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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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 ..........................................................
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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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Table of contents

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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
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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
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Overview of this manual
Continued

DescriptionRevision
Content updated in section:
•Repair, exchange of parts on Clean room robots
•Maintenance, Cleaning of robot
•Maintenance schedule: Interval for replacement of battery pack
changed.
• Section What is an emergency stop? added to chapter Safety.
D
Content updated in sections:
• Article numbers added or replaced in sections Replacement of
complete upper arm on page 128,Replacement of complete lower
arm on page 134,Replacement of gearbox, axes 1-2 and damper,
axis 1 on page 207, and Type C of IRB 140 on page 229.
E
Content updated in sections:
• Required equipment updated in Replacement of motor and timing
belt, axis 3 on page 186.
• Spare part list updated regarding Foundry Plus cable guard and
new wrist.
• Circuit diagrams are not included in this document but delivered
as separate files. See Circuit diagram on page 245.
• List of standards updated, see Applicable standards on page 232.
•Sealing compound updated in Cut the paint or surface on the robot
before replacing parts on page 118.
• Decommissioning chapter added.
The chapter Safety updated with:
•Updated safety signal graphics 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 following updates:
• Corrected amount of oil in axes 3, 5, and 6, see Amount of oil.
• Updates in chapter Calibration.
G
This revision includes the following updates:
• Corrected article number for VK cover, see Replacement of com-
plete upper arm on page 128 and Replacement of motor and timing
belt, axes 5 or 6 on page 197.
H
This revision includes the following updates:
• A new block, about general illustrations, added in section How to
read the product manual on page 16.
• The option Foundry Plus Cable Guard is removed.
• Some general tightening torques have been changed/added, see
updated values in Screw joints on page 235.
• The figure of the base is updated in concerned sections.
• Added Safety risks during handling of batteries on page 35.
J
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Continued

DescriptionRevision
This revision includes the following updates:
• Information regarding disassembly of Clean Room robots added
to concerned repair instructions.
•Changed the instruction for how to fit the o-ring of the axis-4 motor
when refitting the motor, see Replacement of motor, axis 4, IRB
1600 on page 192.
• Added figures that show an alternative layout inside the base, see
Replacing the serial measurement unit and the battery pack on
page 167.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of
oil in gearboxes on page 109.
• Corrected article number for battery pack.
• A new SMB unit and battery is introduced, with longer battery
lifetime.
K
This revision includes the following updates:
•Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 227.
•Spare parts and exploded views are not included in this document
but delivered as a separate document. See Spare part lists Product
manual, spare parts - IRB 140.
L
This revision includes the following updates:
• Minor corrections.
M
This revision includes the following updates:
• Updated section 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 turning the manipulator on page 56.
• Section Amount of oil is removed from the manual, since the data
has been moved to the separate lubrication manual, see Type and
amount of oil in gearboxes on page 109.
Q
Published in release R17.1. The following updates are done in this revi-
sion:
• Added a procedure for how inspect the oil level, see Inspection
activities on page 83.
R
Published in release R17.2. The following updates are made in this revi-
sion:
• Information about coupled axes in Updating revolution counters
on page 220.
• Information about minimum resonance frequency added.
• Updated list of applicable standards.
• Updated inspection of oil level.
• Information about grounding point added, see Grounding and
bonding point on manipulator on page 75.
• Section Start of robot in cold environments on page 78 added.
S
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Continued

DescriptionRevision
Published in release R18.1. The following updates are made in this revi-
sion:
• Added sections in General procedures on page 114
• Safety section restructured.
• Information about myABB Business Portal 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
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Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•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 manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and 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/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual

1 Safety
1.1 General safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried 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 responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
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1 Safety
1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is 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
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB, it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength of the robot could
be affected.
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1 Safety
1.1.1 Limitation of liability
Continued

1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.1.2 Protective stop and emergency stop

1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator or controller.
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1 Safety
1.2.1 Fire extinguishing