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ABB IRB 140 Product Manual
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ABB IRB 140 Product Manual

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Summary of Contents for ABB IRB 140

  • Page 1 ROBOTICS Product manual IRB 140...
  • Page 2 Trace back information: Workspace R18-2 version a18 Checked in 2018-11-20 Skribenta version 5.3.012...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    2.5.2 Customer connections on manipulator ............Start of robot in cold environments ..............Maintenance Introduction ...................... Maintenance schedules ..................3.2.1 Specification of maintenance intervals ............Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 6 Inspecting oil level gearbox axes 5-6 ............3.3.9 Inspecting information labels ..............Cleaning activities ..................... 3.4.1 Cleaning the IRB 140 type C ..............Changing/ replacing activities ................3.5.1 Type of lubrication in gearboxes ..............3.5.2 Changing the oil in axes 5 and 6 gearboxes ..........
  • Page 7 Updating revolution counters ................Checking the synchronization position ..............Decommissioning Environmental information .................. Scrapping of robot ..................... Robot description Type C of IRB 140 ..................... Reference information Introduction ...................... Applicable standards ..................Unit conversion ....................Screw joints ....................Weight specifications ..................
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    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.
  • Page 10 Circuit diagram References to the circuit diagrams for the robot. References Reference Document ID Circuit diagram - IRB 140 type C 3HAC6816-3 Operating manual - General safety information 3HAC031045-001 Product manual - IRC5 3HAC021313-001 IRC5 with main computer DSQC 639.
  • Page 11 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. Content updated in sections: • Required equipment updated in Replacement of motor and timing belt, axis 3 on page 186.
  • Page 12 227. • 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. This revision includes the following updates: • Minor corrections. This revision includes the following updates: •...
  • Page 13 Added section for inspection of labels in maintenance chapter. Published in release R18.2. The following updates are made in this revi- sion: • Reference updated. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 14: Product Documentation

    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.
  • Page 15 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. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 16: How To Read The Product Manual

    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. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 17: Safety

    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.
  • Page 18 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.

  • Page 19: Protective Stop And Emergency Stop

    1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 20: Safety Actions

    1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 21: Emergency Release Of The Robot Axes

    When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 22: Make Sure That The Main Power Has Been Switched Off

    To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 23: Safety Risks

    Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 24 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

  • Page 25: Moving Robots Are Potentially Lethal

    The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 26: First Test Run May Cause Injury Or Damage

    If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 27: Work Inside The Working Range Of The Robot

    Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 28: Enabling Device And Hold-To-Run Functionality

    How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 29: Risks Associated With Live Electric Parts

    The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 30 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 31: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 32: Hot Parts May Cause Burns

    Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 33: Safety Risks Related To Pneumatic/Hydraulic Systems

    Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 34: Brake Testing

    3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 35: Safety Risks During Handling Of Batteries

    Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 36: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    Possible pressure build-up in gearbox Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 37 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 38: Safety Signals And Symbols

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 39 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 40: Safety Symbols On Product Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 41 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 42 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 43 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 44 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 45 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 46 This page is intentionally left blank...

  • Page 47: Installation And Commissioning

    Safety on page 17 before performing any installation work. Note If the IRB 140 type C is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: •...

  • Page 48: Unpacking

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 49 The robot installation is restricted to the mounting options given in following load table(s). Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ± 1020 N ± 2000 N Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 50 25 Hz. The robot should be mounted as rigid as possibly to the floor. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 51 Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 Manipulator, protection type Clean Room IP 67 Manipulator, protection type Wash IP 67 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 52: Working Range, Irb 140

    0° 1092 0° -90° 0° +50° +110° -90° -119 +110° +4° -480 -90° -150° -90° +50° +110° -230° -670 -90° -90° Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 53 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 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 54: Risk Of Tipping/Stability

    Do not change the robot position before securing it to the foundation! WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 55: On-Site Installation

    2 Put one sling line around each leg on the lower arm (positions 1 and 2). 3 Use another sling line to secure the lifting of the control cable (position 3). Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 56: Lifting And Turning The Manipulator

    WARNING The robot will tip forward when lifting it off the ground. xx1600000347 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 57 Loosen the robot from the foundation. CAUTION The IRB 140 type C robot weighs 100 kg. All lifting accessories used must be sized accord- ingly! Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V ©...
  • Page 58 Secure the robot at its working site on the wall or inverted according to Orienting and securing the manipulator on page Reinstall the axis-2 damper, if removed. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 59: Manually Releasing The Brakes

    Release the holding brakes by pushing the brake re- lease button. The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 60 A: B16 24V DC • B: B14 0V Push the brake release button to release the holding brakes, according to the previous procedure. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 61 B: 15 24V DC Locate the R1.MP4-6 connector and discon- nect. Connect an external power supply to re- lease the holding brake on all axis. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 62: Orienting And Securing The Manipulator

    Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re-adjusting the program. Equipment Art. no. Guide sleeves 3HAC 9519-1 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 63: Fitting Equipment On Manipulator

    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 - IRB 140. Note All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts.
  • Page 64 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. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 65: Loads

    Operating manual - IRC5 with FlexPendant. Brake performance Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 66: Setting The System Parameters For A Suspended Or Tilted Robot

    If the robot is mounted on a wall (rotated around the x-axis), then the robot base frame and the system parameter Gravity Alpha must be redefined. The value of Gravity Alpha should then be ±π/2 (±1.570796). Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 67 The system parameter Gravity Alpha is not supported for all robot types. It is not supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R, IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB 6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).
  • Page 68 2.3.7 Setting the system parameters for a suspended or tilted robot Continued Examples of mounting angles tilted around the Y axis (Gravity Beta) xx0200000066 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 69 90° (Wall) 1.570796 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 70 The system parameters are described in Technical reference manual - System parameters. The system parameters are redefined in the Configuration Editor, in RobotStudio or on the FlexPendant. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 71: Bolt Pattern

    Ø 25H8 (2x) Ø 25H8 (2x) Ø 0,25 Ø 0,25 Ø13 Ø 0,6 Ø 0, B - B B - B xx0200000085 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 72 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 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 73: Installation Of Signal Lamp (Option)

    2 Installation and commissioning 2.3.9 Installation of signal lamp (option) 2.3.9 Installation of signal lamp (option) Signal lamp See the assembly instruction delivered with the signal lamp. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 74: Restricting The Working Range

    Technical reference manual - System parameters. Limiting devices Examples of limiting devices are listed below. 1 Light curtains. 2 Tread mats. 3 Other similar devices. 4 Software. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 75: Electrical Connections

    There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1700000974 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 76: Customer Connections On Manipulator

    R1/4" Max. 8 bar/hose inner diameter: 6.5 mm Signal connector on upper arm FCI UT 071412SH44N connector Number of signals: 12 signals, 49V, 500mA Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 77 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 78: Start Of Robot In Cold Environments

    If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 79: Maintenance

    Note If the IRB 140 type C is connected to power, always make sure that the IRB 140 type C is connected to protective earth before starting any maintenance work. For more information see: •...

  • Page 80: Maintenance Schedules

    Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 140 type C: • Calendar time: specified in months regardless of whether the system is running or not.

  • Page 81: Maintenance Schedule

    Replacing the serial measurement alert measurement unit and the system of type battery pack on page 167 RMU101 or RMU102 (3-pole battery contact) Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 82 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 83: Inspection Activities

    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 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 84 Replacing the damper, axis 2 on page 157 • Replacing the damper, axis 3 on page 146 • Replacement of damper, axis 5 on page 148. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 85: Inspecting The Robot Cabling

    Look for abrasions, cuts or crush damages. Replace the cabling if wear or damage is detected. This is detailed in section Replace- ment of cable harness on page 120. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 86: Inspection, Timing Belts

    A more detailed view of the components and its position may be found in chapter Spare part lists on page 243. xx0200000448 Timing belt, axis 3 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 87 These procedures include references to may be required. See refer- the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 88 Belt tension adjustment is detailed in sections Replacement of motor and timing belt, axis 3 on page 186 Replacement of motor and timing belt, axes 5 or 6 on page 197. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 89: Inspecting Oil Level Gearbox Axis 1

    Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 90 The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let out the ex- cess pressure. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 91 118. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 92: Inspecting Oil Level Gearbox Axis 2

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 93 The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let out the ex- cess pressure. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 94 118. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 95: Inspecting Oil Level Gearbox Axis 3

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 96 The upper edge of the oil plug hole Oil level Add oil if required. See Technical reference manual - Lubric- ation in gearboxes Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 97 118. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 98: Inspecting Oil Level Gearbox Axis 4

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 99 The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let out the ex- cess pressure. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 100 118. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 101: Inspecting Oil Level Gearbox Axes

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 102 The lower edge of the oil plug hole Oil Level Add oil if required. See Technical reference manual - Lubric- ation in gearboxes Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 103 118. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 104: Inspecting Information Labels

    Information sign - AbsAcc Label - battery Required equipment Equipment Spare part number Note Labels Spare part lists on page 243. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 105 Check all labels. See the figure in Location of information labels on page 104. Replace any missing or damaged labels. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 106: Cleaning Activities

    General To secure high uptime it is important that the IRB 140 type C is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 140 type C.
  • Page 107 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
  • Page 108 3 Maintenance 3.4.1 Cleaning the IRB 140 type C Continued Cables Movable cables need to be able to move freely: • Remove waste material, such as sand, dust and chips, if it prevents cable movement. • Clean the cables if they have a crusty surface, for example from dry release agents.

  • Page 109: Changing/ Replacing Activities

    Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.

  • Page 110: Changing The Oil In Axes 5 And 6 Gearboxes

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 111 Both oil plugs must be removed in order to drain plugs on page 110. the wrist unit properly. Refit the oil plug, vent hole. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 112 Fill oil in the wrist unit through the oil plug. xx0500001435 • A: Oil plug, draining and filling The position for an inverted robot is the opposite. Refit the oil plug. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 113: Repair

    Safety on page 17 before commencing any service work. Note If the IRB 140 type C is connected to power, always make sure that the IRB 140 type C is connected to earth before starting any repair work. For more information see: •...

  • Page 114: General Procedures

    Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 115 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 116: Mounting Instructions For Seals

    Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 117 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

  • Page 118: Cut The Paint Or Surface On The Robot Before Replacing Parts

    Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 119 Clean Room. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 120: Complete Robot

    Circuit diagram 3HAC 6816-3 See chapter Circuit dia- gram on page 245. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 121 Disconnect connectors in the ma- nipulator base. xx0300000090 Connectors: • A: R1.MP1-3 • B: R1.CS • C: Air hose • D: R1.MP4-6 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 122 153. Gently knock out the VK cover. Detailed in section Removing the VK cover on page 131. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 123 Remove the shield by unscrewing See figure above! its attachment screws. Cut any cable ties securing the cabling inside the lower arm. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 124 R3.FB2 Gently pull the cabling from the base up through the console. Gently pull the cabling out of the lower arm. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 125 • C: Customer signal • D: Power cable, axes 4-6 • E: Pressurized air supply • F: Power cable, axes 1-3 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 126 • E: Signal cables, axes 4, 5 and 6 • F: Signal cable, axis 3 • G: Connectors R3.MP3 and R3.FB3 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 127 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 128: Replacement Of Complete Upper Arm

    Attachment screws, cover armhousing, (4 pcs) CS-connector Pressurized air connector VK cover Cable guide Attachment screws, cable guide Attachment screws, upper arm (6 pcs) Sealing ring Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 129 Run the manipulator arm to a horizontal position. Remove all brackets securing any exterior cabling to the upper arm by unscrewing their attachment screws respectively. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 130 Shown in the figure Location of ment screws. upper arm on page 128! Lift the upper arm and place it on a secure surface. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 131 If the VK cover is damaged, it must be replaced Specified in section Replacement of on refitting. complete upper arm on page 128. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 132 128! Refit any brackets securing any exterior cabling to the upper arm with their attachment screws respectively. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 133 • special attention is paid to the function of the part that has been serviced. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 134: Replacement Of Complete Lower Arm

    Spare part no. Art. no. Note Lower arm, spare 3HAC034935-001 Standard and Foundry versions Includes all required bearings, oil and VK cov- Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 135 118. Remove the console. Detailed in section Replacement of console on page 162. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 136 118 Fit the lifting device and lift the lower arm into position. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 137 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General Calibration information is included in section, Calibration information on page 215 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 138: Replacement Of Base

    Base, spare For spare part Clean room versions. number, see: Includes parallel pin 3HAC • Spare part 3785-2. lists on page 243. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 139 Replacement of motor, axis 2 on page 181 Remove the cable harness. Detailed in section Replacement of cable harness on page 120. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 140: Product Manual - Irb

    Refit the bottom plate and secure it with its at- Shown in the figure Location of base tachment screws. on page 138. Turn the robot to stand upright. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 141 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 142: Upper Arm

    3HAC 10475-1! Wrist unit (CR) 3HAC 026569-003 Clean room versions O-ring sealing plate not in- cluded! Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 143 Remove the wrist unit by unscrewing its Shown in the figure in section Location three attachment screws. of wrist unit on page 142. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 144 B Drive shafts from motors, axes 5 and 6 gears C Adjustment direction D Gear play Tighten the wrist unit attachment screws. Tightening torque: 28 Nm. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 145 These are further detailed in the section First test run may cause injury or dam- age on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 146: Replacing The Damper, Axis

    Run the robot to a position where it is best Shown in the figure Location of damper, to enable access to the access 3 damper. axis 3 on page 146. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 147 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 148: Replacement Of Damper, Axis

    Shown in the figure Location of the damper to be pushed into the recess in the wrist damper, axis 5 on page 148. unit. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 149 Make sure all safety requirements are met when perform- ing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 150: Replacement Of Cover, Arm Housing

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 151 Clean the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 118 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 152 Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 153: Lower Arm

    A more detailed view of the components and its position may be found in section Spare part lists on page 243. xx0200000433 Lower arm Gasket lower-arm cover Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 154 Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, for example secure the lower arm with fixtures if removing motor, axis 2. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 155 Refit the lower arm cover with its attachment screws. Shown in the figure Location of lower arm cover and gasket on page 153. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 156 Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 157: Replacing The Damper, Axis

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 158 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 159: Frame And Base

    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 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 160 159. Remove the cover, console by unscrewing its attach- NOTE! Do not damage the gas- ment screws. ket inside the cover! Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 161 Cut the paint or surface on the robot before replacing parts on page 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 162: Replacement Of Console

    See refer- clude references to the ences to these procedures tools required. in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 163 167. Remove the complete upper Detailed in section Replacement of complete upper arm arm. on page 128. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 164 D: Console attachment screws (10 pcs) • E: Washers (10 pcs) Remove the console by un- Shown in the figure above! screwing its attachment screws. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 165 128. Refit motor 3 and timing belt. Detailed in section Replacement of motor and timing belt, axis 3 on page 186. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 166 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 215. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 167: Replacing The Serial Measurement Unit And The Battery Pack

    (different layouts are shown). DSQC 633A xx1200000831 Battery pack with 2-pole battery contact Serial measurement board (SMB), DSQC 633A SMB attachment screws (2 pcs) Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 168 See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram See chapter Circuit diagram on page 245. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 169 Set the robot system to MOTORS OFF state. This will simplify calibration of the robot after replacement since no coarse calibration will be required. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 170 Battery includes protection circuits. Replace it only with the specified spare part in the refitting instruction or with an ABB approved eqvivalent. Refitting The procedure below details how to refit the serial measurement unit and battery pack.
  • Page 171 Secure the rear cable cover to the base of the robot Shown in the figure Location of with its attachment screws. serial measurement unit and bat- tery pack on page 167! Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 172 Calibration is detailed in a separ- ate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 215. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 173: Replacement Of Control Cable

    Standard and Foundry versions Cover gasket included Control cable, spare 3HAC 13090-1 22 m Standard and Foundry versions Cover gasket included Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 174 Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, for example secure the lower arm with fixtures if removing motor, axis 2. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 175 Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, for example secure the lower arm with fixtures if removing motor, axis 2. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 176 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 177: Motors

    Standard toolkit 3HAC020812-001 Content is defined in section Stand- ard tools on page 239. 3HAC9037-1 For adjusting the gear play, motor/pin- Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 178 1 on page 177. Detailed in section Replacement of cover, console on page 159. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 179 In order to release the brake, connect the 24 VDC Connect to connector R2.MP1 power supply: • +: pin 7 • -: pin 8 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 180 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in section Calibration in- formation on page 215. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 181: Replacement Of Motor, Axis 2

    239. Rotation tool, motor 3HAC9037-1 For adjusting the gear play, motor/pinion Power supply 24 VDC, 1.5 A. For releasing the brakes. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 182 The procedure below details how to remove the axis 2 motor. Action Note Decide which calibration routine to use, and take ac- tions accordingly prior to beginning the repair proced- ure. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 183 Disconnect the brake release voltage. Remove any remaining oil from the gearbox by siphon- ing it off. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 184 Performing a leak-down test on page 241. Refill the gearbox with oil. See, Technical reference manu- al - Lubrication in gearboxes. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 185 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 186: Replacement Of Motor And Timing Belt, Axis

    Attachment screws, lower arm cover (13 pcs) Belt shield Motor 3 Attachment screws, belt shield (3 pcs) Attachment screws, motor 3 (4 pcs) Belt Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 187 Remove the lower arm cover by un- Shown in the figure in section Location of motor screwing its attachment screws. axis 3 on page 186. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 188 Disconnect motor connectors. Connectors: • R3.MP3 • R3.FB3 • R3.H1 (if Safety lamp is fitted) • R3.H2 (if Safety lamp is fitted) Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 189 118 Make sure the mating surfaces on the motor and the lower arm are clean and free from burrs. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 190 • E: Signal cables, axes 4, 5 and 6 • F: Signal cable, axis 3 • G: Connectors R3.MP3 and R3.FB3 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 191 Calibration is detailed in a separate calibra- tion manual enclosed with the calibration tools. General calibration information is included in section Calibration information on page 215. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 192: Replacement Of Motor, Axis 4, Irb 1600

    239. Power supply 24 VDC, max. 1,5 A. For releasing the brakes. Rotation tool, motor 3HAC9037-1 For adjusting the gear play. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 193 The procedure below details how to remove the motor, axis 4. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 194 118 Clean the mating surfaces on the motor and Shown in the figure Location of motor the gearbox. on page 192. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 195 118 Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 196 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 197: Replacement Of Motor And Timing Belt, Axes 5 Or

    Attachment screws, cover armhousing (4 pcs) VK cover Pressurized air hose (on front of upper arm) CS connector Cable guide Attachment screws, cable guide Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 198 Circuit diagram 3HAC6816-3 See chapter Circuit dia- gram on page 245. Sonic Tension Meter Model 505C Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 199 5 or 6 on the upper arm assembly. page 197! Art. no. specified in section Required equipment on page 198 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 200 2. Note Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 201 Reconnect any connector to the CS-connect- Shown in the figure in section Location of motor and timing belt, axes 5 or 6 on page 197! Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 202 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is in- cluded in section Calibration informa- tion on page 215. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 203: Adjustments And Measurements

    Measurement The procedure below details how to measure the gear play for axis 5. Action Note Manually, turn axis 4 90°. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 204 Calculate the gear play value. Gear play value = value 1 - value 2 Determine whether or not the OK < 0.18 mm (4.1 arc minutes) value is OK. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 205: Measuring The Gear Play, Axis

    Measurement The procedure below details how to measure the gear play for axis 6. Action Note Manually, turn axis 4 90°. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 206 Calculate the gear play value. Gear play value = value 1 - value 2 Determine whether or not the OK < 0.30 mm (10.3 arc minutes) value is OK. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 207: Gearboxes

    Sealing ring 3HAC6965-1 Replace only when damaged! Lifting slings Standard toolkit Content is defined in section Standard tools on page 239. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 208 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 209 Fit the lifting slings to the base/gearbox unit and place it with the lower arm side downwards, on top of a suitable workbench. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 210 Clean the joints that have been opened. Cut the paint or surface on the robot before replacing parts on page 118 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 211 - Calibration Pendulum, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 215. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 212 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 213: Service Work On Gearbox, Axis

    If it requires replacement, the complete upper arm is to be replaced. This procedure is detailed in section Replacement of complete upper arm on page 128. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 214 This page is intentionally left blank...

  • Page 215: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

  • Page 216: Calibration Methods

    Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V ©...
  • Page 217 Levelmeter calibration - alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.

  • Page 218: Synchronization Marks And Synchronization Position For Axes

    This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 140 The illustration below shows the calibration scale positions on the robot. xx0200000157 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 219: Calibration Movement Directions For All Axes

    Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 220: Updating Revolution Counters

    Synchronization marks and synchron- ization marks. ization position for axes on page 218. IRB 140, 1400, 2400, 4400, 6600ID/6650ID, 6640ID: Axes 5 and 6 must be positioned together! When all axes are positioned, update the Step 2 - Updating the revolution counter revolution counter.
  • Page 221 Step 2 - Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 222 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 223 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 224. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 224: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 218 date the revolution counters. Updating revolution counters on page 220. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 225: Decommissioning

    Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 226 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 227: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
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  • Page 229: Robot Description

    7.1 Type C of IRB 140 Type C new upper arm and wrist Type C of IRB 140 has a new upper arm, complete and a new wrist unit. As a result of this, the following parts differ from earlier versions: •...
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  • Page 231: Reference Information

    8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 232: Applicable Standards

    Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 233 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 234: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 235: 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 236 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 237 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 238: Weight Specifications

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

  • Page 239: Standard Tools

    Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier T-handle with ball head Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 240: Special Tools

    The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 241: Performing A Leak-Down Test

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 242: Lifting Accessories And Lifting Instructions

    This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 243: Spare Part Lists

    Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
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  • Page 245: Circuit Diagram

    Circuit diagram - Spot welding cabinet 3HAC057185-001 Robots Product Article numbers for circuit diagrams Circuit diagram - IRB 120 3HAC031408-003 Circuit diagram - IRB 140 type C 3HAC6816-3 Circuit diagram - IRB 260 3HAC025611-001 Circuit diagram - IRB 360 3HAC028647-009 Circuit diagram - IRB 460...
  • Page 246 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - Product.ProductName 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.

  • Page 247: Index

    225 disposal, 225 height cleaning, 106 installed at a height, 23 climbing on robot, 23 hold-to-run, 28 Cold environments, 78 HRA, 18 connection humidity Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 248 36 oil change, 36 wrist unit, 110 operational disturbance, 23 operating conditions, 51 pneumatic system, 33 service work, 23 voltage, 29 pedestal safety signals Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 249 Gravity Alpha, 67 replacing, 142 Gravity Beta, 66 screws, tightening torque, 144 spare part number, 142 temperatures operation, 51 zero position storage, 51 checking, 224 testing Product manual - IRB 140 3HAC027400-001 Revision: V © Copyright 2004-2018 ABB. All rights reserved.
  • Page 252 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2004-2018 ABB. All rights reserved. Specifications subject to change without notice.

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