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ABB IRB 140, Product Manual

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ABB IRB 140 Product Manual Download Page 213

4.8.2 Service work on gearbox, axis 4

General

The gearbox, axis 4, is intended to run without requiring any repairs or maintenance
work. 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 128

.

Product manual - IRB 140

213

3HAC027400-001 Revision: V

© Copyright 2004-2018 ABB. All rights reserved.

4 Repair

4.8.2 Service work on gearbox, axis 4

Summary of Contents for IRB 140

Page 1: ...ROBOTICS Product manual IRB 140 ...

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ...ual IRB 140 type C IRB 140T type C IRB 140 6 0 8 type C IRB 140T 6 0 8 type C IRC5 Document ID 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ...icants oil or grease 38 1 4 Safety signals and symbols 38 1 4 1 Safety signals in the manual 40 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Unpacking 48 2 2 1 Pre installation procedure 52 2 2 2 Working range IRB 140 54 2 2 3 Risk of tipping stability 55 2 3 On site installation 55 2 3 1 Lifting the manipulator with lifting slings 56 2 3 2 ...

Page 6: ...acing the wrist unit IRB 1600 146 4 4 2 Replacing the damper axis 3 148 4 4 3 Replacement of damper axis 5 150 4 4 4 Replacement of cover arm housing 153 4 5 Lower arm 153 4 5 1 Replacement of lower arm cover and gasket 157 4 5 2 Replacing the damper axis 2 159 4 6 Frame and base 159 4 6 1 Replacement of cover console 162 4 6 2 Replacement of console 167 4 6 3 Replacing the serial measurement unit...

Page 7: ...8 2 Applicable standards 234 8 3 Unit conversion 235 8 4 Screw joints 238 8 5 Weight specifications 239 8 6 Standard tools 240 8 7 Special tools 241 8 8 Performing a leak down test 242 8 9 Lifting accessories and lifting instructions 243 9 Spare part lists 243 9 1 Spare part lists and illustrations 245 10 Circuit diagram 245 10 1 Circuit diagrams 247 Index Product manual IRB 140 7 3HAC027400 001 R...

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Page 9: ...40 type C Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information about how t...

Page 10: ...46 001 Product specification IRB 140 3HAC049099 001 Product manual spare parts IRB 140 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC16578 1 Operating manual Calibration Pendulum 3HAC050944 001 Operating manual Service Information System 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050917 001 Technical reference manual RAPID Instructions Functions and Data typ...

Page 11: ...phics for the levels Danger and Warning see Safety signals in the manual on page 38 New safety labels on the manipulators see Safety symbols on product labels on page 40 Revised terminology robot replaced with manipulator F This revision includes the following additions New section Restricting the working range on page 74 Lifting and turning the manipulator on page 56 This revision includes the fo...

Page 12: ...tion Setting the system parameters for a suspended or tilted robot on page 66 Turning disk fixture is removed from special tools for Levelmeter calibration N This revision includes the following updates Removed note in Installation of signal lamp P Published in release R16 2 The following updates are done in this revi sion Added a procedure for how to lift and rotate the robot see Lifting and turn...

Page 13: ...added Added Nickel in Environmental information T Published in release R18 2 The following updates are made in this revi sion Added section for inspection of labels in maintenance chapter U Published in release R18 2 The following updates are made in this revi sion Reference updated V Product manual IRB 140 13 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved Overview of this m...

Page 14: ...sioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application...

Page 15: ...ts The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 140 15 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved Product documentation Continued ...

Page 16: ...completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no i...

Page 17: ...arried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is respo...

Page 18: ...working in the work cell 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 robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure tha...

Page 19: ...view The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 140 19 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 20: ...guishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 20 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 21: ...s may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Product man...

Page 22: ... arrest burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system 22 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 23: ...safety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pu...

Page 24: ...modifications to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment a...

Page 25: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 26: ...efore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If...

Page 27: ... in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of th...

Page 28: ...manipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pr...

Page 29: ... risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 ...

Page 30: ...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 30 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 31: ... straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Compact Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled...

Page 32: ... your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 32 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 3 8 Hot...

Page 33: ...ure must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause ...

Page 34: ... as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 34 Product manual IRB 140 3HAC027400 001 Revision V Cop...

Page 35: ...losion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures ...

Page 36: ...tion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic r...

Page 37: ...al volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained volume When draining the oil make sure that as much oil as possible is drained from the gearbox The reason for this is to drain as much oil sludge and metal chips as possible from the ge...

Page 38: ...he instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or dea...

Page 39: ...d conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 140 39 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 40: ...glish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of ...

Page 41: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRB 140 41 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights res...

Page 42: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 42 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 43: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual IRB 140 43 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 44 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...that this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRB 140 45 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

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Page 47: ... important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 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 p...

Page 48: ... specified in Weight robot on page 48 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 51 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 51 7 Before taking the robot to its installation site make sure that the site conforms to Loads on foun...

Page 49: ...le shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance l...

Page 50: ...this will influence the absolute accuracy 5 Maximum tilt The value is recommended for optimal perform ance 22 Hz Note It may affect the manipulator life time to have a lower resonance frequency than recommended Minimum resonance frequency Due to foundation stiffness consider robot mass including equipment i For information about compensating for founda tion flexibility see Application manual Contr...

Page 51: ... hrs 95 at constant temperature gaseous only Maximum ambient humidity Operating conditions robot The table shows the allowed operating conditions for the robot Value Parameter 45 C Minimum ambient temperature 5 C Maximum ambient temperature 95 at constant temperature Maximum ambient humidity Protection classes robot The table shows the available protection types of the robot with the corresponding...

Page 52: ...at wrist centre Pos Axis 3 Axis 2 Z X 0 0 712 450 0 90 0 1092 70 1 50 0 421 314 2 90 110 99 765 3 4 110 119 255 4 150 90 23 480 5 50 90 596 1 6 230 110 558 218 7 90 90 352 670 8 Continues on next page 52 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range IRB 140 ...

Page 53: ...ons below shows the unrestricted working range of axis 1 xx0200000061 Product manual IRB 140 53 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range IRB 140 Continued ...

Page 54: ...avity which may cause the robot to tip over 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 54 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipp...

Page 55: ...lator 1 Sling line for manipulator 2 Sling line for control cable 3 How to lift the manipulator 1 Adjust the manipulator to lifting position according to the illustration 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 Product manual IRB 140 55 3HAC027400 001 Revision V Copyright 2004 2018 ABB Al...

Page 56: ...slings attached to the robot The figure shows lifting slings attached to the robot rigged as choker hitches for lifting and turning the robot for installation on a wall or inverted WARNING The robot will tip forward when lifting it off the ground xx1600000347 Continues on next page 56 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and co...

Page 57: ...o lengthen the reach between the sling and the overhead crane fork lift 2 To facilitate the installation of the slings the axis 2 damper can be removed temporarily xx1600000347 Rig the lifting sling as a choker hitch by passing the lifting sling around the lower arm shaft then through itself then attaching it to the overhead crane or fork lift If necessary use an extra lifting sling to lengthen th...

Page 58: ...r completely inverted WARNING The robot will tip forward when lifting it off the ground 6 Secure the robot at its working site on the wall or inverted according to Orienting and securing the manipulator on page 62 7 Reinstall the axis 2 damper if removed 58 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting an...

Page 59: ...s connected to the controller Use this procedure to release the holding brakes with the internal brake release unit Note Action xx0200000069 The brake release button A is located at the base of the robot 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot arm 2 Release the holding brake...

Page 60: ...o a resistor di ode and to the system board DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0200000071 Supply A B16 24V DC B B14 0V Connect an external power supply to connect or XP1 2 Push the brake release button to release the holding brakes according to the previous procedure 3 Continues on next page 60 Product manual...

Page 61: ...he brake release buttons on the robot Note Illustration Action xx0200000072 Remove the screws and dismount the cover on the back of the robot base 1 A 13 0V B 15 24V DC Locate the R1 MP4 6 connector and discon nect 2 Connect an external power supply to re lease the holding brake on all axis 3 Product manual IRB 140 61 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installa...

Page 62: ...ws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation M12 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 2 5 mm Suitable washer Outer diameter 24 mm Inner diameter 13 4 mm 85 Nm Tightening torque Hole configuration and cross section The bolt pattern requirements are shown in section Bolt pattern on page...

Page 63: ...oduct specification IRB 140 Note All equipment and cables used on the robot must be designed and fitted not to damage the robot and or its parts Illustration holes on upper arm The illustration below shows the stock holes available for fitting extra equipment on the upper arm xx0600003263 Continues on next page Product manual IRB 140 63 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights ...

Page 64: ... 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 64 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Fitting equipment on manipulator Continued ...

Page 65: ...ad diagrams permitted extra loads equipment and their positions as specified in the product specification The loads must also be defined in the software as detailed in 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 Product manual IRB 140 65 3HAC027400 001 R...

Page 66: ...ol the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Gravity Beta If the robot is mounted upside down or on a wall rotated around the y axis then the robot base frame and the sys...

Page 67: ...er 7 axes high performance motion is set see Technical reference manual System parameters Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The parameter Gravity Beta or Gravity Alpha specifies the mounting angle of the robot in radians It is calculated in the following way Gravity Beta A x 3 141593 180 B radians ...

Page 68: ...Gravity Beta xx0200000066 Continues on next page 68 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Setting the system parameters for a suspended or tilted robot Continued ...

Page 69: ...s 0 0 Floor mounted 1 0 785398 45 Tilted 2 1 570796 90 Wall 3 1 570796 90 Wall 4 Note For suspended robots 180 it is recommended to use Gravity Beta instead of Gravity Alpha Continues on next page Product manual IRB 140 69 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Setting the system parameters for a suspended or tilted robot Contin...

Page 70: ... new value is detailed in Mounting angles and values on page67 The system parameters are described in Technical reference manual System parameters The system parameters are redefined in the Configuration Editor in RobotStudio or on the FlexPendant 70 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Setting the syste...

Page 71: ...manipulator Ø 25H8 2x 80 155 A A B B B 39 180 180 X Ø 0 25 Y Ø 25H8 2x 80 Ø13 155 A A B B B B 39 180 180 X Ø 0 25 Y Z A Ø 0 6 Ø 0 A xx0200000085 Continues on next page Product manual IRB 140 71 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Bolt pattern ...

Page 72: ...ustration below shows the cross section of the guide sleeve holes A A xx0200000086 72 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Bolt pattern Continued ...

Page 73: ... Signal lamp See the assembly instruction delivered with the signal lamp Product manual IRB 140 73 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 9 Installation of signal lamp option ...

Page 74: ...on the limited area cannot be classified as a safe zone All work within this zone is prohibited System parameters The system parameters that must be changed Upper joint bound and Lower joint bound are described in 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 74 Product ma...

Page 75: ...oint on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1700000974 Product manual IRB 140 75 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Grounding and bonding point on manipulator ...

Page 76: ...nipulator xx0200000074 Connections Description Connections R1 4 Max 8 bar hose inner diameter 6 5 mm For air on base upper arm FCI UT 071412SH44N connector Signal connector on upper arm Number of signals 12 signals 49V 500mA Continues on next page 76 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Customer connecti...

Page 77: ...in Adapter Tin plated 12 pin Pins for cable area 0 25 0 5 mm 2 Pins for cable area 0 5 1 5 mm 2 Shrinking hose bootled shaped Shrinking hose angled The connection set is delivered in a plastic bag also containing a Technical and assembly instruction Product manual IRB 140 77 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Customer connec...

Page 78: ... regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3...

Page 79: ...ctions and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If the...

Page 80: ...perating time specified in operating hours More frequent running means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System 80 Product manual IRB 1...

Page 81: ...Inspection damper axes 2 3 and 5 on page 83 Regularly i Damper axes 2 3 Inspection Inspecting the robot cabling on page 85 Regularly i Cable harnesses Inspection Inspection timing belts on page 86 36 mths Timing belts Inspection Inspection activities on page 83 12 mths Oil Inspection Replace any damaged missing or unreadable la bels 12 months Information labels Inspection Replace any damaged missi...

Page 82: ...cable harness the shorter intervals ii The battery low alert 38213 Battery charge low is displayed when the battery needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See the replacement instruction for more details iii The battery low alert 38213 Battery charge low is displayed when remainin...

Page 83: ...ure below shows the location of all the dampers to be inspected xx0200000426 Damper axis 2 A xx0200000427 Damper axis 3 A Continues on next page Product manual IRB 140 83 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 1 Inspection damper axes 2 3 and 5 ...

Page 84: ...essure supply to the robot before entering the robot working area 1 Shown in the figure Location of dampers on page 83 Check all dampers for damage such as cracks or existing impressions that are larger than 1 mm 2 Check attachment screws for deformation 3 Replacement is detailed in sec tions Replacing the damper axis 2 on page 157 Replacing the damper axis 3 on page 146 Replacement of damper axis...

Page 85: ...ther tools and procedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Inspection robot cabling Use this procedure to inspect the robot cabling Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Visually inspect ...

Page 86: ... in the figures below A more detailed view of the components and its position may be found in chapter Spare part lists on page 243 xx0200000448 Timing belt axis 3 G Continues on next page 86 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 3 Inspection timing belts ...

Page 87: ...001 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Continues on next page Product manual IRB 140 87 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 3 Inspection timing belts Continued ...

Page 88: ...d Replacement of motor and timing belt axes 5 or 6 on page 197 Gain access to each belt by remov ing covers etc 1 Replace the timing belts if found defective as detailed in sections Replacement of motor and timing belt axis 3 on page 186 and Re placement of motor and timing belt axes 5 or 6 on page 197 Check each belt for damage 2 The belt tension should be Axis 3 F 35 60 N Axis 5 F 35 60 N Axis 6...

Page 89: ...of lubrication in gearboxes on page 109 Lubrication oil Content is defined in section Standard tools on page 239 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 140 89 3HAC027400 001 Revision V Copyright 2004 2018 ...

Page 90: ...isks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 36 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in or...

Page 91: ...te Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 6 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from...

Page 92: ...n Standard tools on page 239 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Continues o...

Page 93: ...s during work with gearbox lubricants oil or grease on page 36 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 Continues on next page Product manual IRB 140 ...

Page 94: ...ion before measuring the oil level See Technical reference manual Lubric ation in gearboxes Add oil if required 5 Tightening torque 10 Nm Refit the oil plug filling Note Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 6 Seal and paint the joints that have been opened Also repair possible damages of the special...

Page 95: ...n Standard tools on page 239 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Continues o...

Page 96: ...e entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 A B xx1700000571 The upper edge of the oil plug hole A Oil level B Measure the oil level at the oil plug hole Required oil level 148 5 mm below the upper edge of the oil plug hole Note Position the axis according to i...

Page 97: ...at have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 7 Product manual IRB 140 97 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 6 Inspecti...

Page 98: ...n Standard tools on page 239 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Continues o...

Page 99: ...mation in the section Safety risks during work with gearbox lubricants oil or grease on page 36 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 Continues on ...

Page 100: ...Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 6 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from pa...

Page 101: ...efined in section Standard tools on page 239 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on pag...

Page 102: ...pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 A B xx1700000572 The lower edge of the oil plug hole A Oil Level B Measure the oil level at the oil plug hole Required oil level 23 3 mm below the lower edge of the oil plug hole Note...

Page 103: ... have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 7 Product manual IRB 140 103 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspectin...

Page 104: ...ating label located inside the base D Calibration label E Lifting instruction label F Foundry or CleanRoom logotype if applicable Location is valid if option lamp unit is selected G1 Foundry or CleanRoom logotype if applicable Location is valid if option lamp unit is not selected G2 Warning label Electricity symbol of flash 6 pcs H UL UR label J Information sign AbsAcc K Label battery L Required e...

Page 105: ... air pressure supply to the robot before entering the robot work ing area 1 See the figure in Location of information labels on page 104 Check all labels 2 Replace any missing or damaged labels 3 Product manual IRB 140 105 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting information labels Continued ...

Page 106: ...protective covers are fitted to the robot before cleaning Never point the water jet at connectors joints sealings or gaskets Do not use compressed air to clean the robot Never use solvents that are not approved by ABB to clean the robot Do not spray from a distance closer than 0 4 m Do not remove any covers or other protective devices before cleaning the robot Cleaning methods The following table ...

Page 107: ...er ABB robots with protection types Standard Foundry Plus Wash or Foundry Prime can be cleaned by rinsing with water water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow ...

Page 108: ...and dust and chips if it prevents cable movement Clean the cables if they have a crusty surface for example from dry release agents 108 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4 1 Cleaning the IRB 140 type C Continued ...

Page 109: ...ce or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A new revision will be published on ABB Library immediately after u...

Page 110: ...es on page 109 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard tools on page 239 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these pro cedures in the step by step instruc tions below CAUTION Always cut the paint wi...

Page 111: ... of oil xx0500001434 Position the robot as shown in the figure to the right upper arm upwards for a standing robot axis 4 180º to a position where the oil plug A faces downwards Note The total amount of oil will not be drained There will remain approximately 50 ml in the wrist unit 3 A Oil plug draining and filling The position for an inverted robot is the opposite Shown in the figure Location of ...

Page 112: ...e figure Location of oil plugs on page 110 Remove the oil plug draining and filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 109 xx0500001435 Position the robot as shown in the figure to the right upper arm downwards for a standing robot axis 4 90º to a position where the oil plug A faces upwards Fill oil in the wrist unit through the ...

Page 113: ...rform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 231 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure ...

Page 114: ...be exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradual...

Page 115: ...tarted 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 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 Product manual IRB 140 ...

Page 116: ... correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page116 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreign...

Page 117: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 118: ...ng agent Knife Lint free cloth 3HAC036639 001 Touch up paint Clean Room White 3HAC037052 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Refit...

Page 119: ... Use Touch up paint Clean Room white to paint the joint Note Always read the instruction in the product data sheet in the paint repair kit for Clean Room 6 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth Product manual IRB 140 119 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 3 Cut the paint or surface on the robot...

Page 120: ...3 Cable harness power axis 4 6 Cable harness sig nals axis 1 3 Cable harness sig nals axis 4 6 Cable harness customer connec tions Content is defined in sec tion Standard tools on page 239 3HAC020812 001 Standard toolkit These procedures include references to the tools re quired Other tools and proced ures may be required See references to these procedures in the step by step in structions below S...

Page 121: ...cks are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Note Illustration Action CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 118 1 Detailed in section Replacing the serial measure ment unit and the battery p...

Page 122: ... Detailed in section Replacement of cover arm housing on page 150 Remove the cover arm housing 6 Detailed in section Replacement of lower arm cover and gasket on page 153 Remove the lower arm cover 7 Detailed in section Removing the VK cover on page 131 Gently knock out the VK cover 8 Continues on next page 122 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights res...

Page 123: ...R3 FB6 F R3 MP5 G R3 MP4 H R3 MP6 Parts J Shield See figure above Remove the shield by unscrewing its attachment screws 10 Cut any cable ties securing the cabling inside the lower arm 11 Continues on next page Product manual IRB 140 123 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement of cable harness Continued ...

Page 124: ...ove the cover console 14 Connectors R3 MP1 R3 MP2 R3 FB1 R3 FB2 Disconnect the connectors inside the console and undo the cable holders 15 Gently pull the cabling from the base up through the console 16 Gently pull the cabling out of the lower arm 17 Continues on next page 124 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement of...

Page 125: ... sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Note Illustration Action Refit in reverse order to what is de tailed above 1 Detailed below are some recom mendations on how to route the cables Clean the joints that have been opened See Cut the paint or sur face on the robot before replacing parts on page 118 2 xx0300000093 Ca...

Page 126: ...Power cables axes 4 5 and 6 D Customer cables signal E Signal cables axes 4 5 and 6 F Signal cable axis 3 G Connectors R3 MP3 and R3 FB3 Continues on next page 126 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement of cable harness Continued ...

Page 127: ...joints that have been opened See Cut the paint or surface on the robot before repla cing parts on page 118 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth 6 Product manual IRB 140 127 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement of cable harness Continued ...

Page 128: ...Spare part lists on page 243 xx0200000446 Cover armhousing A Attachment screws cover armhousing 4 pcs B CS connector C Pressurized air connector D VK cover E Cable guide F Attachment screws cable guide G Attachment screws upper arm 6 pcs H Sealing ring J Continues on next page 128 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 2 Replacemen...

Page 129: ...the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed for example secure the lower arm with fixtures if removing motor axis 2 Removal upper arm The procedure below details how to remove the complete upper arm Note...

Page 130: ... in section Re quired equipment on page 129 Shown in the figure Location of upper arm on page 128 Remove the pressurized air connector from the housing and pull it into the upper arm assembly 9 Art no specified in section Re quired equipment on page 129 Shown in the figure Location of upper arm on page 128 Remove the VK cover from the upper arm lower arm joint 10 Detailed in section Removing the V...

Page 131: ...umference of the VK cover evenly to avoid dam aging it Tap the VK cover with a long blunt edged bar through the hole in the lower arm to press it out 2 Shown in the figure in section Location of upper arm on page 128 Specified in section Replacement of complete upper arm on page 128 If the VK cover is damaged it must be replaced on refitting 3 Continues on next page Product manual IRB 140 131 3HAC...

Page 132: ... page 128 Pull the pressurized air connector through the housing and secure it into fitting in the upper arm assembly 8 Shown in the figure Location of upper arm on page 128 Pull the CS connector through the housing and secure it into the fitting in the upper arm assembly 9 Art no specified in section Required equipment on page 129 Use a special socketto secure it Reconnect any connector previousl...

Page 133: ... page 215 DANGER When performing the first test run after a service activity repair installation or maintenance it is vital that all the service tools and other foreign objects are removed from the manipulator all normal safety equipment is installed properly e g FlexPendant enabling device all personnel are standing at a safe distance from the manipulator i e out of its reach behind safety fences...

Page 134: ...e found in chapter Spare part lists on page 243 xx0200000469 Lower arm A Required equipment Note Art no Spare part no Equipment Standard and Foundry versions 3HAC034935 001 Lower arm spare Includes all required bearings oil and VK cov er Continues on next page 134 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of complete low...

Page 135: ... any repair work on the manipulator Motors and gears are HOT after running the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed for example secure the lower arm with fixtures if removing motor axis 2 Information ...

Page 136: ...r Shown in the figure above Unscrew thelower arm attachment screws 5 Also remove the washer Raise the lifting device to remove the lower arm 6 Refitting lower arm The procedure below details how to refit the complete lower arm Note Action Clean the joints that have been opened See Cut the paint or sur face on the robot before replacing parts on page 118 1 Fit the lifting device and lift the lower ...

Page 137: ...paint the joints that have been opened See Cut the paint or surface on the robot before repla cing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 6 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 7 General Calibration information is included in section Calibration in...

Page 138: ...nd washers gearbox base 10 pcs each D Damper axis 1 E Washer F Required equipment Note Art no Spare part no Equipment Standard and Foundry versions For spare part number see Spare part lists on page 243 Base spare Includes parallel pin 3HAC 3785 2 Clean room versions For spare part number see Spare part lists on page 243 Base spare Includes parallel pin 3HAC 3785 2 Continues on next page 138 Produ...

Page 139: ...ing parts on page118 Removal base The procedure below details how to remove the base from the robot Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before repla...

Page 140: ...etails how to refit the base to the robot Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Clean the joints that have been opened See Cut the paint or surface on the robot before re placing parts on page 118 2 Place the robot with the side of the lower arm downwards on a workbench 3 Clean the m...

Page 141: ...ment of cable harness on page 120 Refit the cable harness 15 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 16 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Reca...

Page 142: ...plug only one shown B Wrist unit C Required equipment Note Art no Spare part no Equipment etc Standard and Foundry versions Wrist Stand ard Foundry O ring sealing plate not in cluded Note The wrist stand ard Foundry is not interchange able with art no 3HAC 10475 1 Clean room versions 3HAC 026569 003 Wrist unit CR O ring sealing plate not in cluded Continues on next page 142 Product manual IRB 140 ...

Page 143: ...efore replacing parts on page118 Removal wrist unit The procedure below details how to remove the complete wrist unit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the ...

Page 144: ...it the o ring sealingplate and the wrist unit to the upper arm with the attachment screws but do not tighten them 6 Use a new o ring Spare part no is specified in Required equipment on page 142 Art no is specified in section Required equipment on page 142 Fit the arm to the rear of the motor 7 xx0200000445 Manually push the wrist to adjust the wrist in relation to the gear in the gear box The gear...

Page 145: ...robot before replacing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 13 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Recalibrate the robot 14 General calibration information is included in section Calibration information on page 215 DANGER Make sure all safety requ...

Page 146: ...ON Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Removing the damper axis 3 Use this procedure to remove the damper Note Action Shown in the figure Location of damper axis 3 on page 146 Run the robot to a position where it is best to enable access to the access 3 damper 1 Continues on ...

Page 147: ...ccess to the location where the axis 3 damper is fitted 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 Refit the damper by gently pressing it onto the cast tab on the upper arm 3 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the secti...

Page 148: ...and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Removal damper axis 5 The procedure below details how to remove the damper axis 5 Note Action Shown in the figure Location of damper axis 5 on page 148 Run the robot to a position that enables the end of the damper to be pushed into the recess in the wrist unit 1 Continues ...

Page 149: ...ssure supply to the robot before entering the robot working area 1 Make sure the damper is turned the correct way Push the end of the damper into the gap between the wrist unit and upper arm 2 Manually move the wrist robot axis 5 in order to pull the damper into position 3 Fold out the damper hooks to secure it in position 4 DANGER Make sure all safety requirements are met when perform ing the fir...

Page 150: ...an Room versions 3HAC 10473 3 Cover arm housing Includes gasket 3HAC 7867 1 3HAC 7867 1 Gasket upper arm cover Content is defined in section Standard tools on page 239 3HAC020812 001 Standard toolkit These procedures in clude references to the tools required Other tools and proced ures may be required See references to these procedures in the step by step instructions be low CAUTION Always cut the...

Page 151: ...wn in the figure Location of cover armhousing on page150 Remove the cover armhousing by unscrewing its attachment screws 3 NOTE Do not damage the gas ket inside the cover Refitting The procedure below details how to refit cover armhousing WARNING Please observe the following before doing any repair work on the manipulator Motors and gears are HOT after running the robot Touching the motors and gea...

Page 152: ...of cover armhousing on page 150 Secure the cover arm housing to the upper arm with its attachment screws 4 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 5 152 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 201...

Page 153: ...in the figure below A more detailed view of the components and its position may be found in section Spare part lists on page 243 xx0200000433 Lower arm A Gasket lower arm cover B Continues on next page Product manual IRB 140 153 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 1 Replacement of lower arm cover and gasket ...

Page 154: ...es in the step by step instruc tions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Removal lower arm cover and gasket The procedure below details how to remove the lower arm cover and gasket WARNING Please observe the following before doing any repair work on the manipula...

Page 155: ...Burns may result from touching the motors or gears Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g to secure the lower arm with fixtures if removing motor axis 2 Note Action Clean the joints that have been opened See Cut the paint or surface on the robot before r...

Page 156: ...bot before replacing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 5 156 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 1 Replacement of lower arm cover and gasket Continued ...

Page 157: ...9 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Continues on next page Product manua...

Page 158: ... screw and washer 4 Refitting the damper Use this procedure to refit the damper Note Action Run the robot to a position where it is best to enable access to the attachment screw of the damper 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 1 pc M6 x 16 Secure the damper with the attachment screw and wa...

Page 159: ...sole A Attachment screws cover console 4 pcs B Gasket C Console D Required equipment Note Art no Spare part no Equipment etc Standard and Foundry version 3HAC 10472 1 Cover console spare Includes gasket 3HAC 7868 1 Clean Room versions 3HAC 10472 3 Cover console spare Includes gasket 3HAC 7868 1 3HAC 7868 1 Gasket cover console Continues on next page Product manual IRB 140 159 3HAC027400 001 Revisi...

Page 160: ...pressure supplies to the robot 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 Note Action CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 118 1 Shown in the fig...

Page 161: ... on the robot before replacing parts on page 118 1 Shown in the figure Location of cover console on page 159 Manually run the robot to a position that enables access to the top of the console 2 Replace if damaged Make sure the gasket inside the cover console has not been damaged 3 Shown in the figure Location of cover console on page 159 Secure the cover console to the console with its at tachment...

Page 162: ... Spare part no Equipment etc Standard and Foundry version 3HAC 10478 1 Console spare Clean Room versions 3HAC 10478 3 Console spare Content is defined in section Standard tools on page 239 3HAC020812 001 Standard toolkit These procedures in clude references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below C...

Page 163: ...apse as parts are removed for example secure the lower arm with fixtures if removing motor axis 2 Note Illustration Action CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 118 1 Detailed in section Replacement of cable harness on page 120 Remove the cable harness 2 Detailed in sectio...

Page 164: ...6 Remove the motor of axis 3 6 Attach the lifting device to the lower arm 7 xx0300000096 Remove the bearing hub by unscrewing its attachment screws 8 Parts A Console B Bearing hub C Bearing hub attachment screws 6 pcs D Console attachment screws 10 pcs E Washers 10 pcs Shown in the figure above Remove the console by un screwing its attachment screws 9 Continues on next page 164 Product manual IRB ...

Page 165: ... sur face on the robot before replacing parts on page 118 1 xx0300000096 Refit the console and secure it with its attachment screws and washers 2 Parts A Console B Bearing hub C Bearing hub attachment screws 6 pcs D Console attachment screws 10 pcs E Washers 10 pcs Tightening torque 11 Nm 1 Nm Shown in the figure above Refit the bearing hub and secure it with its attachment screws 3 Tightening tor...

Page 166: ...or surface on the robot before repla cing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 8 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 9 General calibration information is included in section Calibration information on page 215 166 Product manual IRB 140 3HAC0274...

Page 167: ...e robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety risks during handling of batteries on page35 Location of serial measurement unit and battery pack The serial measurement unit and battery pack are located inside th...

Page 168: ... See Spare parts in Product manual spare parts IRB 1600 1660 Serial measurement unit See Spare parts in Product manual spare parts IRB 1600 1660 Battery pack Indoors Cable tie Replace only if required Gasket base cover Content is defined in section Standard tools on page 239 Standard toolkit IRB 140 These procedures include references to the tools required Other tools and procedures may be require...

Page 169: ...re you are grounded through a special ESD wrist bracelet or similar CAUTION This component is classified as hazardous waste and must be disposed of accordingly If in doubt of the correct disposal procedure please contact your local environmental authority CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging t...

Page 170: ...ct the battery connector to remove the battery pack Battery includes protection circuits Replace it only with the specified spare part in the refitting instruction or with an ABB approved eqvivalent 7 Refitting The procedure below details how to refit the serial measurement unit and battery pack WARNING Please observe the following before doing any repair work on the manipulator Motors and gears a...

Page 171: ...unit 3 Shown in the figure Location of serial measurement unit and bat tery pack on page 167 Place the serial measurement unit in position inside the manipulator base and secure it with its four at tachment screws 4 Shown in the figure Location of serial measurement unit and bat tery pack on page 167 Make sure the gasket sealing the rear cable cover has not been damaged Replace the gasket if requi...

Page 172: ...on a lint free cloth 8 Calibration is detailed in a separ ate calibration manual enclosed with the calibration tools Recalibrate the robot 9 General calibration information is included in section Calibration information on page 215 172 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the serial measurement unit and the battery pa...

Page 173: ...equired equipment Note Art no Spare part no Equipment etc 3 m 3HAC 10476 1 Control cable spare Standard and Foundry versions Cover gasket included 7 m 3HAC 10477 1 Control cable spare Standard and Foundry versions Cover gasket included 15 m 3HAC 11331 1 Control cable spare Standard and Foundry versions Cover gasket included 22 m 3HAC 13090 1 Control cable spare Standard and Foundry versions Cover ...

Page 174: ...nclude references to the tools re quired Other tools and proced ures may be required See references to these procedures in the step by step instructions be low Removal The procedure below details how to remove the control cable WARNING Please observe the following before doing any repair work on the manipulator Motors and gears are HOT after running the robot Touching the motors and gears may resu...

Page 175: ...Pull the cable out of the manipulator base 5 Disconnect the connectors from the control cabinet 6 Refitting The procedure below details how to refit control cable WARNING Please observe the following before doing any repair work on the manipulator Motors and gears are HOT after running the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic p...

Page 176: ...D R1 MP4 6 Included in the spare part Fit a new gasket when refitting the cover 4 Shown in the figure Location of control cable on page 173 Fit the cover onto the manipulator base and secure it with its attachment screws 5 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from ...

Page 177: ...s D Console E Required equipment Note Art no Equipment etc For spare part number see Spare part lists on page 243 Rot ac motor with pinion Must be replaced when replacing motor 21522012 426 O ring Included in the spare parts motor kits Used to lubricate the o ring 3HAB3537 1 Grease Content is defined in section Stand ard tools on page 239 3HAC020812 001 Standard toolkit For adjusting the gear play...

Page 178: ...sult in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed for example secure the lower arm with fixtures if removing motor axis 2 Note Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used Note Action CAUTION Always cut the...

Page 179: ... the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed for example secure the lower arm with fixtures if removing motor axis 2 Note Whenever parting mating motor and gearbox the gears may be damaged if excessive f...

Page 180: ... Art no is specified in section Re quired equipment on page 177 Make sure the cable gland gasket has not been damaged Replace if it has 11 Push the cables into the console and refit the cable gland with its attachment screws 12 Detailed in section Performing a leak down test on page 241 Perform a leak down test 13 Seal and paint the joints that have been opened See Cut the paint or surface on the ...

Page 181: ...ment Note Art no Equipment etc For spare part num ber see Spare part lists on page 243 Rot ac motor with pinion Must be replaced when replacing motor 21522012 426 O ring Loctite 574 Locking liquid For cleaning mating surfaces Isopropanol Content is defined in section Standard tools on page 239 Standard toolkit For adjusting the gear play motor pinion 3HAC9037 1 Rotation tool motor 24 VDC 1 5 A Pow...

Page 182: ...low the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the ...

Page 183: ...ecure the weight of the lower arm properly before re leasing the brakes of motor axis 2 When releasing the holding brakes of the motor the lower arm will be movable and may fall down 8 Connect to connector R3 MP2 pin 7 pin 8 In order to release the brakes connect the 24 VDC power supply to the motor 9 WARNING Oil will be running out of the motor attachment hole when removing the motor It may also ...

Page 184: ... Use the rotation tool to rotate the motor pinion when mating it to the gear 7 Make sure the motor pinion does not get damaged Tightening torque approx 2 Nm Secure the motor with four attachment screws and plain washers but do not tighten yet 8 There should be a barely noticable gear play Adjust the motor in relation to the gear in the gearbox 9 Use the rotation tool to wiggle the motor shaft back...

Page 185: ...ion Pendulum enclosed with the calib ration tools Recalibrate the robot 19 General calibration information is included in section Calibration in formation on page 215 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 20 Product manual IRB 140 185 3HAC027400 001 Revision ...

Page 186: ...w of the components and its position see Spare part lists on page 243 xx0200000448 Lower arm cover A Attachment screws lower arm cover 13 pcs B Belt shield C Motor 3 D Attachment screws belt shield 3 pcs E Attachment screws motor 3 4 pcs F Belt G Continues on next page 186 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 3 Replacement of mot...

Page 187: ...ic and pneumatic pressure supplies to the robot 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 Note Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used Note Action CAUTION Always cut the paint with a knife and grind the paint edge when...

Page 188: ...cables axes 4 5 and 6 F Signal cable axis 3 G Connectors R3 MP3 and R3 FB3 Connectors R3 MP3 R3 FB3 R3 H1 if Safety lamp is fitted R3 H2 if Safety lamp is fitted Disconnect motor connectors 5 Continues on next page 188 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 3 Replacement of motor and timing belt axis 3 Continued ...

Page 189: ...ure to refit the motor axis 3 WARNING Please observe the following before doing any repair work on the manipulator Motors and gears are HOT after running the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Take any necessary measures to ensure that the manipulator does not collapse as parts are removed for e...

Page 190: ...ng screws 7 Tightening torque 4 Nm 0 5 Nm Fit the belt shield and secure it with the two remaining screws 8 Tightening torque 4 Nm 0 5 Nm Tighten the last motor attachment screws 9 xx0200000449 Refit the cabling as shown 10 A Cable ties B Pressurized air hose C Power cables axes 4 5 and 6 D Customer cables signal E Signal cables axes 4 5 and 6 F Signal cable axis 3 G Connectors R3 MP3 and R3 FB3 C...

Page 191: ...spirit on a lint free cloth 11 Calibration is detailed in a separate calibra tion manual enclosed with the calibration tools Recalibrate the robot 12 General calibration information is included in section Calibration information on page215 Product manual IRB 140 191 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 3 Replacement of motor and timing belt axis 3 Cont...

Page 192: ...etc Does not include the o ring For spare part number see Spare part lists on page 243 Rot ac motor with pinion Must be replaced when re placing motor 3HAC3772 24 O ring Used for lubricating the o ring 3HAB3537 1 Grease Content is defined in section Standard tools on page239 3HAC020812 001 Standard toolkit 24 VDC max 1 5 A Power supply For releasing the brakes For adjusting the gear play 3HAC9037 ...

Page 193: ...bration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If no previous reference values exist and no new refe...

Page 194: ...ect the 24 VDC power supply to the motor 6 Shown in the figure Location of motor on page 192 Remove the motor axis 4 by unscrewing the motor attachment screws 7 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage 8 Make sure the motor pinion is not damaged Remove the motor by gently lifting it out 9 Remove the o ring from the arm housing 10 Refitting motor ...

Page 195: ...aft 6 There should be a barely noticable gear play Adjust the motor in relation to the gear in the gearbox 7 Use the arm tool to wiggle the motor shaft back and forth to feel the play Shown in the figure Location of motor on page 192 Tighten the motor attachment screws 8 Tightening torque 6 Nm 0 6 Nm Detailed in section Replacement of motor and timing belt axes 5 or 6 on page 197 Refit motors 5 an...

Page 196: ...ded in section Calibration informa tion on page 215 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 13 196 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 4 Replacement of motor axis 4 IRB 1600 Continued ...

Page 197: ...ound in chapter Spare part lists on page 243 xx0600003261 Lower arm cover A Attachment screws lower arm cover B Cover armhousing C Attachment screws cover armhousing 4 pcs D VK cover E Pressurized air hose on front of upper arm F CS connector G Cable guide H Attachment screws cable guide J Continues on next page Product manual IRB 140 197 3HAC027400 001 Revision V Copyright 2004 2018 ABB All right...

Page 198: ...nd Foundry versions Axes 5 and 6 3HAC6779 1 Timing belt 3HAA2166 13 VK cover Content is defined in section Standard tools on page 239 3HAC020812 001 Standard toolkit For fitting the CS con nector Special socket 30 mm These procedures in clude references to the tools required Other tools and proced ures may be required See references to these proced ures in the step by step instructions below See c...

Page 199: ... arm is close to horizontal 2 Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 197 Remove the lower arm cover by unscrewing its attachment screws 3 Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 197 Remove the rear cover armhousing by un screwing its four attachment screws 4 Connectors R3 MP4 R3 MP5 R3 MP6 R3 FB4 R3 FB5 R3 F...

Page 200: ...tor and timing belt axes 5 or 6 on page 197 Remove the pulley and belt from motor axis 6 14 Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 197 Remove the pulley and belt from motor axis 5 15 Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 197 Remove the motor console ax 5 6 by un screwing its attachment screws 16 Refitting ...

Page 201: ...axes 5 or 6 on page 197 Fit timing belt axis 6 9 Correct belt tension F 20 40 N Repeat the belt adjustment procedure de tailed above for the remaining motor axis 6 10 Tightening torque 4 Nm 0 5 Nm Secure the motor with its attachment screws 11 Shown in the figure in section Location of motor and timing belt axes 5 or 6 on page 197 Fit the belt shield with its attachment screws 12 Tightening torque...

Page 202: ...on page 197 Refit the rear cover armhousing with its four attachment screws 19 Refit any brackets securing any exterior cabling to the upper arm with their attach ment screws respectively 20 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work wipe the robot free from particles with spirit on a lint ...

Page 203: ...cedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below WARNING Please observe the following before doing any repair work on the manipulator Motors and gears are HOT after running the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneuma...

Page 204: ...alue 1 3 xx0200000458 Apply 40 N load as shown 4 Remove the load and read Value 2 5 Gear play value value 1 value 2 Calculate the gear play value 6 OK 0 18 mm 4 1 arc minutes Determine whether or not the value is OK 7 204 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 6 1 Measuring the gear play axis 5 Continued ...

Page 205: ...eferences to the tools required Other tools and proced ures may be required See references to these proced ures in the step by step in structions below WARNING Please observe the following before doing any repair work on the manipulator Motors and gears are HOT after running the robot Touching the motors and gears may result in burns Turn off all electric power hydraulic and pneumatic pressure sup...

Page 206: ...alue 1 3 xx0200000461 Apply 40 N load as shown 4 Remove the load and read Value 2 5 Gear play value value 1 value 2 Calculate the gear play value 6 OK 0 30 mm 10 3 arc minutes Determine whether or not the value is OK 7 206 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 6 2 Measuring the gear play axis 6 Continued ...

Page 207: ...ipment Note Art no Equipment Includes gearbox all required lubricant all o rings and sealing rings For spare part num ber see Spare part lists on page 243 Gearbox axis 1 and 2 3HAC7527 1 Damper axis 1 For cleaning the mating surfaces before fitting Isopropanol 2 ml 12340011 116 Flange sealing Loctite 574 Locking liquid Replace only when damaged 3HAC6965 1 Sealing ring Lifting slings Content is def...

Page 208: ...ws bottom plate 26 pcs C Attachment screws and washers gearbox base 10 pcs each D Damper axis 1 E Washer F CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page118 Continues on next page 208 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Rep...

Page 209: ...ove the motor axis 1 6 Detailed in section Replacement of cable harness on page 120 Remove the cable harness 7 Detailed in section Replacing the serial measure ment unit and the battery pack on page 167 Remove the serial measurement board 8 Detailed in section Replacement of complete upper arm on page 128 Remove the upper arm 9 Detailed in section Replacement of complete lower arm on page 134 Remo...

Page 210: ... in the figure Refitting gearbox unit axes 1 2 on page 210 Fit the damper axis 1 1 Detailed in section Refitting gearbox unit axes 1 2 on page 210 Proceed with assembling the robot 2 Refitting gearbox unit axes 1 2 The procedure below details how to refit the complete gearbox unit axes 1 2 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the ro...

Page 211: ...n page 128 Refit the upper arm 12 Detailed in section Replacing the serial measurement unit and the battery pack on page 167 Refit the serial measurement board 13 Detailed in section Replacement of cable harness on page 120 Refit the cable harness 14 Detailed in sections Replacement of motor axis 1 on page 177 Refitting motor axis 2 on page184 Refit the motors axes 1 and 2 15 Detailed in section P...

Page 212: ...irst test run These are further detailed in the section First test run may cause injury or damage on page 26 20 212 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 8 1 Replacement of gearbox axes 1 2 and damper axis 1 Continued ...

Page 213: ...at 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 128 Product manual IRB 140 213 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 4 Repair 4 8 2 Service work on gearbox axis 4 ...

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Page 215: ...tion counter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 220 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot...

Page 216: ...Absolute accuracy calibration focuses on pos itioning accuracy in the Cartesian coordinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The fi...

Page 217: ...e method and the different routines further CalibWare Absolute Accuracy calibration To achieve a good positioning in the Cartesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculates new compensation parameters This is further detailed in the Application manual CalibWare Field 5 0 If a service operati...

Page 218: ...he synchronization position for each axis Synchronization marks IRB 140 The illustration below shows the calibration scale positions on the robot xx0200000157 218 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 5 Calibration information 5 3 Synchronization marks and synchronization position for axes ...

Page 219: ...ll handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 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 Product manual IRB 140 219 3HAC027400 001 Revision V...

Page 220: ...Select axis by axis motion mode 1 See Synchronization marks and synchron ization position for axes on page 218 Jog the manipulator to align the synchron ization marks IRB 140 1400 2400 4400 6600ID 6650ID 6640ID Axes 5 and 6 must be positioned together 2 Step 2 Updating the revolution counter with the FlexPendant on page 221 When all axes are positioned update the revolution counter 3 Correct calib...

Page 221: ...t Yes Yes IRB 140 If the synchronization marks seem to be wrong even if the motor calibration data is correct try to rotate the axis one turn update the revolution counter and check the synchronization marks again try both directions if needed Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action On the ABB ...

Page 222: ...2 Tap the mechanical unit in question xx1500000943 A screen is displayed tap Rev Counters en0400000771 3 Continues on next page 222 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 5 Calibration information 5 5 Updating revolution counters Continued ...

Page 223: ...ating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury Check t...

Page 224: ...218 and Updating revolution counters on page 220 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1 2 o...

Page 225: ...rs Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance...

Page 226: ...to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 226 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 227: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 140 227 3HAC027400 001 Revision V Copyright 2004 2018 ABB All ri...

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Page 229: ...is installed 1 On the FlexPendant ABB menu tap System Info 2 Tap System properties The RobotWare version is displayed on the right side Contact ABB if you are unsure of the type Which parts are interchangeable and which are not The following parts are not interchangeable The wrist unit with spare part no 3HAC026569 001 is not interchangeable with spare part no 3HAC10475 1 The o ring sealing plate ...

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Page 231: ...apter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 140 231 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 232: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 233: ... R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 140 233 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 8 Reference information 8 2 Applicable standards Continued ...

Page 234: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 234 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 235: ...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 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensi...

Page 236: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 237: ...ening torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 140 237 3HAC027400 001 Rev...

Page 238: ...ssory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 100 kg All lifting accessories used must be sized accord ingly 238 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB ...

Page 239: ...rd toolkit and any tools listed in the instruction Contents standard toolkit Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 10 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 Socket head cap no 5 socket 1 2 bit L 20 mm 1 Socket head cap no 6 socket 1 2 bit L 20 mm 1 Socket head cap no 8 socket 1 2 bit L 2...

Page 240: ...tion Note Art no Description 68080011 LP Angle bracket 3HAC13908 9 Calibration bracket 3HAC13908 4 Calibration tool ax1 Includes one sensor 6369901 347 Levelmeter 2000 kit 3HAC13908 5 Measuring pin 68080011 GM Sensor fixture 3HAC0392 1 Sensor plate 3HAC13908 1 Sync adapter Calibration equipment Calibration Pendulum The following table specifies the calibration equipment needed when calibrating the...

Page 241: ...nder no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no pressure loss occ...

Page 242: ...ting 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 242 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 8 Reference information 8 9 Lifting accessories and lifting i...

Page 243: ...iews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 140 243 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 9 Spare part lists 9 1 Spare part lists and illustrations ...

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Page 245: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 246: ... 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 246 Product manual IRB 140 3HAC027400 001 Revision V Copyright 2004 2018 ABB All rights reserved 10 Circuit diagram 10 1 Circuit diagrams C...

Page 247: ...inguisher 20 cast iron disposal 225 cleaning 106 climbing on robot 23 Cold environments 78 connection external safety devices 24 copper disposal 225 cracks damper 84 D damage damper 84 damper axis 2 83 attachment screw 158 replacing 157 spare part number 157 damper axis 3 inspection 83 replacing 146 spare part number 146 damper axis 5 inspection 83 replacing 148 spare part number 148 danger levels...

Page 248: ...al 23 plastic disposal 225 position robot when draining wrist unit 111 when filling oil in wrist unit 112 positive directions axes 219 product standards 232 protection classes 51 protection type 51 protective equipment 24 protective wear 24 push button unit releasing the brakes 59 R region specific regulations 17 release brakes 21 releasing brakes external power supply to connector R1 MP 60 manual...

Page 249: ...ge 51 testing brakes 34 three position enabling device 28 tightening torques attachment screws base gearbox unit 140 motor axis 2 184 motor axis 4 195 wrist unit 144 tools calibration equipment Levelmeter 240 Calibration Pendulum 240 for service 240 rotational tool article number 192 torques on foundation 49 U updating revolution counters 220 V validity and responsibility 17 velocity adjusting 78 ...

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Page 252: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC027400 001 Rev V en Copyright 2004 2018 ABB All rights reserved Specifications subject to change without notice ...

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