ABB IRB 140 type C Product Manual
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ABB IRB 140 type C Product Manual

Articulated robot
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Product manual
Articulated robot
IRB 140 type C
IRB 140T type C
IRB 140-6/0.8 type C
IRB 140T-6/0.8 type C
M2004

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Summary of Contents for ABB IRB 140 type C

  • Page 1 Product manual Articulated robot IRB 140 type C IRB 140T type C IRB 140-6/0.8 type C IRB 140T-6/0.8 type C M2004...
  • Page 3 Product manual IRB 140 type C IRB 140T type C IRB 140-6/0.8 type C IRB 140T-6/0.8 type C M2004 Document ID: 3HAC027400-001 Revision: C...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents Overview ................7 Product documentation, M2004 .
  • Page 6 Table of Contents 3 Maintenance 3.1 Introduction ............... 59 3.2 Maintenance schedules .
  • Page 7 Table of Contents 5 Calibration information 5.1 Introduction ..............163 5.2 Calibration methods .
  • Page 8 Table of Contents 3HAC027400-001 Revision: C...

  • Page 9: Overview

    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:...
  • Page 10 Overview Continued References Reference Document Id Product manual - IRC5 3HAC021313-001 Product specification - IRB 140 3HAC9041-1 Operating manual - IRC5 with FlexPendant 3HAC16590-1 Operating manual - Calibration Pendulum 3HAC16578-1 Operating manual - Service Information System 3HAC025709-001 Technical reference manual - RAPID Instructions, Functions and 3HAC16581-1 Data types Revisions...

  • Page 11: Product Documentation, M2004

    This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
  • Page 12 Product documentation, M2004 Continued Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals includes: • Getting started - IRC5 and RobotStudio •...

  • Page 13: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller.
  • Page 14 How to read the product manual 3HAC027400-001 Revision: C...

  • Page 15: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page •...

  • Page 16: General Safety Information

    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. Related information...

  • Page 17: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 18 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! WARNING! Take any necessary measures to ensure that the robot...

  • Page 19: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces Safe handling 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).

  • Page 20: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 1.2.2.3. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.

  • Page 21: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 22: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 23: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

  • Page 24: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot system (manipulator or controller)! 3HAC027400-001 Revision: C...

  • Page 25: Emergency Release Of The Robot's Arm

    1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: •...

  • Page 26: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as detailed below: 1.

  • Page 27: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC027400-001 Revision: C...

  • Page 28: Safe Use Of The Flexpendant

    1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

  • Page 29: Work Inside The Manipulator's Working Range

    1 Safety 1.2.3.7. Work inside the manipulator's working range 1.2.3.7. Work inside the manipulator's working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 30: Translate The Information On Safety And Information Labels

    Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 31: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 32 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.

  • Page 33: Danger - Moving Manipulators Are Potentially Lethal

    1 Safety 1.3.2. DANGER - Moving manipulators are potentially lethal! 1.3.2. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range.

  • Page 34: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.3. DANGER - First test run may cause injury or damage! 1.3.3. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):...

  • Page 35: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.4. WARNING - The unit is sensitive to ESD! 1.3.4. WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.

  • Page 36: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.5. WARNING - Safety risks during work with gearbox oil 1.3.5. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...

  • Page 37: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot. 3HAC027400-001 Revision: C...

  • Page 38: Unpacking

    2 Installation and commissioning 2.2.1. Pre-installation procedure 2.2 Unpacking 2.2.1. Pre-installation procedure General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the manipulator:...
  • Page 39 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Loads on foundation, robot The table below shows the different 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.
  • Page 40 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Protection classes The table below shows the protection class of the main parts of the robot system: Equipment Protection class Robot IP 67 Control cabinet IP 54 Programming unit IP 54 3HAC027400-001 Revision: C...

  • Page 41: Working Range, Irb 140

    2 Installation and commissioning 2.2.2. Working range, IRB 140 2.2.2. Working range, IRB 140 Working range axis 2 -3 The illustration below shows the unrestricted working range axis 2-3. xx0200000058 Position at wrist centre Angle (degrees) Axis 2 Axis 3 0°...
  • Page 42 2 Installation and commissioning 2.2.2. Working range, IRB 140 Continued Working range axis 1 The illustrations below shows the unrestricted working range of axis 1. xx0200000061 3HAC027400-001 Revision: C...

  • Page 43: Risk Of Tipping/Stability

    2 Installation and commissioning 2.2.3. Risk of tipping/Stability 2.2.3. Risk of tipping/Stability General The section below details instructions for making sure the manipulator does not tip over when it has not been safely secured to the foundation. Procedure The procedure below details how to make sure the manipulator does not tip during installation while not secured to the foundation.

  • Page 44: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting manipulator with lifting slings 2.3 On-site installation 2.3.1. Lifting manipulator with lifting slings General This section details how to lift the manipulator using lifting slings. Equipment Note Sling line Length: 2 m. Load: 500 kg. Illustration The following figures shows how to lift the manipulator with lifting slings.

  • Page 45: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. Manually releasing the brakes General The section below details how to release the holding brakes of each axis' motor. This may be done in one of three ways: • using the brake release unit when the robot is connected to the controller. •...
  • Page 46 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Using the brake release unit with an external power supply This section details how to release the holding brakes with the internal brake release unit using an external voltage supply. This is done if the robot is not connected to the controller. Action Note/Illustration Also, be careful not to interchange the...
  • Page 47 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Using External power supply This section details how to release the holding brakes using a external voltage supply. If the positions of the robot axes are to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable the brake release buttons on the robot.

  • Page 48: Orienting And Securing The Manipulator

    2 Installation and commissioning 2.3.3. Orienting and securing the manipulator 2.3.3. Orienting and securing the manipulator General This section details how to orient and secure the manipulator to the foundation in order to safely run the robot. Bolting requirements When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts.

  • Page 49: Restricting The Working Space

    2 Installation and commissioning 2.3.4. Restricting the working space 2.3.4. Restricting the working space General When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited.

  • Page 50: Fitting Equipment On Manipulator

    2 Installation and commissioning 2.3.5. Fitting equipment on manipulator 2.3.5. Fitting equipment on manipulator General The manipulator features mounting holes for additional equipment. In addition to the stock mounting holes, extra mounting holes may be added on the manipulator under certain conditions. These special conditions are specified in the Product Specification.
  • Page 51 2 Installation and commissioning 2.3.5. Fitting equipment on manipulator Continued Illustration, holes on mounting flange The illustration below shows the stock holes available for fitting equipment on the mounting flange. xx0200000063 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.

  • Page 52: Loads

    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. 3HAC027400-001 Revision: C...

  • Page 53: Suspended Mounting

    2 Installation and commissioning 2.3.7. Suspended mounting 2.3.7. Suspended mounting General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the robot in a suspended position is basically the same as for floor mounting. NOTE! With suspended installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can...
  • Page 54 2 Installation and commissioning 2.3.7. Suspended mounting Continued xx0200000066 Defining the parameter The value of the system parameter Gravity beta must be redefined when changing the mounting angle of the robot. The parameter belongs to the type Robot, in the topic Motion. How to calculate a new value is detailed in Mounting angles and values on page The parameter is further detailed in the Technical reference manual - System parameters.

  • Page 55: Bolt Pattern

    2 Installation and commissioning 2.3.8. Bolt pattern 2.3.8. Bolt pattern Hole configuration The illustration below shows the hole configuration used when securing the manipulator: xx0200000085 Continues on next page 3HAC027400-001 Revision: C...
  • Page 56 2 Installation and commissioning 2.3.8. Bolt pattern Continued Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes: xx0200000086 3HAC027400-001 Revision: C...

  • Page 57: Electrical Connections

    2 Installation and commissioning 2.4.1. Customer connections on manipulator 2.4 Electrical connections 2.4.1. Customer connections on manipulator General For connection of extra equipment on the manipulator there are cables integrated into the manipulator's cabling. There are both air and electrical connectors on the manipulator. xx0200000074 Connections Connections...
  • Page 58 Recommended parts To connect power and signal conductors to the upper arm connector, the following parts are recommended xx0200000132 ABB’s recommended contact set, for connector R2.CS (3HAC 12497-1) contains: • Multipole connector 12 pin • Adapter Tin plated 12 pin •...

  • Page 59: Making Robot Ready For Operation (Cleanroom)

    2 Installation and commissioning 2.5.1. Additional installation procedure 2.5 Making robot ready for operation, Cleanroom 2.5.1. Additional installation procedure General Cleanroom robots are specially designed to work in a cleanroom environment. Cleanroom robots are designed in order to prevent from particle emission from the robot. For example is maintenance work possible to perform without cracking the paint.
  • Page 60 2 Installation and commissioning 2.5.1. Additional installation procedure 3HAC027400-001 Revision: C...

  • Page 61: Maintenance

    3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

  • Page 62: Maintenance Schedules

    3 Maintenance 3.2.1. Maintenance schedule, IRB 140 3.2 Maintenance schedules 3.2.1. Maintenance schedule, IRB 140 General The robot, consisting of manipulator and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below.
  • Page 63 3 Maintenance 3.2.1. Maintenance schedule, IRB 140 Continued Battery type selection The table below shows the selection criteria for the three available battery types. Change interval, Change interval, Operation pattern 3-cell lithium 6-cell lithium Max. 4 weeks power off per year 60 mths 60 mths Weekend power off + operation pattern 1...

  • Page 64: Inspection Activities

    3 Maintenance 3.3.1. Inspection, damper axes 2, 3 and 5 3.3 Inspection activities 3.3.1. Inspection, damper axes 2, 3 and 5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0200000426 Damper, axis 2 xx0200000427 Damper, axis 3 Continues on next page...
  • Page 65 3 Maintenance 3.3.1. Inspection, damper axes 2, 3 and 5 Continued Required equipment Equipment Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 182, in part 2 of the Product manual. Inspection, dampers The procedure below details how to inspect the dampers. Action Note DANGER!

  • Page 66: Inspection, Robot Cabling

    3 Maintenance 3.3.2. Inspection, robot cabling 3.3.2. Inspection, robot cabling Location, robot cabling The robot cabling comprises the cabling between the robot and controller cabinet as well as the externally visible cabling around motors 1 and 2. A more detailed view of the components and its position may be found in chapter Spare part lists and exploded views on page 189, in part 2 of the product manual.

  • Page 67: Inspection, Timing Belts

    3 Maintenance 3.3.3. Inspection, timing belts 3.3.3. Inspection, timing belts Location of timing belts Axes 3, 5 and 6 are fitted with timing belts. These are located as shown in the figures below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 68 3 Maintenance 3.3.3. Inspection, timing belts Continued xx060000326 Timing belt, axis 6 Timing belt, axis 5 Required equipment Equipment, etc. Art. no. Note Standard toolkit 3HAC020812-001 The contents are defined in section Standard toolkit on page 182, in part 2 of the Product manual.
  • Page 69 3 Maintenance 3.3.3. Inspection, timing belts Continued Inspection The procedure below details how to inspect the timing belts. WARNING! Please observe the following before commencing any repair work on the manipulator: • Some parts are HOT after running the robot, e.g. motors and lights! Burns may result from touching them! •...

  • Page 70: Cleaning Activities

    3 Maintenance 3.4.1. Cleaning, complete robot 3.4 Cleaning activities 3.4.1. Cleaning, complete robot General The protection class of Foundry and Wash versions is IP 67, i.e. the robot is watertight. Required equipment Equipment, etc. Note May be used on version Foundry and Wash! •...

  • Page 71: Changing/ Replacing Activities

    3 Maintenance 3.5.1. Oil change, gearbox axes 5 and 6 3.5 Changing/ replacing activities 3.5.1. Oil change, gearbox axes 5 and 6 Location of oil plugs The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page...
  • Page 72 3 Maintenance 3.5.1. Oil change, gearbox axes 5 and 6 Continued Draining, wrist unit The procedure below details how to drain oil from the gearboxes in the wrist unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! Handling gearbox oil involves several safety risks.
  • Page 73 3 Maintenance 3.5.1. Oil change, gearbox axes 5 and 6 Continued Filling oil, wrist unit The procedure below details how to fill oil in the gearboxes in the wrist unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! Handling gearbox oil involves several safety...
  • Page 74 3 Maintenance 3.5.1. Oil change, gearbox axes 5 and 6 3HAC027400-001 Revision: C...

  • Page 75: Repair

    4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g.

  • Page 76: Complete Robot

    4 Repair 4.2.1. Replacement of cable harness 4.2 Complete robot 4.2.1. Replacement of cable harness Location of cable harness The cable harness runs from the base to the motors of axes 3-6. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 77 4 Repair 4.2.1. Replacement of cable harness Continued Removal, cable harness The procedure below details how to remove the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 78 4 Repair 4.2.1. Replacement of cable harness Continued Action Note/Illustration 3. Remove the cable holder by unscrewing its attachment screws. xx0300000091 • A: Cable holder • B: Attachment screws • C: Cable securing screws 4. Remove the cables from the See figure above! cable holder by unscrewing the cable securing screws.
  • Page 79 4 Repair 4.2.1. Replacement of cable harness Continued Action Note/Illustration 8. Disconnect connectors in the rear of the upper arm. xx0300000092 Connectors: • A: R2.CS • B: Pressurized air connection • C: R3.FB4 • D: R3.FB5 • E: R3.FB6 • F: R3.MP5 •...
  • Page 80 4 Repair 4.2.1. Replacement of cable harness Continued Action Note/Illustration 11. Disconnect the connectors inside the lower arm. xx0200000449 • G: Connectors R3.MP3 and R3.FB3 12. Pull the cables out of the upper arm. 13. Remove the cover, console. Detailed in section Replacement of cover, console on page 112.
  • Page 81 4 Repair 4.2.1. Replacement of cable harness Continued Refitting, cable harness The procedure below details how to refit the cable harness. WARNING! Please observe the following before commencing any repair work on the manipulator: • - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! •...
  • Page 82 4 Repair 4.2.1. Replacement of cable harness Continued Action Note/Illustration 3. Cable layout in the lower arm. xx0200000449 • A: Cable ties • B: Pressurized air hose • C: Power cables, axes 4, 5 and 6 • D: Customer cables, signal •...
  • Page 83 4 Repair 4.2.1. Replacement of cable harness Continued Action Note/Illustration 4. Cable holder in the upper arm. xx0300000094 Cables: • A: Customer signal • B: Signal • C: Pressurized air supply • D: Power cables 3HAC027400-001 Revision: C...

  • Page 84: Replacement Of Complete Upper Arm

    4 Repair 4.2.2. Replacement of complete upper arm 4.2.2. Replacement of complete upper arm Location of upper arm The upper arm is located on top of the manipulator as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 85 4 Repair 4.2.2. Replacement of complete upper arm Continued Required equipment Equipment Spare part no. Art. no. Note Upper arm, spare Std/F 3HAC10466-1 Standard and Foundry versions Includes all required sealings and gaskets. Upper arm, spare CR 3HAC 10466-3 Clean room versions Includes all required sealings and gaskets.
  • Page 86 4 Repair 4.2.2. Replacement of complete upper arm Continued Removal, upper arm The procedure below details how to remove the complete upper arm. Action Note 1. Run the manipulator arm to a horizontal position. 2. Remove all brackets securing any exterior cabling to the upper arm by unscrewing their attachment screws respectively.
  • Page 87 4 Repair 4.2.2. Replacement of complete upper arm Continued Action Note 9. Remove the VK-cover from the upper arm/lower Shown in the figure Location of arm joint. upper arm on page Detailed in section Removing the VK cover on page 10.
  • Page 88 4 Repair 4.2.2. Replacement of complete upper arm Continued Action Note 1. Remove the lower arm cover by unscrewing its attachment screws. 2. Tap the VK coverwith a long blunt edged bar Make sure to press the through the hole in the lower arm to press it out. circumference of the VK cover evenly to avoid damaging it.
  • Page 89 4 Repair 4.2.2. Replacement of complete upper arm Continued Action Note 11. Refit the rear cover armhousing with its four Shown in the figure Location of attachment screws. upper arm on page 12. Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively.

  • Page 90: Replacement Of Complete Lower Arm

    4 Repair 4.2.3. Replacement of complete lower arm 4.2.3. Replacement of complete lower arm Location of lower arm The lower arm is located between upper arm and frame as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 91 4 Repair 4.2.3. Replacement of complete lower arm Continued Required equipment Equipment Spare part no. Art. no. Note Lower arm, spare 3HAC 10468-1 Standard and Foundry versions Includes all required bearings, oil and VK cover. Lower arm, spare 3HAC 10468-4 Clean room versions Includes all required bearings, oil and VK...
  • Page 92 4 Repair 4.2.3. Replacement of complete lower arm Continued Action Info 2. DO NOT under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a complete rebuild! xx0300000101 Parts: •...
  • Page 93 4 Repair 4.2.3. Replacement of complete lower arm Continued Refitting, lower arm The procedure below details how to refit the complete lower arm. Action Note 1. Fit the lifting device and lift the lower arm into position. 2. Fit the lower arm to gearbox, axis 2, and secure it with its attachment screws and washers.

  • Page 94: Replacement Of Base

    4 Repair 4.2.4. Replacement of base 4.2.4. Replacement of base Location of base The base is located at the bottom of the robot as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 95 4 Repair 4.2.4. Replacement of base Continued Equipment Spare part no. Art. no. Note Locking liquid Loctite 574 For sealing the base to the gearbox 1-2. Grease 3HAB 3537-1 For lubricating the V-ring. Isopropanol For cleaning the mating surfaces. Standard toolkit The contents are defined in section Standard toolkit...
  • Page 96 4 Repair 4.2.4. Replacement of base Continued Action Note 10. Secure the weight of the base and remove the Shown in the figure Location of base gearbox/base attachment screws and washer. on page 11. Separate the base from the gearbox unit. Refitting, base The procedure below details how to refit the base to the robot.
  • Page 97 4 Repair 4.2.4. Replacement of base Continued Action Note 15. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 163. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 98: Upper Arm

    4 Repair 4.3.1. Replacement of wrist unit 4.3 Upper arm 4.3.1. Replacement of wrist unit Location of wrist unit The wrist unit is located in the frontmost part of the upper arm. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 99 4 Repair 4.3.1. Replacement of wrist unit Continued Equipment, etc. Spare part no. Art. no. Note 3HAC 9037-1 For adjusting the gear play, motor/pinion. Other tools and These procedures include procedures may be references to the tools required. required. See references to these procedures in the step-by-step...
  • Page 100 4 Repair 4.3.1. Replacement of wrist unit Continued Action Note 7. Manually push the wrist to adjust the wrist in relation to the gear in the gearbox. Minimize the gear play as shown in the figure. xx0200000445 A. Wrist unit, axes 5 and 6 gears B.

  • Page 101: Replacement Of Damper, Axis 3

    4 Repair 4.3.2. Replacement of damper, axis 3 4.3.2. Replacement of damper, axis 3 Location of damper, axis 3 The damper, axis 3, is shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 102 4 Repair 4.3.2. Replacement of damper, axis 3 Continued Removal, damper axis 3 The procedure below details how to remove the damper, axis 3. Action Note 1. Run the robot to a position that enables access to Shown in the figure Location of damper, axis 3.

  • Page 103: Replacement Of Damper, Axis 5

    4 Repair 4.3.3. Replacement of damper, axis 5 4.3.3. Replacement of damper, axis 5 Location of damper, axis 5 The damper, axis 5, is located as shown in the figure below! xx0600002806 Damper, axis 5 Recess Required equipment Equipment, etc. Spare part no.
  • Page 104 4 Repair 4.3.3. Replacement of damper, axis 5 Continued Removal, damper axis 5 The procedure below details how to remove the damper, axis 5. Action Note 1. Run the robot to a position that enables the end of the Shown in the figure Location of damper to be pushed into the recess in the wrist unit.

  • Page 105: Replacement Of Cover, Arm Housing

    4 Repair 4.3.4. Replacement of cover, arm housing 4.3.4. Replacement of cover, arm housing Location of cover, armhousing The cover, armhousing is located on the rear of the upper arm as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 106 4 Repair 4.3.4. Replacement of cover, arm housing Continued Removal The procedure below details how to remove the cover, armhousing. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...

  • Page 107: Lower Arm

    4 Repair 4.4.1. Replacement of lower arm cover and gasket 4.4 Lower arm 4.4.1. Replacement of lower arm cover and gasket Location of lower arm cover and gasket The lower arm cover and gasket are located as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page...
  • Page 108 4 Repair 4.4.1. Replacement of lower arm cover and gasket Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Cover l. arm, spare, Std/F 3HAC 10471-1 Standard and Foundry versions No lamp unit included Includes gasket 3HAC 7869-1 Cover l.
  • Page 109 4 Repair 4.4.1. Replacement of lower arm cover and gasket Continued Refitting, lower arm cover and gasket The procedure below details how to refit the lower arm cover and gasket. WARNING! Please observe the following before commencing any repair work on the manipulator: •...

  • Page 110: Replacement Of Damper, Axis 2

    4 Repair 4.4.2. Replacement of damper, axis 2 4.4.2. Replacement of damper, axis 2 Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 111 4 Repair 4.4.2. Replacement of damper, axis 2 Continued Removal, damper axis 2 The procedure below details how to remove the damper, axis 2. Action Note 1. Run the robot to a position that enables you to access the attachment screw of damper, axis 2. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

  • Page 112: Replacement Of Indicator Lamp

    4 Repair 4.4.3. Replacement of indicator lamp 4.4.3. Replacement of indicator lamp Location of indicator lamp The indicator lamp is located on the side of the lower arm as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 113 4 Repair 4.4.3. Replacement of indicator lamp Continued Removal The procedure below details how to remove the indicator lamp. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...

  • Page 114: Frame And Base

    4 Repair 4.5.1. Replacement of cover, console 4.5 Frame and base 4.5.1. Replacement of cover, console Location of cover, console The cover, console is located on top of the console as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 115 4 Repair 4.5.1. Replacement of cover, console Continued Required equipment Equipment, etc. Spare part. no. Art. no. Note Cover, console, spare 3HAC 10472-1 Standard and Foundry version Includes gasket 3HAC 7868-1 Cover, console, spare 3HAC 10472-3 Clean Room versions Includes gasket 3HAC 7868-1 Gasket, cover console 3HAC 7868-1...
  • Page 116 4 Repair 4.5.1. Replacement of cover, console Continued Refitting The procedure below details how to refit cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...

  • Page 117: Replacement Of Console

    4 Repair 4.5.2. Replacement of console 4.5.2. Replacement of console Location of console The console is located on top of gearbox, axes 1-2 as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 118 4 Repair 4.5.2. Replacement of console Continued Removal The procedure below details how to remove the cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 119 4 Repair 4.5.2. Replacement of console Continued Action Note/Illustration 7. Remove the bearing hub by unscrewing its attachment screws. xx0300000096 Parts: • A: Console • B: Bearing hub • C: Bearing hub attachment screws (6 pcs) • D: Console attachment screws (10 pcs) •...
  • Page 120 4 Repair 4.5.2. Replacement of console Continued Refitting The procedure below details how to refit cover, console. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 121 4 Repair 4.5.2. Replacement of console Continued Action Note/Illustration 7. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 163. 3HAC027400-001 Revision: C...

  • Page 122: Replacement Of Serial Measurement Unit And Battery Pack

    4 Repair 4.5.3. Replacement of serial measurement unit and battery pack 4.5.3. Replacement of serial measurement unit and battery pack Location of serial measurement unit and battery pack The serial measurement unit and battery pack are located inside the manipulator base as shown in the figure below.
  • Page 123 4 Repair 4.5.3. Replacement of serial measurement unit and battery pack Continued Equipment, etc. Spare part. no. Art. no. Note Standard Toolkit, IRB 140 3HAC020812-001 The contents are defined in section Standard toolkit on page 182, in part 2 of the Product manual.
  • Page 124 Cut the cable tie and disconnect 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. Continues on next page 3HAC027400-001 Revision: C...
  • Page 125 4 Repair 4.5.3. Replacement of serial measurement unit and battery pack Continued Refitting The procedure below details how to refit the serial measurement unit and battery pack. WARNING! Please observe the following before commencing any repair work on the manipulator: •...
  • Page 126 4 Repair 4.5.3. Replacement of serial measurement unit and battery pack Continued Action Note 6. Secure the rear cable cover to the base of the Shown in the figure Location of robot with its attachment screws. serial measurement unit and battery pack on page 120! 7.

  • Page 127: Replacement Of Control Cable

    4 Repair 4.5.4. Replacement of control cable 4.5.4. Replacement of control cable Location of control cable The control cable is located on the rear of the manipulator base as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 128 4 Repair 4.5.4. Replacement of control cable Continued Equipment, etc. Spare part. no. Art. no. Note Control cable, spare 3HAC 13089-1 30 m Standard and Foundry versions Cover gasket included Control cable, spare 3HAC 10476-4 Clean Room versions Cover gasket included Control cable, spare 3HAC 10477-2 Clean Room versions...
  • Page 129 4 Repair 4.5.4. Replacement of control cable Continued Removal The procedure below details how to remove the control cable. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...
  • Page 130 4 Repair 4.5.4. Replacement of control cable Continued Refitting The procedure below details how to refit control cable. WARNING! Please observe the following before commencing any repair work on the manipulator: • Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! •...

  • Page 131: Motors

    4 Repair 4.6.1. Replacement of motor, axis 1 4.6 Motors 4.6.1. Replacement of motor, axis 1 Location of motor axis 1 The motor axis 1 is located on the rear of the manipulator as shown in the figure below: A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 132 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art no. Note 3HAC 9037-1 For adjusting the gear play, motor/pinion Power supply 24 VDC, max. 1,5 A For releasing the brakes Other tools and These procedures include procedures may be references to the tools required.
  • Page 133 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 5. In order to release the brakes, connect the 24 VDC Connect to connector power supply: R3.MP1 • +: pin 7 • -: pin 8 6. Remove the motor by unscrewing its four attachment Shown in the figure Location screws and plain washers.
  • Page 134 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 8. Tighten the motor attachment screws. Tightening torque: approx 11 Nm ± 1 Nm 9. Disconnect the brake release voltage. 10. Make sure the cable gland gasket has not been Art.

  • Page 135: Replacement Of Motor, Axis 2

    4 Repair 4.6.2. Replacement of motor, axis 2 4.6.2. Replacement of motor, axis 2 Location of motor axis 2 The motor axis 2 is located on the front of the robot as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 136 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, 1.5 A. For releasing the brakes. Other tools and These procedures include procedures may be references to the tools required.
  • Page 137 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Action Note WARNING! Oil will be running out of the motor attachment hole when removing the motor! It may also be hot! Take any necessary measures to collect the oil. 9. Remove the motor by unscrewing its four attachment Shown in the figure Location screws and plain washers.
  • Page 138 4 Repair 4.6.2. Replacement of motor, axis 2 Continued Action Note 10. Tighten the motor attachment screws. Tightening torque: approx 11 Nm ± 1 Nm 11. Disconnect the brake release voltage. 12. Make sure the cable gland cover gasket has not been Art no.

  • Page 139: Replacement Of Motor And Timing Belt, Axis 3

    4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 4.6.3. Replacement of motor and timing belt, axis 3 Location of motor axis 3 The motor axis 3 is located behind the lower arm cover on the right hand side of the manipulator as shown in the figure below.
  • Page 140 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Rot. ac motor with 3HAC 7866-1 pinion 3HAC 021756-001 Timing belt 3HAC 6793-1 Grease 3HAB 3537-1 For lubricating the o-ring.
  • Page 141 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Continued Action Note 3. Cut the cable ties to facilitate accessing the motor. xx0200000449 • A: Cable ties • B: Pressurized air hose • C: Power cables, axes 4, 5 and 6 •...
  • Page 142 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Continued Action Note 5. DO NOT under any circumstance unscrew the three screws securing the belt wheel! Doing so will cause the manipulator to require a complete rebuild! xx0300000102 Parts: •...
  • Page 143 4 Repair 4.6.3. Replacement of motor and timing belt, axis 3 Continued Action Note 5. Adjust the position of the motor in such a Correct belt tension F=35 - 60 N way that the correct belt tension is achieved. 6. DO NOT adjust the belt tension using the intermediate wheel securing screws.

  • Page 144: Replacement Of Motor, Axis 4

    4 Repair 4.6.4. Replacement of motor, axis 4 4.6.4. Replacement of motor, axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. A more detailed view of the components and its position may be found in section Spare part lists and exploded views on page 189, in part 2 of the product manual...
  • Page 145 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instructions below.

  • Page 146: Location Of Motor

    4 Repair 4.6.4. Replacement of motor, axis 4 Continued Refitting, motor axis 4 The procedure below details how to refit the motor, axis 4. Action Note 1. Clean the mating surfaces on the motor and the Shown in the figure Location of motor gearbox.

  • Page 147: A More Detailed View Of The Components And Its Position May Be Found In Section Lists And Exploded Views On Page

    4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Location of motor and timing belt, axes 5 or 6 The motor and timing belt axes 5 or 6 are located in the rear of the upper arm as shown in the figure below.

  • Page 148: Art. No

    4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Continued Attachment screws, motor console Timing belt, axis 6 Pulley, axis 6 Timing belt, axis 5 Pulley, axis 5 Motor console, ax. 5-6 Motor, axis 4 Motor, axis 5 Motor, axis 6 Required equipment Equipment, etc.
  • Page 149 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Continued Removal The procedure below details how to remove motor, axis 5 or 6. WARNING! Please observe the following before commencing any repair work on the manipulator: •...
  • Page 150 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Continued Action Note 9. Remove the cable guide by unscrewing its Shown in the figure in section Location two attachment screws. of motor and timing belt, axes 5 or 6 on page 145! 10.
  • Page 151 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Continued Action Note 5. Tighten the motor attachment screws to This will facilitate adjustment of the enable the motor to be shifted slightly. belt tension. 6. Adjust the belt tension using a suitable tool Correct belt tension: axis 5, 25 - 50 N and axis 6, 20 - 40 N 7.
  • Page 152 4 Repair 4.6.5. Replacement of motor and timing belt, axes 5 or 6 Continued Action Note 19. Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively. 20. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 153: 24 Vdc, Max. 1,5 A

    4 Repair 4.6.6.1. Measuring the gear play, axis 5 4.6.6. Adjustments and measurements 4.6.6.1. Measuring the gear play, axis 5 General After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed below.
  • Page 154 4 Repair 4.6.6.1. Measuring the gear play, axis 5 Continued Measurement The procedure below details how to measure the gear play for axis 5. Action Note 1. Manually, turn axis 4 90°. 2. Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure.

  • Page 155: Measuring The Gear Play, Axis 6

    4 Repair 4.6.6.2. Measuring the gear play, axis 6 4.6.6.2. Measuring the gear play, axis 6 General After reassembly due to repair work or any other reason, the gear play must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed below.
  • Page 156 4 Repair 4.6.6.2. Measuring the gear play, axis 6 Continued Measurement The procedure below details how to measure the gear play for axis 6. Action Note 1. Manually, turn axis 4 90°. 2. Fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure.

  • Page 157: Gearboxes

    4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 4.7 Gearboxes 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Location of gearbox unit, axes 1-2 The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that both gearboxes, 1 and 2, are a single unit! The damper, axis 1, is shown in the figure in the procedure! A more detailed view of the components and its position may be found in section...
  • Page 158 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Continued Equipment Spare part no. Art. no. Note Locking liquid Loctite 574 Sealing ring 3HAC 6965-1 Replace only when damaged! Lifting slings Standard toolkit The contents are defined in section Standard toolkit on page 182, in part 2 of the Product...
  • Page 159 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Continued Removal, gearbox unit axes 1-2 The procedure below details how to remove the complete gearbox unit, axes 1-2. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 160 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Continued Removal of damper, axis 1 The procedure below details how to remove the damper, axis 1. Action Note 1. Open the base of the robot. Detailed in section Removal, gearbox unit axes 1-2 on page 157.
  • Page 161 4 Repair 4.7.1. Replacement of gearbox, axes 1-2 and damper, axis 1 Continued Action Note 9. Secure the base to the foundation Attachment bolts and the tightening torque are specified in section Attachment screws on page 46 10. Refit the lower arm. Detailed in section Refitting of complete lower...

  • Page 162: Service Work On Gearbox, Axis 4

    4 Repair 4.7.2. Service work on gearbox, axis 4 4.7.2. 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.

  • Page 163: Amount Of Oil

    4 Repair 4.7.3. Amount of oil 4.7.3. Amount of oil Overview When a part is replaced or repaired it is offen nessecary to add oil into the gearboxes. Type and amount of oil in gearboxes Gearbox Type of oil Art. no. Amount Axis 1 Mobilgear 600 XP320...
  • Page 164 4 Repair 4.7.3. Amount of oil 3HAC027400-001 Revision: C...

  • Page 165: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 164, and further detailed in separate Calibration manuals.

  • Page 166: Calibration Methods

    5 Calibration information 5.2. Calibration methods 5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of Description Calibration method calibration Standard The calibrated robot is positioned at home...
  • Page 167 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

  • Page 168: Calibration Scales And Correct Axis Position

    5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales, IRB 140 The illustration below shows the calibration scale positions on IRB 140: xx0200000157 3HAC027400-001 Revision: C...

  • Page 169: Calibration Movement Directions For All Axes

    5 Calibration information 5.4. Calibration movement directions for all axes 5.4. Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.

  • Page 170: Updating Revolution Counters

    5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using the pendant. Step 1 - Manually running the robot to the calibration position This procedure details the first step when updating the revolution counter;...
  • Page 171 This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
  • Page 172 5 Calibration information 5.5. Updating revolution counters Continued Action CAUTION! If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See section Checking the calibration position on page 171.

  • Page 173: Checking The Calibration Position

    This section describes how to create a program, which runs all the robot axes to their zero position. Action Note 1. On ABB menu tap Program Editor. 2. Create a new program. 3. Use MoveAbsJ in the Motion&Proc menu. 4. Create the following program: MoveAbsJ...
  • Page 174 5 Calibration information 5.6. Checking the calibration position 3HAC027400-001 Revision: C...

  • Page 175: Robot Description

    6 Robot description 6.1. Type C of IRB 140 6 Robot description 6.1. Type C of IRB 140 Type C- new upper arm and wrist Type C of IRB 140 have a new upper arm, complete and a new wrist unit. As a result of this, the following parts differ from earlier versions: •...
  • Page 176 6 Robot description 6.1. Type C of IRB 140 3HAC027400-001 Revision: C...

  • Page 177: Reference Information

    7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in Product manual (part 1 of 2), procedures. 3HAC027400-001 Revision: C...

  • Page 178: Unit Conversion

    7 Reference information 7.2. Unit conversion 7.2. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 179: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
  • Page 180 7 Reference information 7.3. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
  • Page 181 7 Reference information 7.3. Screw joints Continued The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque Dimension Nm - Nominal Nm - Min.

  • Page 182: Weight Specifications

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

  • Page 183: Document References

    7 Reference information 7.5. Document references 7.5. Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentation. Product specification, robot The product specification includes generic technical data. The specification listed below is the English version.

  • Page 184: Standard Toolkit

    7 Reference information 7.6. Standard toolkit 7.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

  • Page 185: Special Tools

    7 Reference information 7.7. Special tools 7.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 182, and of special tools, listed directly in the instructions and also gathered in this section.

  • Page 186: Performing A Leak-Down Test

    7 Reference information 7.8. Performing a leak-down test 7.8. Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.

  • Page 187: Lifting Equipment And Lifting Instructions

    7 Reference information 7.9. Lifting equipment and lifting instructions 7.9. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

  • Page 188: Mounting Instructions For Bearings

    7 Reference information 7.10. Mounting instructions for bearings 7.10. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to grease the bearings, if not specified otherwise.

  • Page 189: Mounting Instructions For Seals

    7 Reference information 7.11. Mounting instructions for seals 7.11. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 190 If the flange surfaces are defective, the parts may not be used because leakage could occur. 2. Clean the surfaces properly and in accordance with ABB recommendations. 3. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 191: Spare Part Lists And Exploded Views

    8 Spare part lists and exploded views 8.1. Introduction 8 Spare part lists and exploded views 8.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC027400-001 Revision: C...

  • Page 192: Spare Parts - Robot Irb 140

    8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 8.2. Spare parts - robot IRB 140 Robot IRB 140, spare parts list The items specified below are shown in the figures Robot IRB 140, exploded view 1 of 5 on page 194 Robot IRB 140, exploded view 5 of 5 on page 198.
  • Page 193 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Item Art. no. Name Rem. 3HAC 11331-1 Control cable spare Std/F L = 15 m 3HAC 11331-2 Control cable spare CR L = 15 m 3HAC 13089-1 Control cable spare Std/F L = 30 m...
  • Page 194 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Item Art. no. Name Rem. 3HAC 7880-1 Damper axis 2 3HAA 2356-14 Washer SRKB 6.4x18x1.6 3HAB 3402-15 Hex. socket head cap screw M5x20 8.8 Gleitmo 610 9ADA 312-5 Plain washer 5.3x10x1...
  • Page 195 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Item Art. no. Name Rem. 550 ml 3HAC 0860-1 Lubricating oil Optimol Optigear BM 3HAC 026581-003 Upper arm, spare CR 3HAC 026569-003 3HAC 10439-3 Cover armhousing, spare CR 3HAC 11922-1 Slip strip Continues on next page...
  • Page 196 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 1 of 5 xx0600003264 Continues on next page 3HAC027400-001 Revision: C...
  • Page 197 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 2 of 5 xx0600003265 Continues on next page 3HAC027400-001 Revision: C...
  • Page 198 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 3 of 5 xx0600003266 Continues on next page 3HAC027400-001 Revision: C...
  • Page 199 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 4 of 5 xx0600003267 Continues on next page 3HAC027400-001 Revision: C...
  • Page 200 8 Spare part lists and exploded views 8.2. Spare parts - robot IRB 140 Continued Robot IRB 140, exploded view 5 of 5 xx0600003268 3HAC027400-001 Revision: C...

  • Page 201: Circuit Diagram

    9 Circuit diagram 9.1. Introduction 9 Circuit diagram 9.1. Introduction Overview This chapter includes the circuit diagram for the robot. 3HAC027400-001 Revision: C...
  • Page 202 9 Circuit diagram 9.1. Introduction 3HAC027400-001 Revision: C...
  • Page 203 Circuit Diagram CONTENTS Page Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............101-108 IRB 140...
  • Page 204 Manipulator Circuit Diagram 3HAC 6816-3 LIST OF CONTENTS IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 205 Manipulator Circuit Diagram 3HAC 6816-3 CONNECTION POINT LOCATIONS IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 206 Manipulator Circuit Diagram 3HAC 6816-3 SERIAL MEASUREMENT BOARD IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 207 Manipulator Circuit Diagram 3HAC 6816-3 MOTOR AXIS 1 - 3 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 208 Manipulator Circuit Diagram 3HAC 6816-3 FEEDBACK AXIS 1 - 3 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 209 Manipulator Circuit Diagram 3HAC 6816-3 MOTOR AXIS 4 - 6 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 210 Manipulator Circuit Diagram 3HAC 6816-3 FEED-BACK AXIS 4 - 6 IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 211 Manipulator Circuit Diagram 3HAC 6816-3 CUSTOMER CONNECTIONS IRB 140 Sheet no. N o . o f S h e e t s 8...
  • Page 212 Index documentation article numbers, other manuals 181 Absolute Accuracy, calibration 165 calibration 181 controller 181 robot system 181 base brake release buttons 43 replacing 92 screws, tightening torque 94 damage elimination 33 spare part number 92 sensitive equipment 33 brake release unit wrist strap connection point 33 releasing the brakes 43 explanation, safety symbols 29...
  • Page 213 Index oil change Validity and responsibility 14 gearbox axes 5 and 6 69 VK-covers, spare part number safety risks 34 at base 92 wrist unit 69 operators manual, article number 181 wall mounting 51 weight position, robot 166 gearbox unit 157 when draining wrist unit 70 wrist unit when filling oil in wrist unit 71...
  • Page 215 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 140t type cIrb 140-6/0.8 type cIrb 140t-6/0.8 type c

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