ABB IRB 140 User manual

ROBOTICS
Product manual
IRB 140

Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012

Product manual
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.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2004-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
14Product documentation ....................................................................................................................
16How to read the product manual ......................................................................................................
171 Safety
171.1 General safety information ..................................................................................
171.1.1 Limitation of liability .................................................................................
191.1.2 Protective stop and emergency stop ...........................................................
201.2 Safety actions ...................................................................................................
201.2.1 Fire extinguishing ....................................................................................
211.2.2 Emergency release of the robot axes ..........................................................
221.2.3 Make sure that the main power has been switched off ....................................
231.3 Safety risks ......................................................................................................
231.3.1 Safety risks during installation and service work on robots ..............................
251.3.2 Moving robots are potentially lethal ............................................................
261.3.3 First test run may cause injury or damage ....................................................
271.3.4 Work inside the working range of the robot ..................................................
281.3.5 Enabling device and hold-to-run functionality ...............................................
291.3.6 Risks associated with live electric parts .......................................................
311.3.7 The unit is sensitive to ESD .......................................................................
321.3.8 Hot parts may cause burns .......................................................................
331.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
341.3.10 Brake testing ..........................................................................................
351.3.11 Safety risks during handling of batteries ......................................................
361.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
381.4 Safety signals and symbols .................................................................................
381.4.1 Safety signals in the manual ......................................................................
401.4.2 Safety symbols on product labels ...............................................................
472 Installation and commissioning
472.1 Introduction ......................................................................................................
482.2 Unpacking .......................................................................................................
482.2.1 Pre-installation procedure .........................................................................
522.2.2 Working range, IRB 140 ............................................................................
542.2.3 Risk of tipping/stability .............................................................................
552.3 On-site installation ............................................................................................
552.3.1 Lifting the manipulator with lifting slings ......................................................
562.3.2 Lifting and turning the manipulator ............................................................
592.3.3 Manually releasing the brakes ...................................................................
622.3.4 Orienting and securing the manipulator .......................................................
632.3.5 Fitting equipment on manipulator ...............................................................
652.3.6 Loads ....................................................................................................
662.3.7 Setting the system parameters for a suspended or tilted robot .........................
712.3.8 Bolt pattern ............................................................................................
732.3.9 Installation of signal lamp (option) ..............................................................
742.4 Restricting the working range ..............................................................................
742.4.1 Restricting the working range ....................................................................
752.5 Electrical connections ........................................................................................
752.5.1 Grounding and bonding point on manipulator ...............................................
762.5.2 Customer connections on manipulator ........................................................
782.6 Start of robot in cold environments ......................................................................
793 Maintenance
793.1 Introduction ......................................................................................................
803.2 Maintenance schedules ......................................................................................
803.2.1 Specification of maintenance intervals ........................................................
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Table of contents

813.2.2 Maintenance schedule .............................................................................
833.3 Inspection activities ...........................................................................................
833.3.1 Inspection, damper axes 2, 3 and 5 .............................................................
853.3.2 Inspecting the robot cabling .....................................................................
863.3.3 Inspection, timing belts ............................................................................
893.3.4 Inspecting oil level gearbox axis 1 ..............................................................
923.3.5 Inspecting oil level gearbox axis 2 ..............................................................
953.3.6 Inspecting oil level gearbox axis 3 ..............................................................
983.3.7 Inspecting oil level gearbox axis 4 ..............................................................
1013.3.8 Inspecting oil level gearbox axes 5-6 ...........................................................
1043.3.9 Inspecting information labels .....................................................................
1063.4 Cleaning activities .............................................................................................
1063.4.1 Cleaning the IRB 140 type C ......................................................................
1093.5 Changing/ replacing activities ..............................................................................
1093.5.1 Type of lubrication in gearboxes ................................................................
1103.5.2 Changing the oil in axes 5 and 6 gearboxes .................................................
1134 Repair
1134.1 Introduction ......................................................................................................
1144.2 General procedures ...........................................................................................
1144.2.1 Mounting instructions for bearings .............................................................
1164.2.2 Mounting instructions for seals ..................................................................
1184.2.3 Cut the paint or surface on the robot before replacing parts ............................
1204.3 Complete robot .................................................................................................
1204.3.1 Replacement of cable harness ...................................................................
1284.3.2 Replacement of complete upper arm ...........................................................
1344.3.3 Replacement of complete lower arm ...........................................................
1384.3.4 Replacement of base ...............................................................................
1424.4 Upper arm .......................................................................................................
1424.4.1 Replacing the wrist unit, IRB 1600 ..............................................................
1464.4.2 Replacing the damper, axis 3 .....................................................................
1484.4.3 Replacement of damper, axis 5 ..................................................................
1504.4.4 Replacement of cover, arm housing ............................................................
1534.5 Lower arm .......................................................................................................
1534.5.1 Replacement of lower arm cover and gasket ................................................
1574.5.2 Replacing the damper, axis 2 .....................................................................
1594.6 Frame and base ................................................................................................
1594.6.1 Replacement of cover, console ..................................................................
1624.6.2 Replacement of console ...........................................................................
1674.6.3 Replacing the serial measurement unit and the battery pack ...........................
1734.6.4 Replacement of control cable ....................................................................
1774.7 Motors ............................................................................................................
1774.7.1 Replacement of motor, axis 1 ....................................................................
1814.7.2 Replacement of motor, axis 2 ....................................................................
1864.7.3 Replacement of motor and timing belt, axis 3 ...............................................
1924.7.4 Replacement of motor, axis 4, IRB 1600 ......................................................
1974.7.5 Replacement of motor and timing belt, axes 5 or 6 ........................................
2034.7.6 Adjustments and measurements ................................................................
2034.7.6.1 Measuring the gear play, axis 5 ......................................................
2054.7.6.2 Measuring the gear play, axis 6 ......................................................
2074.8 Gearboxes .......................................................................................................
2074.8.1 Replacement of gearbox, axes 1-2 and damper, axis 1 ...................................
2134.8.2 Service work on gearbox, axis 4 .................................................................
2155 Calibration information
2155.1 When to calibrate .............................................................................................
2165.2 Calibration methods ...........................................................................................
2185.3 Synchronization marks and synchronization position for axes ...................................
2195.4 Calibration movement directions for all axes ..........................................................
6 Product manual - IRB 140
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© Copyright 2004-2018 ABB. All rights reserved.
Table of contents

2205.5 Updating revolution counters ...............................................................................
2245.6 Checking the synchronization position ..................................................................
2256 Decommissioning
2256.1 Environmental information ..................................................................................
2276.2 Scrapping of robot .............................................................................................
2297 Robot description
2297.1 Type C of IRB 140 .............................................................................................
2318 Reference information
2318.1 Introduction ......................................................................................................
2328.2 Applicable standards .........................................................................................
2348.3 Unit conversion .................................................................................................
2358.4 Screw joints ....................................................................................................
2388.5 Weight specifications .........................................................................................
2398.6 Standard tools ..................................................................................................
2408.7 Special tools ....................................................................................................
2418.8 Performing a leak-down test ................................................................................
2428.9 Lifting accessories and lifting instructions ..............................................................
2439 Spare part lists
2439.1 Spare part lists and illustrations ...........................................................................
24510 Circuit diagram
24510.1 Circuit diagrams ................................................................................................
247Index
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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the IRB 140 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:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on robot. Contains general
safety aspects as well as more specific information about how
to avoid personal injuries and damage to the product.
Safety, service
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used in the work of planning periodical maintenance.
Maintenance
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Continues on next page
Product manual - IRB 140 9
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Overview of this manual

ContentsChapter
Procedures that does not require specific calibration equipment.
General information about calibration.
Calibration information
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional
documents, safety standards, etc.
Reference information
Complete spare part list and complete list of robot components,
shown in exploded views.
Spare parts and exploded
views
References to the circuit diagrams for the robot.Circuit diagram
References
Document IDReference
3HAC6816-3Circuit diagram - IRB 140 type C
3HAC031045-001Operating manual - General safety information i
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC041346-001Product specification - IRB 140
3HAC049099-001Product manual, spare parts - IRB 140
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050917-001Technical reference manual - RAPID Instructions, Functions and
Data types
3HAC030421-001Application manual - CalibWare Field 5.0
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition, see also Type C of IRB 140 on page 229.-
IRB 140-6/0.8 and IRB 140T-6/0.8 added.A
Clean Room added.B
Changes made in:
•Prerequisites in section Overview
•Oil change in section Maintenance
Content updated in section:
•Making robot ready for operation, Clean room ,Additional install-
ation procedure.
C
Continues on next page
10 Product manual - IRB 140
3HAC027400-001 Revision: V
© Copyright 2004-2018 ABB. All rights reserved.
Overview of this manual
Continued