1. DL manuals
  2. ABB
  3. Robotics
  4. IRB 140
  5. Product Manual

ABB IRB 140 Product Manual - Overview Of This Manual

Manual is about: IRB 140 series type C

Summary of IRB 140

  • Page 1

    Abb robotics product manual irb 140

  • Page 2

    Trace back information: workspace r13-1 version a7 checked in 2013-04-02 skribenta version 1184.

  • 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: k © copyright 2004-2013 abb. All rights reserved..

  • 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...

  • Page 5: Table Of Contents

    Table of contents 9 overview of this manual ................................................................................................................... 12 product documentation, m2004 ....................................................................................................... 14 h...

  • Page 6

    79 3 maintenance 79 3.1 introduction ...................................................................................................... 80 3.2 maintenance schedules ...................................................................................... 80 3.2.1 specification of maintenance interv...

  • Page 7

    200 5.5 updating revolution counters ............................................................................... 202 5.6 checking the calibration position .......................................................................... 203 6 decommissioning 203 6.1 environmental information .............

  • Page 8

    This page is intentionally left blank.

  • Page 9: Overview Of This Manual

    Overview of this manual about this manual this manual contains instructions for: • mechanical and electrical installation of the robot • maintenance of the robot • mechanical and electrical repair of the robot. Usage this manual should be used during: • installation, from lifting the robot to its wo...

  • Page 10

    Contents chapter complete spare part list and complete list of robot components, shown in exploded views. Spare parts and exploded views references to the circuit diagrams for the robot. Circuit diagram references document id reference 3hac6816-3 circuit diagram - irb 140 type c 3hac021313-001 produ...

  • Page 11

    Description revision content updated in sections: • required equipment updated in replacement of motor and timing belt, axis 3 on page 166 . • spare part list updated regarding foundry plus cable guard and new wrist. • circuit diagrams are not included in this document but delivered as separate file...

  • Page 12

    Product documentation, m2004 categories for manipulator documentation the manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be orde...

  • Page 13

    An application manual generally contains information about: • the purpose of the application (what it does and when it is useful). • what is included (for example cables, i/o boards, rapid instructions, system parameters, dvd with pc software). • how to install included or required hardware. • how t...

  • Page 14

    How to read the product manual reading the procedures the procedures contain references to figures, tools, material, and so on. The references are read as described below. References to figures the procedures often include references to components or attachment points located on the manipulator/cont...

  • Page 15: 1 Safety

    1 safety 1.1 introduction to safety information overview the safety information in this manual is divided into 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 general safety i...

  • Page 16

    1.2 general safety information 1.2.1 introduction to general safety information definitions this section details general safety information for personnel performing installation, repair and maintenance work. Sections the general safety information is divided into the following sections. Containing c...

  • Page 17

    1.2.2 safety in the manipulator system validity and responsibility 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. To protect personnel, the complete system must be des...

  • Page 18

    1.2.3 safety risks 1.2.3.1 safety risks during installation and service work on manipulators overview this section includes information on general safety risks to be considered when performing installation and service work on the manipulator. These safety instructions have to be read and followed by...

  • Page 19

    • the axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving manipulator parts, there is a risk of being crushed by the parallel arm (if there is one). • energy stored in the manipulator for the purpose of counterbalancing certain axes ...

  • Page 20

    Cabling description safety risk caution the cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Cable packs are sensitive to mechanical damage! Gearboxes and motors description safety risk caution whenever partin...

  • Page 21

    1.2.3.2 caution - hot parts may cause burns! Description during normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity. Because of a higher environment temperat...

  • Page 22

    1.2.3.3 safety risks related to tools/work pieces 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). Safe design grippers/e...

  • Page 23

    1.2.3.4 safety risks related to pneumatic/hydraulic systems general special safety regulations apply to pneumatic and hydraulic systems. Note all components that remain pressurized after separating the machine from the power supply must be provided with clearly visible drain facilities and a warning...

  • Page 24

    1.2.3.5 safety risks during operational disturbances general • the industrial manipulator is a flexible tool that can be used in many different industrial applications. • all work must be carried out professionally and in accordance with the applicable safety regulations. • care must be taken at all...

  • Page 25

    1.2.3.6 risks associated with live electric parts voltage related risks, general work on the electrical equipment of the manipulator must be performed by a qualified electrician in accordance with electrical regulations. • although troubleshooting may, on occasion, need to be carried out while the p...

  • Page 26

    Voltage related risks, manipulator a danger of high voltage is associated with the manipulator in: • the power supply for the motors (up to 800 vdc). • the user connections for tools or other parts of the installation (max. 230 vac). See chapter installation and commissioning on page 53 . Voltage re...

  • Page 27

    1.2.4 safety actions 1.2.4.1 safety fence dimensions general install a safety cell around the manipulator to ensure safe manipulator installation and operation. Dimensioning dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the manipulator is d...

  • Page 28

    1.2.4.2 fire extinguishing note use a carbon dioxide (co 2 ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 28 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights reserved. 1 safety 1.2.4.2 fire extinguishing.

  • Page 29

    1.2.4.3 emergency release of the manipulator’s arm description in an emergency situation, any of the manipulator's axes may be released manually by pushing the brake release buttons on the manipulator. How to release the brakes is detailed in the section: • manually releasing the brakes on page 63 ....

  • Page 30

    1.2.4.4 brake testing when to test during operation, the holding brake of each axis normally wears down. A test can 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 described below: 1 run ea...

  • Page 31

    1.2.4.5 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: k 31 © copyright 2004-2013 abb. All rights reser...

  • Page 32

    1.2.4.6 safe use of the flexpendant enabling device the enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are sto...

  • Page 33

    1.2.4.7 work inside the manipulator's working range warning if work must be carried out within the manipulator’s work area, 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 operational and to bloc...

  • Page 34

    1.2.5 safety stops 1.2.5.1 what is an emergency stop? Definition of emergency stop an emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts, and disconnects power from any potentially dangerous functions co...

  • Page 35

    Classification of stops the safety standards that regulate automation and manipulator equipment define categories in which each type of stop applies: ... Then it is classified as... If the stop is... Category 0 (zero) uncontrolled category 1 controlled emergency stop devices in a manipulator system ...

  • Page 36

    1.3 safety related instructions 1.3.1 safety signals in the manual introduction to safety signals this section specifies all dangers that can arise when doing the work described in this manual. Each danger consists of: • a caption specifying the danger level (danger, warning, or caution) and the typ...

  • Page 37

    Significance designation symbol describes important facts and conditions. Note xx0100000004 describes where to find additional information or how to do an operation in an easier way. Tip xx0100000098 3hac027400-001 revision: k 37 © copyright 2004-2013 abb. All rights reserved. 1 safety 1.3.1 safety ...

  • Page 38

    1.3.2 safety symbols on manipulator labels introduction to labels this section describes safety symbols used on labels (stickers) on the manipulator. Symbols are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain...

  • Page 39

    Description symbol see user documentation xx0900000813 read user documentation for details. Which manual to read is defined by the symbol: • no text: product manual. • eps: application manual - electronic position switches. Before dismantling see product manual xx0900000816 do not dismantle xx090000...

  • Page 40

    Description symbol crush xx0900000817 risk of crush injuries. Heat xx0900000818 risk of heat that can cause burns. Moving robot xx0900000819 the robot can move unexpectedly. Xx1000001141 brake release buttons xx0900000820 xx1000001140 continues on next page 40 3hac027400-001 revision: k © copyright ...

  • Page 41

    Description symbol lifting bolt xx0900000821 chain sling with shortener xx1000001242 lifting of robot xx0900000822 oil xx0900000823 can be used in combination with prohibition if oil is not allowed. Mechanical stop xx0900000824 no mechanical stop xx1000001144 stored energy xx0900000825 warns that th...

  • Page 42

    Description symbol pressure xx0900000826 warns that this part is pressurized. Usually contains additional text with the pressure level. Shut off with handle xx0900000827 use the power switch on the controller. 42 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights reserved. 1 safety 1.3...

  • Page 43

    1.3.3 danger - moving manipulators are potentially lethal! Description any moving manipulator is a potentially lethal machine. When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any ...

  • Page 44

    1.3.4 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 tes...

  • Page 45

    1.3.5 danger - make sure that the main power has been switched off! Description working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these dangers, do not proceed working before eliminating the...

  • Page 46

    Elimination, dual cabinet controller note/illustration action xx0600002783 switch off the main switch on the drive module. 1 k: main switch, drive module a: main switch, control module switch off the main switch on the control module. 2 46 3hac027400-001 revision: k © copyright 2004-2013 abb. All ri...

  • Page 47

    1.3.6 warning - the unit is sensitive to esd! Description esd (electrostatic 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...

  • Page 48

    Panel mounted controller xx0600003249 panel mounted control module a panel mounted drive module b wrist strap button note! When not used, the wrist strap must always be attached to the wrist strap button. C 48 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights reserved. 1 safety 1.3.6 ...

  • Page 49

    1.3.7 warning - safety risks during handling of batteries description under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact. There is a risk of exposure only...

  • Page 50

    1.3.8 warning - safety risks during work with gearbox lubricants (oil or grease) description when handling gearbox lubricants, there is a risk of both personal injury and product damage occurring. The following safety information must be regarded before performing any work with lubricants in the gea...

  • Page 51

    Elimination/action description warning make sure not to overfill the gearbox when filling it with oil or grease! Overfilling of gearbox lubricant can lead to internal over-pres- sure inside the gearbox which in turn may: • damage seals and gas- kets • completely press out seals and gaskets • prevent...

  • Page 52

    This page is intentionally left blank.

  • Page 53

    2 installation and commissioning 2.1 introduction general this chapter contains information for installing the irb 140 type c at the working site. More detailed technical data can be found in the product specification for the irb 140 type c, such as: • load diagram • permitted extra loads (equipment...

  • Page 54

    2.2 unpacking 2.2.1 pre-installation procedure introduction this section is 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 installation craftsmen ...

  • Page 55

    Loads on foundation, robot the illustration shows the directions of the robots stress forces. The directions are valid for all floor mounted and suspended robots. Xy xy z z t f f t xx1100000521 force in any direction in the xy plane f xy force in the z plane f z bending torque in any direction in th...

  • Page 56

    Max. Load (emergency stop) endurance load (in operation) force ± 1710 nm ± 1020 nm torque xy ± 485 nm ± 250 nm torque z suspended max. Load (emergency stop) endurance load (in operation) force ± 2000 n ± 1020 n force xy + 1000 ± 1250 n + 1000 ± 620 n force z ± 1500 nm ± 700 nm torque xy ± 470 nm ± 2...

  • Page 57

    Value parameter 95% at constant temperature maximum ambient humidity protection classes, robot the table shows the protection class of the robot: protection class equipment ip 67 manipulator, protection type standard ip 67 manipulator, protection type foundry plus ip 67 manipulator, protection type ...

  • Page 58

    2.2.2 working range, irb 140 working range axis 2 -3 the illustration below shows the unrestricted working range axis 2-3. Xx0200000058 angle (degrees) position at wrist centre pos. Axis 3 axis 2 z x 0° 0° 712 450 0 -90° 0° 1092 70 1 +50° 0° 421 314 2 -90° +110° 99 765 3 +4° +110° -119 255 4 -150° -...

  • Page 59

    Working range axis 1 the illustrations below shows the unrestricted working range of axis 1. Xx0200000061 3hac027400-001 revision: k 59 © copyright 2004-2013 abb. All rights reserved. 2 installation and commissioning 2.2.2 working range, irb 140 continued.

  • Page 60

    2.2.3 risk of tipping/stability risk of tipping if the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over. The shipping position is the most stable p...

  • Page 61

    2.3 on-site installation 2.3.1 lifting the manipulator with lifting slings introduction this section details how to lift the manipulator using lifting slings. Note equipment length: 2 m. Load: 500 kg. Sling line for manipulator sling line for control cable illustration xx0200000084 sling line for ma...

  • Page 62

    2.3.2 lifting and turning the manipulator recommendation use lifting slings to lift the manipulator. See lifting the manipulator with lifting slings on page 61 . For more information contact abb. 62 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights reserved. 2 installation and commiss...

  • Page 63

    2.3.3 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. • using the brake release unit when the robot is disconnec...

  • Page 64

    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. Note action also, be careful not to interchange the 2...

  • Page 65

    Using external power supply this section details how to release the holding brakes using an 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 t...

  • Page 66

    2.3.4 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 ...

  • Page 67

    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 68

    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...

  • Page 69

    2.3.6 loads introduction any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of the center of gravity and inertia factor) to avoid jolting movements and overloading the motors. If this is not done correctly operation stops can occur. References l...

  • Page 70

    2.3.7 setting the system parameters for a suspended robot 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...

  • Page 71

    Xx0200000066 defining the parameter in the software 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 72

    2.3.8 bolt pattern hole configuration the illustration below shows the hole configuration used when securing the manipulator: Ø 25h8 (2x) 80 Ø13 155 a b d b b - b 3 9 1 8 0 1 8 0 x Ø 0,25 y Ø 25h8 (2x) 80 Ø13 155 a d b b b - b 3 9 1 8 0 1 8 0 x Ø 0,25 y z d xx0200000085 continues on next page 72 3ha...

  • Page 73

    Cross section, guide sleeve hole the illustration below shows the cross section of the guide sleeve holes: xx0200000086 3hac027400-001 revision: k 73 © copyright 2004-2013 abb. All rights reserved. 2 installation and commissioning 2.3.8 bolt pattern continued.

  • Page 74

    2.3.9 installation of signal lamp (option) note do not use the signal lamp in a clean room environment. Signal lamp see the assembly instruction delivered with the signal lamp. 74 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights reserved. 2 installation and commissioning 2.3.9 instal...

  • Page 75

    2.4 restricting the working range 2.4.1 restricting the working range introduction when installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it can collide with other objects, its working space should be limited. Warning the working s...

  • Page 76

    2.5 electrical connections 2.5.1 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 description connecti...

  • 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 • pins for cable area 0.25-0.5 mm...

  • Page 78

    This page is intentionally left blank.

  • Page 79: 3 Maintenance

    3 maintenance 3.1 introduction structure of this chapter this chapter describes all the maintenance activities recommended for the irb 140 type c. It is based on the maintenance schedule found at the beginning of the chapter. The schedule contains information about required maintenance activities in...

  • Page 80

    3.2 maintenance schedules 3.2.1 specification of maintenance intervals 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 wheth...

  • Page 81

    3.2.2 maintenance schedule general the robot, consisting of robot and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below. Non-predictable situations also give rise to inspections of the r...

  • Page 82

    Ii the battery low alert (38213 battery charge low) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced. See the replacement instruction for more details. Iii the ...

  • Page 83

    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 a xx0200000427 damper, axis 3 a continues on next page 3hac027400-001 revision: k 83 © copyright 2004-2013 abb. A...

  • Page 84

    Required equipment note art. No. Equipment content is defined in section standard tools on page 215 . - standard toolkit inspection, dampers the procedure below details how to inspect the dampers. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure sup...

  • Page 85

    3.3.2 inspection, robot cabling introduction caution always read the specific instructions for clean room robots before doing any repair work, see replacing parts on clean room robots on page 100 location, robot cabling the robot cabling comprises the cabling between the robot and controller cabinet...

  • Page 86

    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 chapter spare part lists on page 219 . Xx0200000448 timing belt, axis 3 g con...

  • Page 87

    Xx0600003261 timing belt, axis 6 r timing belt, axis 5 u required equipment note art. No. Equipment, etc. Content is defined in section standard tools on page 215 . 3hac020812-001 standard toolkit these procedures include references to the tools required. Other tools and procedures may be required. ...

  • Page 88

    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! • turn off all electrical powe...

  • Page 89

    3.4 cleaning activities 3.4.1 cleaning, robot warning turn off all electrical power supplies to the manipulator before entering its work space. General to secure high uptime it is important that the robot is cleaned regularly. The frequency of cleaning depends on the environment in which the robot w...

  • Page 90

    Cleaning with water and steam cleaning methods that can be used for abb robots with protection standard, foundry plus, wash and foundry prime. Note equipment, etc. Vacuum cleaner cloth with mild detergent • max. Water pressure at the nozzle: 700 kn/m 2 (7 bar) i • fan jet nozzle should be used, min....

  • Page 91

    3.5 changing/ replacing activities 3.5.1 type of lubrication in gearboxes introduction this section describes where to find information about the type of lubrication, article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubric...

  • Page 92

    3.5.2 changing the oil in axes 5 and 6 gearboxes 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 chapter spare part lists on page 219 . Xx0600002846 oil plug, drai...

  • Page 93

    Draining, wrist unit the procedure below details how to drain oil from the gearboxes in the wrist unit. Note/illustration action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 warning handling gea...

  • Page 94

    Filling oil, wrist unit the procedure below details how to fill oil in the gearboxes in the wrist unit. Note/illustration action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 warning handling gea...

  • Page 95: 4 Repair

    4 repair 4.1 introduction structure of this chapter this chapter describes all repair activities recommended for the irb 140 type c and any external unit. It is made up of separate procedures, each describing a specific repair activity. Each procedure contains all the information required to perform...

  • Page 96

    4.2 general procedures 4.2.1 mounting instructions for bearings general this section describes how to mount and grease different types of bearings on the robot. Equipment note art. No. Equipment, etc. Used to grease the bearings, if not specified otherwise. 3hab3537-1 grease assembly of all bearings...

  • Page 97

    • during operation, the bearing should be filled to 70-80% of the available volume. • ensure that grease is handled and stored properly to avoid contamination. Grease the different types of bearings as following description: • grooved ball bearings must be filled with grease from both sides. • taper...

  • Page 98

    4.2.2 mounting instructions for seals general this section describes how to mount different types of seals onto the robot. Equipment note art. No. Equipment, etc. Used to lubricate the seals. 3hab3537-1 grease rotating seals the procedure below describes how to fit rotating seals. Caution please obs...

  • Page 99

    Flange seals and static seals the following procedure describes how to fit flange seals and static seals. Action check the flange surfaces. They must be even and free from pores. 1 it is easy to check flatness using a gauge on the fastened joint (without sealing com- pound). If the flange surfaces a...

  • Page 100

    4.2.3 replacing parts on clean room robots general when replacing parts on a clean room robot, it is important to make sure that after the replacement, no particles will be emitted from the joint between the structure and the new part, and that the easy cleaned surface is retained. Required equipmen...

  • Page 101

    Description action xx0900000122 seal all refitted joints with sikaflex 521fc. 3 xx0900000125 use the tooling pin to even out the surface of the sikaflex seal. 4 sikaflex 521fc skin dry time (15 minutes). Wait 15 minutes. 5 3hac035355-001 note always read the instruction in the product data sheet in ...

  • Page 102

    4.3 complete robot 4.3.1 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 chapter spare part lists on page 219 . Required equipment note art. No. Spare part n...

  • Page 103

    Removal, cable harness the procedure below details how to remove the cable harness. Warning please observe the following before doing any repair work on the manipulator: • motors and gears are hot after running the robot! Touching the motors and gears may result in burns! • turn off all electric pow...

  • Page 104

    Note/illustration action xx0300000091 remove the cable holder by un- screwing its attachment screws. 4 • a: cable holder • b: attachment screws • c: cable securing screws see figure above! Remove the cables from the cable holder by unscrewing the cable securing screws. 5 detailed in section replacem...

  • Page 105

    Note/illustration action xx0300000092 disconnect connectors in the rear of the upper arm. 9 connectors: • a: r2.Cs • b: pressurized air connection • c: r3.Fb4 • d: r3.Fb5 • e: r3.Fb6 • f: r3.Mp5 • g: r3.Mp4 • h: r3.Mp6 parts: • j: shield see figure above! Remove the shield by unscrewing its attachme...

  • Page 106

    Note/illustration action xx0200000449 disconnect the connectors inside the lower arm. 12 • g: connectors r3.Mp3 and r3.Fb3 pull the cables out of the upper arm. 13 detailed in section replacement of cover, console on page 141 . Remove the cover, console. 14 connectors: • r3.Mp1 • r3.Mp2 • r3.Fb1 • r...

  • Page 107

    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! • - turn off all e...

  • Page 108

    Note/illustration action xx0200000449 cable layout in the lower arm. 4 • a: cable ties • b: pressurized air hose • c: power cables, axes 4, 5 and 6 • d: customer cables, signal • e: signal cables, axes 4, 5 and 6 • f: signal cable, axis 3 • g: connectors r3.Mp3 and r3.Fb3 continues on next page 108 ...

  • Page 109

    Note/illustration action xx0300000094 cable holder in the upper arm. 5 cables: • a: customer signal • b: signal • c: pressurized air supply • d: power cables clean room robots: seal and paint the joints that have been opened. See replacing parts on clean room robots on page 100 note after all repair...

  • Page 110

    4.3.2 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 chapter spare part lists on page 219 . Xx0200000446 cover, armhousing a attachment sc...

  • Page 111

    Required equipment note art. No. Spare part no. Equipment standard and foundry versions. 3hac026581-001 upper arm, spare std/f includes all required seal- ings and gaskets. Clean room versions. 3hac026581-003 upper arm, spare cr includes all required seal- ings and gaskets. To be replaced if damaged...

  • Page 112

    Note action 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. 3 shown in the figure location of upper arm on page 110 ! Remove the rear cover armhousing by unscrewing its four att...

  • Page 113

    Note action shown in the figure location of upper arm on page 110 ! Remove the upper arm by unscrewing its six attach- ment screws. 13 lift the upper arm and place it on a secure surface. 14 removing the vk cover the procedure below details how to remove the vk cover from the upper arm. Xx0200000433...

  • Page 114

    Note action specified in section replacement of complete upper arm on page 110 . If the vk cover is damaged, it must be replaced on refitting. 3 refitting the procedure below details how to refit the complete upper arm. Note action clean room robots: clean the joints that have been opened. See repla...

  • Page 115

    Note action clean room robots: seal and paint the joints that have been opened. See replacing parts on clean room robots on page 100 note after all repair work, wipe the robot free from particles with spirit on a lint free cloth. 14 calibration is detailed in a separate calibration manual enclosed w...

  • Page 116

    4.3.3 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 chapter spare part lists on page 219 . Xx0200000469 lower arm a required equipment ...

  • Page 117

    Note art. No. Spare part no. Equipment clean room versions 3hac034937-001 lower arm, spare includes all required bearings, oil and vk cov- er. Content is defined in sec- tion standard tools on page 215 . 3hac020812-001 standard toolkit lifting capacity >16 kg lifting device for lower arm for fitting...

  • Page 118

    Info action xx0300000101 do not under any circumstance unscrew the six screws on top of the lower arm! Doing so will cause the manipulator to require a com- plete rebuild! 3 parts: • a: do not touch these screws! (note! Only 2 screws are shown.) xx0300000097 remove the vk cover by pressing a screwdr...

  • Page 119

    Note action xx0300000097 fit the lower arm to gearbox, axis 2, and secure it with its attachment screws and washers. 3 parts: • a: washer • b: lower arm attachment screws (10 pcs) • c: vk cover tightening torque: 35 nm ± 3 nm shown in the figure above! Fit a new vk cover by gently tap- ping it into ...

  • Page 120

    4.3.4 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 chapter spare part lists on page 219 . Xx0200000423 base a bottom plate b attachment screws, bottom plate (2...

  • Page 121

    Note art. No. Spare part no. Equipment loctite 574 locking liquid for sealing the base to the gearbox 1-2. For lubricating the v-ring. 3hab3537-1 grease for cleaning the mating surfaces. Isopropanol content is defined in sec- tion standard tools on page 215 . - standard toolkit these procedures incl...

  • Page 122

    Note action unfasten the base from the installation site by removing the attachment bolts from the founda- tion. 8 fit the lifting slings to the robot, lift it and place it with the side of the lower arm downwards on a work bench. 9 shown in the figure location of base on page 120 . Remove the botto...

  • Page 123

    Note action detailed in sections replacement of motor, axis 1 on page 158 and replace- ment of motor, axis 2 on page 162 re- spectively. Refit motors 1 and 2. 13 detailed in section replacing the serial measurement unit and the bat- tery pack on page 148 . Refit the serial measurement unit. 14 detai...

  • Page 124

    4.4 upper arm 4.4.1 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 chapter spare part lists on page 219 . Xx0600002847 attachment screws, wrist unit (3 pcs) a o...

  • Page 125

    Note art. No. Spare part no. Equipment, etc. Must be replaced. O-ring sealing plate note! The o-ring sealing plate is not interchangeable with art.No. 3hac 7191-1! For lubricating the o-ring sealing plate. 3hac 3537-1 grease content is defined in section standard tools on page 215 . - standard toolk...

  • Page 126

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 3 art. No. Is specified in section required equipment on page 124 . Lightly lubricate the o-ring sealingplate with grease. 4 connect to con...

  • Page 127

    Note action clean room robots: seal and paint the joints that have been opened. See repla- cing parts on clean room robots on page 100 note after all repair work, wipe the robot free from particles with spirit on a lint free cloth. 13 calibration is detailed in a separate calibra- tion manual enclos...

  • Page 128

    4.4.2 replacing the damper, axis 3 location of damper, axis 3 a more detailed view of the components and its position may be found in chapter spare part lists on page 219 . Xx0200000427 damper, axis 3 a required equipment note art. No. Equipment, etc. 3hac 7881-1 damper, axis 3 content is defined in...

  • Page 129

    Note action remove the damper by gently prying it from the cast tab. 3 refitting the damper axis 3 use this procedure to refit the damper. Note action shown in the figure location of damper, axis 3 on page 128 . Run the robot to a position where it is best to enable access to the location where the ...

  • Page 130

    4.4.3 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 a recess b required equipment note spare part no. Equipment, etc. 3hab 8964-1 damper, axis 5 content is defined in section standard tools on page 21...

  • Page 131

    Refitting, damper axis 5 the procedure below details how to refit the damper, axis 5. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 make sure the damper is turned the correct way! Pus...

  • Page 132

    4.4.4 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 chapter spare part lists on page 219 . Xx0200000464 cover, arm hou...

  • Page 133

    Removal the procedure below details how to remove the cover, armhousing. Warning please observe the following before doing any repair work on the manipulator: • motors and gears are hot after running the robot! Touching the motors and gears may result in burns! • turn off all electric power, hydraul...

  • Page 134

    Note action replace if damaged. Make sure the gasket inside the cover, arm housing has not been damaged. 3 shown in the figure location of cover, armhousing on page 132 . Secure the cover, arm housing to the upper arm with its attachment screws. 4 clean room robots: seal and paint the joints that ha...

  • Page 135

    4.5 lower arm 4.5.1 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 on page 219 . Xx0200000433 lo...

  • Page 136

    Cover l. Arm, spare (without lamp unit) c cover l. Arm, spare (with lamp unit) d required equipment note art. No. Spare part no. Equipment, etc. For spare part number, see: • spare part lists on page 219 . Lower arm standard and foundry versions 3hac 10471-1 cover, lover arm, spare, std/f no lamp un...

  • Page 137

    Note action caution always cut the paint with a knife and grind the paint edge when disassembling parts of a clean room robot! See replacing parts on clean room robots on page 100 1 shown in the figure location of lower arm cover and gasket on page 135 . Remove the lower arm cover by unscrewing its ...

  • Page 138

    Note action clean room robots: seal and paint the joints that have been opened. See replacing parts on clean room robots on page 100 note after all repair work, wipe the robot free from particles with spirit on a lint free cloth. 5 138 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights...

  • Page 139

    4.5.2 replacing the damper, axis 2 location of damper, axis 2 a more detailed view of the components and its position may be found in chapter spare part lists on page 219 . Xx0200000426 damper, axis 2 a required equipment note art. No. Equipment, etc. 3hac 7880-1 damper, axis 2 content is defined in...

  • Page 140

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. 3 remove the damper by unscrewing the attach- ment screw and washer. 4 refitting the damper use this procedure to refit the damper. Note ...

  • Page 141

    4.6 frame and base 4.6.1 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 chapter spare part lists on page 219 . Xx0200000462 cover, conso...

  • Page 142

    Note art. No. Spare part. No. Equipment, etc. Content is defined in section standard tools on page 215 . 3hac020812-001 standard toolkit these procedures in- clude references to the tools required. Other tools and proced- ures may be required. See references to these procedures in the step- by-step ...

  • Page 143

    Refitting the procedure below details how to refit cover, console. Warning please observe the following before doing any repair work on the manipulator: • motors and gears are hot after running the robot! Touching the motors and gears may result in burns! • turn off all electric power, hydraulic, an...

  • Page 144

    4.6.2 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 chapter spare part lists on page 219 . Xx0200000462 cover, console a attachment screws, cover, con...

  • Page 145

    Removal the procedure below details how to remove the cover, console. Warning please observe the following before doing any repair work on the manipulator: • motors and gears are hot after running the robot! Touching the motors and gears may result in burns! • turn off all electric power, hydraulic,...

  • Page 146

    Note/illustration action xx0300000096 remove the bearing hub by unscrewing its attachment screws. 8 parts: • a: console • b: bearing hub • c: bearing hub attachment screws (6 pcs) • d: console attachment screws (10 pcs) • e: washers (10 pcs) shown in the figure above! Remove the console by un- screw...

  • Page 147

    Note/illustration action xx0300000096 refit the console and secure it with its attachment screws and washers. 2 parts: • a: console • b: bearing hub • c: bearing hub attachment screws (6 pcs) • d: console attachment screws (10 pcs) • e: washers (10 pcs) tightening torque: 11 nm ± 1 nm shown in the f...

  • Page 148

    4.6.3 replacing the serial measurement unit and the battery pack note the battery low alert (38213 battery charge low) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be r...

  • Page 149

    Rmu101 xx1300000279 battery pack rmu with 3-pole battery contact a serial measurement board (smb), rmu 101 b attachment screws (2 pcs) c required equipment all spare parts are listed in spare parts - robot irb 140 on page 220 . Note there are different variants of smb units and batteries. The varian...

  • Page 150

    Removal the procedure below details how to remove the serial measurement unit and battery pack. Warning please observe the following before doing any repair work on the manipulator: • motors and gears are hot after running the robot! Touching the motors and gears may result in burns! • turn off all ...

  • Page 151

    Note action xx1200000830 remove the rear cable cover from the base of the robot by unscrewing its attachment screws. 3 shown in the figure location of serial measurement unit and battery pack on page 148 ! Remove the serial measurement unit by unscrew- ing its attachment screws. The removal is simpl...

  • Page 152

    Danger follow these instruction to prevent the unit to be damaged from esd: • the unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic voltages. • before handling, make sure you are grounded through a special esd wrist bracelet or similar. Caution this com...

  • Page 153

    Note action clean room robots: seal and paint the joints that have been opened. See replacing parts on clean room robots on page 100 note after all repair work, wipe the robot free from particles with spirit on a lint free cloth. 8 calibration is detailed in a separ- ate calibration manual enclosed ...

  • Page 154

    4.6.4 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 chapter spare part lists on page 219 . Xx0200000467 gasket, base-cover a...

  • Page 155

    Note art. No. Spare part. No. Equipment, etc. 30 m 3hac 13089-1 control cable, spare standard and foundry versions cover gasket included 3 m 3hac 10476-4 control cable, spare clean room versions cover gasket included 7 m 3hac 10477-2 control cable, spare clean room versions cover gasket included 15 ...

  • Page 156

    Note action caution always cut the paint with a knife and grind the paint edge when disas- sembling parts of a clean room ro- bot! See replacing parts on clean room robots on page 100 1 make sure the robot system has been switched off, and that no power is supplied to the manipulator. 2 shown in the...

  • Page 157

    Note action clean room robots: clean the joints that have been opened. See replacing parts on clean room robots on page 100 1 shown in the figure location of control cable on page 154 . Place the control cable on the floor with the manipulator base cover close to the manipulator. 2 xx0300000090 conn...

  • Page 158

    4.7 motors 4.7.1 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 chapter spare part lists on page 219 . Xx0200000407 motor, axis 1 a ...

  • Page 159

    Note art no. Equipment, etc. 24 vdc, max. 1,5 a power supply for releasing the brakes these procedures include references to the tools required. Other tools and procedures may be required. See refer- ences to these procedures in the step-by-step instruc- tions below. See chapter circuit diagram on p...

  • Page 160

    Note action connectors: • r3.Mp1 • r3.Fb1 disconnect the motor 1 connectors inside the con- sole. 3 cut any cable ties and remove any brackets securing the cables. 4 shown in the figure location of motor axis 1 on page 158 . Remove the cable gland by removing its attachment screws, and pull the cabl...

  • Page 161

    Note action make sure the motor is turned the right way, i.E. Connections rear- wards. Fit the motor, making sure the motor pinion is properly mated to gearbox 1. 5 make sure the motor pinion does not get damaged! Tightening torque: approx 2 nm fit the motor with four attachment screws and plain was...

  • Page 162

    4.7.2 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. A more detailed view of the components and its position may be found in chapter spare part lists on page 219 . Xx0200000408 motor, axis 2 a cover for connector ac...

  • Page 163

    Note art. No. Spare part no. Equipment, etc. These procedures include ref- erences to the tools required. Other tools and pro- cedures may be re- quired. See refer- ences to these pro- cedures in the step- by-step instructions below. See chapter circuit diagram on page 229 . - circuit diagram remova...

  • Page 164

    Note action 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 shown in the figure location of motor axis 2 on page 162 . Remove the motor by unscrewing its four attachment screws and plain washe...

  • Page 165

    Note action tightening torque: approx 11 nm ± 1 nm tighten the motor attachment screws. 11 disconnect the brake release voltage. 12 art no. Is specified in section re- quired equipment on page 162 . Make sure the cable gland cover gasket has not been damaged. Replace if it has. 13 push the cables in...

  • Page 166

    4.7.3 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. For a more detailed view of the components and its position, see spare part lists on page 219 . X...

  • Page 167

    Required equipment note art. No. Spare part no. Equipment, etc. 3hac7866-1 rotating ac motor with pinion 3hac021756-001 3hac6793-1 timing belt content is defined in section standard tools on page 215 . 3hac020812-001 standard toolkit these procedures in- clude references to the tools required. Other...

  • Page 168

    Note action xx0200000449 cut the cable ties to simplify accessing the motor. 4 • a: cable ties • b: pressurized air hose • c: power cables, axes 4, 5 and 6 • d: customer cables, signal • e: signal cables, axes 4, 5 and 6 • f: signal cable, axis 3 • g: connectors r3.Mp3 and r3.Fb3 connectors: • r3.Mp...

  • Page 169

    Note action xx0300000102 do not under any circumstance un- screw the three screws securing the belt wheel! Doing so will cause the manipulator to require a complete re- build! 6 parts: • do not touch these screws! (3 pcs) shown in the figure in section location of motor axis 3 on page 166 . Remove t...

  • Page 170

    Note action fit the motor in the lower arm. 3 shown in the figure in section location of motor axis 3 on page 166 . Fit the belt. 4 tighten the two motor attachment screws slightly, but not completely. 5 correct belt tension f=35 - 60 n adjust the position of the motor in such a way that the correct...

  • Page 171

    Note action clean room robots: seal and paint the joints that have been opened. See repla- cing parts on clean room robots on page 100 note after all repair work, wipe the robot free from particles with spirit on a lint free cloth. 11 calibration is detailed in a separate calibra- tion manual enclos...

  • Page 172

    4.7.4 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 chapter spare part lists on page 219 . Xx0600003262 attachment screws, motor 4...

  • Page 173

    Note art. No. Spare part no. Equipment, etc. These procedures include references to the tools re- quired. Other tools and proced- ures may be required. See references to these procedures in the step- by-step instructions be- low. See chapter circuit diagram on page 229 . Circuit diagram removal, mot...

  • Page 174

    Refitting, motor axis 4 the procedure below details how to refit the motor, axis 4. Note action clean room robots: clean the joints that have been opened. See replacing parts on clean room robots on page 100 1 shown in the figure location of motor on page 172 . Clean the mating surfaces on the motor...

  • Page 175

    Note action clean room robots: seal and paint the joints that have been opened. See replacing parts on clean room robots on page 100 note after all repair work, wipe the robot free from particles with spirit on a lint free cloth. 11 calibration is detailed in a separate calibration manual enclosed w...

  • Page 176

    4.7.5 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. A more detailed view of the components and its position may be found in chapter spare pa...

  • Page 177

    Belt shield k attachment screws, belt shield l motor attachment screws, 4 pcs per motor m attachment screws, motor console n timing belt, axis 6 r pulley, axis 6 s timing belt, axis 5 u pulley, axis 5 v motor console, ax. 5-6 w motor, axis 4 x motor, axis 5 y motor, axis 6 z required equipment note ...

  • Page 178

    Removal the procedure below details how to remove motor, axis 5 or 6. Warning please observe the following before doing any repair work on the manipulator: • motors and gears are hot after running the robot! Touching the motors and gears may result in burns! • turn off all electric power, hydraulic,...

  • Page 179

    Note action shown in the figure in section location of motor and timing belt, axes 5 or 6 on page 176 ! Remove the pressurized air connector from the housing and pull it into the upper arm assembly. 8 art. No. Specified in section required equipment on page 177 ! Shown in the figure in section locat...

  • Page 180

    Note action clean room robots: clean the joints that have been opened. See replacing parts on clean room robots on page 100 1 make sure the mating surfaces on the motor and the console are clean and free from burrs. 2 shown in the figure in section location of motor and timing belt, axes 5 or 6 on p...

  • Page 181

    Note action connectors • r3.Mp4 • r3.Mp5 • r3.Mp6 • r3.Fb4 • r3.Fb5 • r3.Fb6 reconnect all cables to/from motors 4-6. 16 shown in the figure in section location of motor and timing belt, axes 5 or 6 on page 176 ! Refit the cable guide with its two attachment screws. 17 shown in the figure in section...

  • Page 182

    4.7.6 adjustments and measurements 4.7.6.1 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. Certain measurement tools ...

  • Page 183

    Note action xx0200000457 fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure. Apply the 40 n load as shown. 2 remove the load and read value 1. 3 xx0200000458 apply 40 n load as shown. 4 remove the load and read value 2. 5 gear play value = value 1 - value 2 calc...

  • Page 184

    4.7.6.2 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. Certain measurement tools must be fashioned to enable measuri...

  • Page 185

    Note action xx0200000460 fit the dial fitting arm and dial to the manipulator turning disk as shown in the figure. Apply the 40 n load as shown. 2 remove the load and read value 1. 3 xx0200000461 apply 40 n load as shown. 4 remove the load and read value 2. 5 gear play value = value 1 - value 2 calc...

  • Page 186

    4.8 gearboxes 4.8.1 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...

  • Page 187

    Note art. No. Equipment these procedures include references to the tools required. Other tools and proced- ures may be required. See references to these pro- cedures in the step-by- step instructions below. Illustration, base xx0200000423 base a bottom plate b attachment screws, bottom plate (26 pcs...

  • Page 188

    Removal, gearbox unit axes 1-2 the procedure below details how to remove the complete gearbox unit, axes 1-2. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 caution always cut the pain...

  • Page 189

    Note action shown in the figure illustration, base on page 187 . Remove the bottom plate by un- screwing its 26 attachment screws. 14 secure the weight of the base with lifting slings. 15 shown in the figure illustration, base on page 187 . Remove the gearbox/base attach- ment screws and washer. 16 ...

  • Page 190

    Note action clean the mating surfaces of the base and of the gearbox unit with isopropanol. 5 shown in the figure illustration, base on page 187 . Fit a small amount of loctite 574 on the mating surface in the gearbox unit. 6 shown in the figure illustration, base on page 187 . Fit the base to the g...

  • Page 191

    Note action calibration is detailed in a separate calib- ration manual enclosed with the calibra- tion tools. Recalibrate the robot. 19 general calibration information is included in section calibration information on page 195 . Danger make sure all safety requirements are met when performing the fi...

  • Page 192

    4.8.2 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. This procedure is det...

  • Page 193

    4.8.3 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 axis 1- 2 amount art. No. Type of oil gearbox 1200 ml 11712016-604 mobilgear 600 xp 320 axis 1 1000 ml 11712016-604 mobilgear 600 xp 320 axis 2 ty...

  • Page 194

    This page is intentionally left blank.

  • Page 195: 5 Calibration Information

    5 calibration information 5.1 introduction general this chapter includes general information about the different calibration methods and also the detailed procedures that do not require specific calibration equipment. When the robot system must be recalibrated, it is done according to the documentat...

  • Page 196

    5.2 calibration methods overview this section specifies the different types of calibration and the calibration methods that are supplied by abb. Types of calibration calibration method description type of calibration calibration pendulum (standard method) the calibrated robot is positioned at home p...

  • Page 197

    Calibration methods each calibration method is detailed in a separate manual. Following is a brief description of the methods available. 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...

  • Page 198

    5.3 calibration scale 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 198 3hac027400-001 ...

  • Page 199

    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 and so on. Positive directions are shown in the graphic below. This is no...

  • Page 200

    5.5 updating revolution counters introduction this section describes how to do a rough calibration of each manipulator axis, which is updating the revolution counter value for each axis using the flexpendant. Step 1 - manually running the manipulator to the calibration position use this procedure to...

  • Page 201

    Action tap the mechanical unit in question. 2 a screen is displayed, tap rev. Counters. En0400000771 tap update revolution counters.... A dialog box is displayed warning that updating the revolution counters may change programmed manipulator positions: • tap yes to update the revolution counters. • ...

  • Page 202

    5.6 checking the calibration position introduction check the calibration position before beginning any programming of the robot system. This may be done: • using a moveabsj instruction with argument zero on all axes. • using the jogging window on the flexpendant. Using a moveabsj instruction use thi...

  • Page 203: 6 Decommissioning

    6 decommissioning 6.1 environmental information hazardous material the table specifies some of the materials in the product and their respective use throughout the product. Dispose components properly to prevent health or environmental hazards. Example application material serial measurement board b...

  • Page 204

    This page is intentionally left blank.

  • Page 205: 7 Robot Description

    7 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: • upper arm, complete • wrist unit • o-ring sealing plate how to know which type the r...

  • Page 206

    This page is intentionally left blank.

  • Page 207: 8 Reference Information

    8 reference information 8.1 introduction general this chapter includes general information, complementing the more specific information in the different procedures in the manual. 3hac027400-001 revision: k 207 © copyright 2004-2013 abb. All rights reserved. 8 reference information 8.1 introduction.

  • Page 208

    8.2 applicable safety standards standards, en iso the manipulator system is designed in accordance with the requirements of: description standard safety of machinery - basic concepts, general principles for design - part 1: basic terminology, methodology en iso 12100 -1 safety of machinery - basic c...

  • Page 209

    Description standard safety standard for robots and robotic equipment ansi/ul 1740 (option 429-1) industrial robots and robot systems - general safety require- ments can/csa z 434-03 (option 429-1) 3hac027400-001 revision: k 209 © copyright 2004-2013 abb. All rights reserved. 8 reference information...

  • Page 210

    8.3 unit conversion converter table use the following table to convert units used in this manual. Units quantity 39.37 in 3.28 ft. 1 m length 2.21 lb. 1 kg weight 0.035 ounces 1 g weight 14.5 psi 100 kpa 1 bar pressure 0.225 lbf 1 n force 0.738 lbf-ft 1 nm moment 0.264 us gal 1 l volume 210 3hac0274...

  • Page 211

    8.4 screw joints general this section describes how to tighten the various types of screw joints on the irb 140 type c. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. Unbrako screws unbrako is a special typ...

  • Page 212

    • always tighten the joint by hand, and never use pneumatic tools. • use the correct tightening technique, that is do not jerk. Tighten the screw in a slow, flowing motion. • maximum allowed total deviation from the specified value is 10%! Oil-lubricated screws with slotted or cross-recess head scre...

  • Page 213

    Tightening torque (nm) class 12.9, lubricated i tightening torque (nm) class 10.9, lubricated i dimension 950 790 m24 i lubricated with molycote 1000, gleitmo 603 or equivalent water and air connectors the following table specifies the recommended standard tightening torque for water and air connect...

  • Page 214

    8.5 weight specifications definition in installation, repair, and maintenance procedures, weights of the components handled are sometimes specified. 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 compo...

  • Page 215

    8.6 standard tools general all service (repairs, maintenance, and installation) procedures contains 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 standar...

  • Page 216

    8.7 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 the section standard tools on page 215 , and of special tools, listed directly in the instructions and also gathered in thi...

  • Page 217

    8.8 performing a leak-down test general after refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment note art. No. Equipment, etc. 3hac0207-1 leakdown tester - leak detection spray procedure note acti...

  • Page 218

    8.9 lifting accessories and lifting instructions general many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure. The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction deliv...

  • Page 219: 9 Spare Part Lists

    9 spare part lists 9.1 introduction definitions this chapter specifies all spare parts and replacement articles of the robot. 3hac027400-001 revision: k 219 © copyright 2004-2013 abb. All rights reserved. 9 spare part lists 9.1 introduction.

  • Page 220

    9.2 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 224 to robot irb 140, exploded view 5 of 5 on page 228 . Note part article number item base spare 3hac10470-1 1 bottom plate 3hac8999-1 2 m5x...

  • Page 221

    Note part article number item damper axis 1 3hac7527-1 15 m10x35 8.8 gleitmo 610 hex. Socket head cap screw 3hab3402-52 16 washer 3hac7950-1 17 protecting plate 3hac9860-1 18 protective earth cable 3hac8466-1 19 d = 10 hose clip 3hac9063-1 20 membrane sk615 503-2 21 cbk bracket sk616 013-f 22 actuat...

  • Page 222

    Note part article number item d = 6 m6 l = 16 parallel pin 3hac3785-6 61 85x11 sealing ring (v-ring) 3hab3732-19 62 m6x12 torx pan head screw 9ada618-55 63 d = 11 clamp 21662018-2 64 connector bracket 3hac10481-1 65 2.5x101 cable straps, outdoors 21662055-1 66 lubricating oil 11712016-604 67 gearbox...

  • Page 223

    Note part article number item m8x25 12.9 gleitmo 610 hex. Socket head cap screw 3hab3409-37 153 8.4x16x1.6 plain washer 9ada312-7 154 r 1/8" plug 25291920-2 155 m8x35 12.9 gleitmo 610 hex. Socket head cap screw 3hab3409-39 157 8.4x18x2 spring washer, conical 9ada334-7 158 99x10.5 sealing ring (v-rin...

  • Page 224

    Robot irb 140, exploded view 1 of 5 4 5 7 6 8 11 9 2 3 25 12 10 3 30 ba se co mp le te 29 31 in si d e o f b a se 22 23 28 3 3 31 20 19 in si d e o f co ve r 1 33 15 32 18 16 3 5 n m 17 24 27 r1 /4 8 13 34 36 35 37 38 39 21 26 xx0600003264 continues on next page 224 3hac027400-001 revision: k © copy...

  • Page 225

    Robot irb 140, exploded view 2 of 5 xx0600003265 continues on next page 3hac027400-001 revision: k 225 © copyright 2004-2013 abb. All rights reserved. 9 spare part lists 9.2 spare parts - robot irb 140 continued.

  • Page 226

    Robot irb 140, exploded view 3 of 5 10 7 10 3 10 1 10 2 64 3 10 5 10 4 11 2 11 1 10 6 8 11 3 4 ,1 n m ) 66 l o w e r a rm co m p le te w it h ca b le s (sh o w n w it h o u t co ve r) d o n o t lo o se n th e se sc re w s 11 5 11 6 1 0 3 00 1 6 8 3 5 o o se e se 6 7 11 10 8 l o w e r a rm sh o w n w...

  • Page 227

    Robot irb 140, exploded view 4 of 5 1 7 4 1 7 5 8 1 2 1 1 2 1 6 3 1 6 9 1 6 9 1 7 6 1 5 6 1 0 8 1 5 7 1 5 8 1 7 3 1 6 2 1 6 4 1 6 2 1 6 0 1 6 3 1 1 2 1 1 2 1 6 3 1 1 1 1 1 2 1 6 1 1 1 2 1 1 1 1 8 1 1 5 2 1 5 1 1 5 3 1 5 4 1 8 0 1 5 9 35 n m 6 n m 4 .1 n m 28 n m 67 1 8 4 1 8 2 1 8 5 1 8 6 u pp er ar...

  • Page 228

    Robot irb 140, exploded view 5 of 5 xx0600003268 228 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights reserved. 9 spare part lists 9.2 spare parts - robot irb 140 continued.

  • Page 229: 10 Circuit Diagram

    10 circuit diagram 10.1 about circuit diagrams overview the circuit diagrams are not included in this manual, but delivered as separate documents on the documentation dvd. See the article numbers in the tables below. Controllers article numbers for circuit diagrams product 3hac024480-005 circuit dia...

  • Page 230

    Article numbers for circuit diagrams product 3hac13347-1 circuit diagram - irb 6650s 3hac025744-001 3hac025744-001 circuit diagram - irb 6660 3hac029940-001 3hac13347-1 circuit diagram - irb 7600 3hac025744-001 230 3hac027400-001 revision: k © copyright 2004-2013 abb. All rights reserved. 10 circuit...

  • Page 231: Index

    Index a absolute accuracy, calibration, 197 aluminum disposal, 203 b base brake release buttons, 63 replacing, 120 screws, tightening torque, 122 spare part number, 120 batteries disposal, 203 handling, 49 battery replacing, 148 battery pack replacing, interval, 81 battery shutdown service routine, ...

  • Page 232

    Lifting accessory, 214 lithium disposal, 203 m main power switching off, 45 main switch controller cabinet, 45 control module, 46 drive module, 46 manipulator symbols, 38 motor axis 2 brake release with power supply, 163 replacing, 162 spare part number, 162 tightening torque, 165 motor axis 4 brake...

  • Page 233

    Safety, 36 sync marks, 198 system parameter gravity beta, 70 t testing brakes, 30 tightening torques, attachment screws base-gearbox unit, 122 motor axis 2, 165 motor axis 4, 174 wrist unit, 126 tools calibration equipment, levelmeter, 216 calibration pendulum equipment, 216 for service, 216 rotatio...

  • Page 236

    Contact us abb ab discrete automation and motion robotics s-721 68 vÄsterÅs, sweden telephone +46 (0) 21 344 400 abb as, robotics discrete automation and motion box 265 n-4349 bryne, norway telephone: +47 51489000 abb engineering (shanghai) ltd. 5 lane 369, chuangye road kangqiao town, pudong distri...