po- marks within the tolerance zones. sition on page 198. IRB 140, 1400, 2400, 4400, 6600ID/6650ID, 6640ID: Axes 5 and 6 must be positioned together! When all axes are positioned, store the re- Step 2 - Storing the revolution counter volution counter settings.
  • Page 201 If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi- tioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See Checking the calibration position on page 202. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 202: Checking The Calibration Position

    Check that the calibration marks for the Calibration scale and correct axis pos- axes align correctly. If they do not, update ition on page 198, and Updating revolution the revolution counters! counters on page 200. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 203: Decommissioning

    Also note that: • Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 204 This page is intentionally left blank...

  • Page 205: Robot Description

    7.1 Type C of IRB 140 Type C new upper arm and wrist Type C of IRB 140 has a new upper arm, complete and a new wrist unit. As a result of this, the following parts differ from earlier versions: •...
  • Page 206 This page is intentionally left blank...

  • Page 207: Reference Information

    8 Reference information 8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 208: Applicable Safety Standards

    Safety of machinery - General requirements for the design and construction of fixed and movable guards Other standards Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 209 8.2 Applicable safety standards Continued Standard Description ANSI/UL 1740 Safety standard for robots and robotic equipment (option 429-1) CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require- ments (option 429-1) 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 210: Unit Conversion

    3.28 ft. 39.37 in Weight 1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 211: Screw Joints

    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.
  • Page 212 Molycote 1000, Gleitmo 603 or equivalent with allen head screws. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 213 The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 214: Weight Specifications

    All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

  • Page 215: Standard Tools

    Socket head cap no: 5, socket 1/2" bit L 20 mm Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier T-handle with ball head 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 216: Special Tools

    The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 217: Performing A Leak-Down Test

    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. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 218: Lifting Accessories And Lifting Instructions

    The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. This implies that the instructions delivered with the lifting accessories should be stored for later reference. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 219: Spare Part Lists

    9 Spare part lists 9.1 Introduction 9 Spare part lists 9.1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 220: Spare Parts - Robot Irb 140

    Robot IRB 140, spare parts list The items specified below are shown in the figures Robot IRB 140, exploded view 1 of 5 on page 224 Robot IRB 140, exploded view 5 of 5 on page 228. Item Article number...
  • Page 221 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Item Article number Part Note 3HAC7527-1 Damper axis 1 3HAB3402-52 Hex. socket head cap screw M10x35 8.8 Gleitmo 610 3HAC7950-1 Washer 3HAC9860-1 Protecting plate 3HAC8466-1 Protective earth cable...
  • Page 222 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Item Article number Part Note 3HAC3785-6 Parallel pin D = 6 m6 L = 16 3HAB3732-19 Sealing ring (V-ring) 85x11 9ADA618-55 Torx pan head screw M6x12 21662018-2 Clamp...
  • Page 223 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Item Article number Part Note 3HAB3409-37 Hex. socket head cap screw M8x25 12.9 Gleitmo 610 9ADA312-7 Plain washer 8.4x16x1.6 25291920-2 Plug R 1/8" 3HAB3409-39 Hex. socket head cap screw M8x35 12.9 Gleitmo 610...
  • Page 224 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 1 of 5 xx0600003264 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 225 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 2 of 5 xx0600003265 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 226 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 3 of 5 xx0600003266 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 227 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 4 of 5 xx0600003267 Continues on next page 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 228 9 Spare part lists 9.2 Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 5 of 5 xx0600003268 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 229: Circuit Diagram

    Circuit diagram - Euromap 3HAC024120-004 Robots Product Article numbers for circuit diagrams Circuit diagram - IRB 120 3HAC031408-003 Circuit diagram - IRB 140 type C 3HAC6816-3 Circuit diagram - IRB 260 3HAC025611-001 Circuit diagram - IRB 360 3HAC028647-009 Circuit diagram - IRB 460...
  • Page 230 10.1 About circuit diagrams Continued Product Article numbers for circuit diagrams Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.

  • Page 231: Index

    R1.MP, 64 disposal, 203 inspection, 83 cracks, damper, 84 inverted mounting, 70 damage, damper, 84 labels damper, axis 2, 83 manipulator, 38 attachment screw, 140 Levelmeter calibration, 197 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 232 EN ISO, 208 working range, 75 protection, 208 revolution counters safety, 208 storing on FlexPendant, 200 steel updating, 200 disposal, 203 risk of tipping, 60 suspended mounting, 70 robot symbols 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 233 Levelmeter, 216 wrist unit Calibration Pendulum equipment, 216 oil change, 92 for service, 216 replacing, 124 rotational tool, article number, 172 screws, tightening torque, 126 spare part number, 124 3HAC027400-001 Revision: K © Copyright 2004-2013 ABB. All rights reserved.
  • Page 236 Telephone +46 (0) 21 344 400 ABB AS, Robotics Discrete Automation and Motion Box 265 N-4349 BRYNE, Norway Telephone: +47 51489000 ABB Engineering (Shanghai) Ltd. 5 Lane 369, ChuangYe Road KangQiao Town, PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc.

This manual is also suitable for:

Irb 140-6/0.8Irb 140tIrb 140t-6/0.8

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