ABB IRB 140 User manual

ABB Robotics
Product manual
IRB 140

Trace back information:
Workspace R13-1 version a7
Checked in 2013-04-02
Skribenta version 1184

Product manual
IRB 140 type C
IRB 140T type C
IRB 140-6/0.8 type C
IRB 140T-6/0.8 type C
M2004
Document ID: 3HAC027400-001
Revision: K
© Copyright 2004-2013 ABB. All rights reserved.

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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2004-2013 ABB. All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation, M2004 .......................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 Introduction to safety information ......................................................................... 161.2 General safety information .................................................................................. 161.2.1 Introduction to general safety information .................................................... 171.2.2 Safety in the manipulator system ............................................................... 181.2.3 Safety risks ............................................................................................ 181.2.3.1 Safety risks during installation and service work on manipulators ......... 211.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 221.2.3.3 Safety risks related to tools/work pieces .......................................... 231.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 241.2.3.5 Safety risks during operational disturbances ..................................... 251.2.3.6 Risks associated with live electric parts ........................................... 271.2.4 Safety actions ......................................................................................... 271.2.4.1 Safety fence dimensions ............................................................... 281.2.4.2 Fire extinguishing ........................................................................ 291.2.4.3 Emergency release of the manipulator’s arm .................................... 301.2.4.4 Brake testing .............................................................................. 311.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 321.2.4.6 Safe use of the FlexPendant .......................................................... 331.2.4.7 Work inside the manipulator's working range ................................... 341.2.5 Safety stops ........................................................................................... 341.2.5.1 What is an emergency stop? .......................................................... 361.3 Safety related instructions .................................................................................. 361.3.1 Safety signals in the manual ...................................................................... 381.3.2 Safety symbols on manipulator labels ......................................................... 431.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 441.3.4 DANGER - First test run may cause injury or damage! ................................... 451.3.5 DANGER - Make sure that the main power has been switched off! .................... 471.3.6 WARNING - The unit is sensitive to ESD! ..................................................... 491.3.7 WARNING - Safety risks during handling of batteries ..................................... 501.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
532 Installation and commissioning
532.1 Introduction ...................................................................................................... 542.2 Unpacking ....................................................................................................... 542.2.1 Pre-installation procedure ......................................................................... 582.2.2 Working range, IRB 140 ........................................................................... 602.2.3 Risk of tipping/stability ............................................................................. 612.3 On-site installation ............................................................................................ 612.3.1 Lifting the manipulator with lifting slings ...................................................... 622.3.2 Lifting and turning the manipulator ............................................................. 632.3.3 Manually releasing the brakes ................................................................... 662.3.4 Orienting and securing the manipulator ....................................................... 672.3.5 Fitting equipment on manipulator .............................................................. 692.3.6 Loads .................................................................................................... 702.3.7 Setting the system parameters for a suspended robot .................................... 722.3.8 Bolt pattern ............................................................................................ 742.3.9 Installation of signal lamp (option) .............................................................. 752.4 Restricting the working range .............................................................................. 752.4.1 Restricting the working range .................................................................... 762.5 Electrical connections ........................................................................................ 762.5.1 Customer connections on manipulator .......................................................
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Table of contents

793 Maintenance
793.1 Introduction ...................................................................................................... 803.2 Maintenance schedules ...................................................................................... 803.2.1 Specification of maintenance intervals ........................................................ 813.2.2 Maintenance schedule ............................................................................. 833.3 Inspection activities ........................................................................................... 833.3.1 Inspection, damper axes 2, 3 and 5 ............................................................. 853.3.2 Inspection, robot cabling .......................................................................... 863.3.3 Inspection, timing belts ............................................................................ 893.4 Cleaning activities ............................................................................................. 893.4.1 Cleaning, robot ...................................................................................... 913.5 Changing/ replacing activities .............................................................................. 913.5.1 Type of lubrication in gearboxes ................................................................ 923.5.2 Changing the oil in axes 5 and 6 gearboxes .................................................
954 Repair
954.1 Introduction ...................................................................................................... 964.2 General procedures ........................................................................................... 964.2.1 Mounting instructions for bearings ............................................................. 984.2.2 Mounting instructions for seals .................................................................. 1004.2.3 Replacing parts on Clean Room robots ....................................................... 1024.3 Complete robot ................................................................................................. 1024.3.1 Replacement of cable harness ................................................................... 1104.3.2 Replacement of complete upper arm .......................................................... 1164.3.3 Replacement of complete lower arm ........................................................... 1204.3.4 Replacement of base ............................................................................... 1244.4 Upper arm ....................................................................................................... 1244.4.1 Replacement of wrist unit ......................................................................... 1284.4.2 Replacing the damper, axis 3 ..................................................................... 1304.4.3 Replacement of damper, axis 5 .................................................................. 1324.4.4 Replacement of cover, arm housing ............................................................ 1354.5 Lower arm ....................................................................................................... 1354.5.1 Replacement of lower arm cover and gasket ................................................ 1394.5.2 Replacing the damper, axis 2 ..................................................................... 1414.6 Frame and base ................................................................................................ 1414.6.1 Replacement of cover, console .................................................................. 1444.6.2 Replacement of console ........................................................................... 1484.6.3 Replacing the serial measurement unit and the battery pack ........................... 1544.6.4 Replacement of control cable .................................................................... 1584.7 Motors ............................................................................................................ 1584.7.1 Replacement of motor, axis 1 ................................................................... 1624.7.2 Replacement of motor, axis 2 .................................................................... 1664.7.3 Replacement of motor and timing belt, axis 3 ............................................... 1724.7.4 Replacement of motor, axis 4 .................................................................... 1764.7.5 Replacement of motor and timing belt, axes 5 or 6 ........................................ 1824.7.6 Adjustments and measurements ................................................................ 1824.7.6.1 Measuring the gear play, axis 5 ...................................................... 1844.7.6.2 Measuring the gear play, axis 6 ...................................................... 1864.8 Gearboxes ....................................................................................................... 1864.8.1 Replacement of gearbox, axes 1-2 and damper, axis 1 ................................... 1924.8.2 Service work on gearbox, axis 4 ................................................................. 1934.8.3 Amount of oil .........................................................................................
1955 Calibration information
1955.1 Introduction ..................................................................................................... 1965.2 Calibration methods ........................................................................................... 1985.3 Calibration scale and correct axis position ............................................................. 1995.4 Calibration movement directions for all axes ..........................................................
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Table of contents

2005.5 Updating revolution counters ............................................................................... 2025.6 Checking the calibration position ..........................................................................
2036 Decommissioning
2036.1 Environmental information ..................................................................................
2057 Robot description
2057.1 Type C of IRB 140 .............................................................................................
2078 Reference information
2078.1 Introduction ...................................................................................................... 2088.2 Applicable safety standards ................................................................................ 2108.3 Unit conversion ................................................................................................. 2118.4 Screw joints .................................................................................................... 2148.5 Weight specifications ......................................................................................... 2158.6 Standard tools .................................................................................................. 2168.7 Special tools .................................................................................................... 2178.8 Performing a leak-down test ............................................................................... 2188.9 Lifting accessories and lifting instructions ..............................................................
2199 Spare part lists
2199.1 Introduction ...................................................................................................... 2209.2 Spare parts - robot IRB 140 .................................................................................
22910 Circuit diagram
22910.1 About circuit diagrams .......................................................................................
231Index
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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
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
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
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
Continues on next page
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Overview of this manual

ContentsChapter
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
3HAC021313-001Product manual - IRC5
3HAC041346-001Product specification - IRB 140
3HAC16590-1Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC025709-001Operating manual - Service Information System
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC16581-1Technical reference manual - RAPID Instructions, Functions and
Data types
3HAC030421-001Application manual - CalibWare Field 5.0
Revisions
DescriptionRevision
First edition, see also Type C of IRB 140 on page 205.-
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, Cleanroom ,Additional installa-
tion procedure.
C
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 110,Replacement of complete lower
arm on page 116,Replacement of gearbox, axes 1-2 and damper,
axis 1 on page 186, and Type C of IRB 140 on page 205.
E
Continues on next page
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Overview of this manual
Continued