IRC5-IRB140 Prod Man 3HAC023297-001 - References - Rev - en PDF

Product manual (part 2 of 2), reference information
Articulated robot
IRB 140
M2000, M2000A, M2004

Product manual (part 2 of 2), reference information
IRB 140
M2000
M2000A
M2004
Document ID: 3HAC 023297-001

Revision: -
The information in this manual is subject to change without notice and
should not be construed as a commitment by ABB. ABB assumes no
responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing
herein shall be construed as any kind of guarantee or warranty by ABB
for losses, damages to persons or property, fitness for a specific purpose
or the like.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABB’s written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
© Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Reference information 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.10 Mounting instructions for bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.11 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Spare part / part list 27

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Spare part / part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Foldouts 33
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Circuit diagram 35
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3HAC 023297-001 Revision: - 3

Table of Contents
4 3HAC 023297-001 Revision: -

Overview
Overview
About this manual

This manual contains reference information for all procedures in part 1: Product manual,
procedures.
Usage
This manual should be used during:
• installation
• maintenance work
• repair work.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
The reader should...
• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Reference information Useful information when performing installation, maintenance
or repair works. Includes lists of necessary tools, additional
documents, safety standards, etc.
Spare part / Part list Complete spare part lists and complete lists of robot
components, shown in the foldouts.
Foldouts Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Circuit diagram for the robot.
3HAC 023297-001 Revision: - 5

Overview
Revisions
Revision Description
- First edition
Replaces previous manuals:
• Installation and commissioning manual
• Maintenance manual
• Repair manual, part 1
• Repair manual, part 2
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Section Document references added to the chapter Reference
information.
• Information about the controller removed from the manual.
• Additional spare part numbers for the motors.
6 3HAC 023297-001 Revision: -

Product documentation, M2000/M2000A
Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.
3HAC 023297-001 Revision: - 7

Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
8 3HAC 023297-001 Revision: -

• How to use the application

• Examples of how to use the application
Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudioOnline
• Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
3HAC 023297-001 Revision: - 9

10 3HAC 023297-001 Revision: -

1 Reference information
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
3HAC 023297-001 Revision: - 11

1.2. Applicable Safety Standards
1.2. Applicable Safety Standards
Standards, general
The robot is designed in accordance with the requirements of:
• ISO10218, Jan. 1992, Industrial Robot Safety
• ANSI/RIA 15.06-1999
• ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing
systems - Basic requirements
• DIN 19258 - Interbus-S, International Standard
Standards, safety fence

The following standards are applicable to the safety fence surrounding the robot cell:
• ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing
systems - Basic requirements
• prEN 999:1995
Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:
• IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached
by the upper limbs.
• EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human
body.
• EN 811 Safety of machinery - Safety distance to prevent danger zones being reached
by the lower limbs.
• Pr EN 999 Safety of machinery - The positioning of protective equipment in respect
of approach speeds of the human body.
• EN 1088 Safety of machinery - Interlocking device associated with guards principles
for design and selection.
12 3HAC 023297-001 Revision: -

1.3. Unit conversion
1.3. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal
3HAC 023297-001 Revision: - 13

1.4. Screw joints
1.4. Screw joints
General
This section details how to tighten the various types of screw joints on the robot and the
controller.
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 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.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After
this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
• Use the correct tightening torque for each type of screw joint.
14 3HAC 023297-001 Revision: -

1.4. Screw joints
• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.
• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil- Class 10.9, oil- Class 12.9, oil-
lubricated lubricated lubricated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34
M10 55 66
M12 96 115
M16 235 280
3HAC 023297-001 Revision: - 15

1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90
16 3HAC 023297-001 Revision: -

1.5. Weight specifications
1.5. Weight specifications
Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for
each manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
3HAC 023297-001 Revision: - 17

1.6. Document references
General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot

The product specification includes generic technical data. The specification listed below is
the English version.
Document name Document ID

Product specification 3HAC 9041-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name Document ID

Product manual, S4Cplus M2000 3HAC 021333-001
Product manual, S4Cplus M2000A 3HAC 021128-001
Product manual, IRC5 M2004 3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name Document ID Note

User’s guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation
of S4Cplus based robot systems.
Operator’s manual (IRC5) 3HAC 16590-1
Calibration manuals

Calibration Pendulum 3HAC 16578-1 Enclosed with the Calibration Pendulum
Instruction Toolkit.
Instructions for Levelmeter 3HAC 022907-001 Enclosed with the Levelmeter 2000.
calibration (alternative
method)
CalibWare 2.0 Users Guide 3HAC 16090-1 Calibration tool for Absolute Accuracy
calibration.
18 3HAC 023297-001 Revision: -

Additional documentation

External axes 3HAC 9299-1
3HAC 023297-001 Revision: - 19

1.7. Standard toolkit
1.7. Standard toolkit
General
All service (repair, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. All special tools, i.e. all tools that are not considered
standard as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents
Standard tool, IRB 140: 3HAC020812-001 contains:
Qty Art. no. Tool

1 - Ring-open-end spanner 8-19mm
1 - Socket head cap 2,5-17mm
1 - Torx socket no:20-60
1 - Torque wrench 10-100Nm
1 - Small screwdriver
1 - Ratchet head for torque wrench 1/2
1 - Socket head cap no:5, socket 1/2"" bit L 20mm
1 - Small cutting plier
20 3HAC 023297-001 Revision: -

1.8. Performing a leak-down test
1.8. Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc. Art. no. Note

Leakdown tester 3HAC 0207-1
Leak detection spray -
Procedure
Step Action Note/Illustration

1. Finish the refitting procedure of the motor or gear in
question.
2. Remove the topmost oil plug on the gear in question, Art. no. is specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3. Apply compressed air, and raise the pressure with the Recommended value: 0.2 -
knob until the correct value is shown on the 0.25 bar (20 - 25 kPa)
manometer.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is
be detected. significantly colder or
warmer than the gearbox to
be tested, a slight pressure
increase or decrease
respectively may occur. This
is quite normal.
6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection Art. no. is specified above!
spray .
Bubbles indicate a leak.
8. When the leak has been localized: take the
necessary measures to correct the leak.
3HAC 023297-001 Revision: - 21

1.9. Lifting equipment and lifting instructions
1.9. Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in
the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
22 3HAC 023297-001 Revision: -

1.10. Mounting instructions for bearings
1.10. Mounting instructions for bearings
General
This section details how to mount and grease different types of bearings on the manipulator.
Equipment

Grease 3HAB 3537-1 Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Follow the instructions below when mounting a bearing on the manipulator.
1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.
2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and
other contamination. Cast components must be free from foundry sand.
3. Bearing rings, inner rings and roller elements must under no circumstances be subjected
to direct impact. Furthermore, the roller elements must not be exposed to any stresses
during the assembly work.
Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered
bearing on the manipulator.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
Note! The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the
bearing.
Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
• The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
• 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 detailed below:
• 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.
3HAC 023297-001 Revision: - 23

1.11. Mounting instructions for seals
General
This sections details how to mount different types of seals to the manipulator.
Equipment

Grease 3HAB 3537-1 Used to lubricate the seals.
Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
Step Action Note

1. Check the seal to ensure that:
• the seal is of the correct type (provided with cutting
edge).
• there is no damage to the sealing edge (feel with a
fingernail).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced, as it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page
to the seal.) 24.
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
24 3HAC 023297-001 Revision: -

Flange seals and static seals

The procedure below details how to fit flange seals and static seals.
Step Action Note

1. Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint
(without sealing compund).
If the flange surfaces are defective, the parts may not be used
beacuse leakage could occur.
2. Clean the surfaces properly and in accordance with ABB
ROBOTICS PRODUCTS recommendations.
3. Distribute the sealing compound evenly over the surface, preferably
with a brush.
4. Tighten the screws evenly when fastening the flange joint.
O-rings
The procedure below details how to fit o-rings.
Step Action Note

1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings
may not be used.
3. Check the o-ring grooves. Defective o-rings
The grooves must be geometrically correct and free from pores may not be used.
and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.
3HAC 023297-001 Revision: - 25

26 3HAC 023297-001 Revision: -

2 Spare part / part list
2.1. Introduction

2.1. Introduction
Definitions
This chapter specifies all spare parts and replacement articles of the robot.
3HAC 023297-001 Revision: - 27

2.2. Spare part / part list
Spare part / part list

The table below details all replacement articles on the robot. The items refer to chapter
Foldouts.
Item Qty Art. no. Name Rem.

1 1 3HAC 10470-1 Base spare
2 1 3HAC 8999-1 Bottom plate
3 26 9ADA 629-44 Torx pan head roll. screw M5x12
4 1 3HAC 6599-1 Gasket bottom plate
5 1 3HAC 9522-1 Serial meas. board ass.
6 1 4944 026-4 Battery pack 7.2V 4Ah NiCd
7 2 2166 2055-6 Cable straps, outdoors 7.6x368
8 28 9ADA 618-46 Torx pan head screw M5x20
9 1 3HAC 9030-1 Cable bracket
10 1 3HAC 9415-1 Clamp
11 1 3HAC 6755-1 Cable holder
13 1 3HAC 10476-1 Control cable spare Std/F L=3m
14 1 3HAC 10477-1 Control cable spare Std/F L=7m
15 1 3HAC 7527-1 Damper axis 1
16 20 3HAB 3402-52 Hex. socket head cap screw M10x35 8.8
Gleitmo 610
17 2 3HAC 7950-1 Washer
18 2 3HAC 9860-1 Protecting plate
19 1 3HAC 8466-1 Protective earth cable
20 2 3HAC 9063-1 Hose clip D = 10
21 1 SK 615 503-2 Membrane
22 1 SK 616 013-F Bracket CBK
23 1 1SFA Actuator black
616100R1006
24 1 3HAC 7870-1 Gasket base-cover
25 10 9ADA 290-1 Hexagon nut with flange M5
26 1 2529 1920-2 Plug R 1/8"
27 2 2522 2101-8 Protective hood D=11.4-13
28 1 3HAC 8806-1 Clamp
29 1 3HAC 7370-1 Cable harness IRB 140
30 1 3HAC 2589-1 Instruction plate Battery
replacement
32 20 ml 1234 0011-116 Flange sealing Lotctite 574
33 1 3HAC 10470-3 Base, spare CR
34 1 3HAC 10476-4 Control cable spare CR L=3m
28 3HAC 023297-001 Revision: -


35 1 3HAC 10477-2 Control cable spare CR L=7m
36 1 3HAC 11331-1 Control cable spare Std/F L = 15 m
37 1 3HAC 11331-2 Control cable spare CR L = 15 m
50 1 3HAC 10467-1 Gearbox axes 1-2, spare Std/F Item 67 incl.
51 2 3HAC 10469-1 Motor with pinion spare Std/F
3HAC 021965-001
52 24 3HAB 3409-25 Hex socket head cap screw M6x20 12.9
Gleitmo 610
53 18 9ADA 312-6 Plain washer 6.4x12x1.6
54 2 2152 2012-426 O-ring 74.5x3
55 1 3HAC 6788-1 Bearing hub
56 1 3HAC 10478-1 Console spare Std/F
57 1 3HAC 10472-1 Cover console spare Std/F Item 58 incl.
58 1 3HAC 7868-1 Gasket console-cover
59 1 3HAC 5894-1 Cable bracket T=1.5
60 1 3HAC 6965-1 Sealing ring 150x189x8.5
61 3 3HAC 3785-6 Parallel pin D = 6 m6 L = 16
62 2 3HAB 3732-19 Sealing ring (V-ring) 85x11
64 2 2166 2018-2 Clamp D = 11
65 1 3HAC 10481-1 Connector bracket
67 3000 ml 1171 2016-604 Lubricating oil
68 1 3HAC 10467-3 Gearbox axes 1-2, spare CR
69 2 3HAC 10469-3 / Motor with pinion, spare CR
3HAC 021966-001
70 1 3HAC 10478-3 Console, spare CR
71 1 3HAC 10472-3 Cover console, spare CR
72 1 3HAC 10645-1 Clamp D = 4.7
100 1 3HAC 10468-1 Lower arm (axis 3), spare Item 67, 107
and 108 incl.
101 1 3HAC 10471-1 Cover, without lamp unit Item 103 incl.
102 1 3HAC 10474-1 Cover, with lamp unit Item 103 incl.
103 1 3HAC 7869-1 Gasket lower-arm cover
104 1 3HAC 7866-1 / Rot. ac motor incl. pinion
3HAC 021756-001
105 1 3HAC 6793-1 Timing belt
106 1 3HAC 6762-1 Belt shield
107 1 3HAB 3643-17 Groove ball bearing 80x100x10
108 2 3HAA 2166-13 VK-Cover D = 100 B = 10
110 1 3HAA 2356-14 Washer SRKB 6.4x18x1.6
3HAC 023297-001 Revision: - 29


Gleitmo 610
112 12 9ADA 312-5 Plain washer 5.3x10x1
113 1 3HAC 9258-1 Indicator lamp
114 1 3HAC 10468-4 Lower arm, spare CR
115 1 3HAC 10471-3 Cover, without lamp unit
116 1 3HAC 10474-3 Cover, with lamp unit
150 1 3HAC 10466-1 Upper arm compl. with wrist Motors incl.
151 1 3HAC 10475-1 Wrist, spare Std/F Item 155, 181
and 182 incl.
152 1 3HAC 7191-1 O-ring sealing plate
Gleitmo 610
154 3 9ADA 312-7 Plain washer 8.4x16x1.6
155 3 2529 1920-2 Plug R 1/8"
156 1 3HAC 10479-1 Axis 4 complete, spare Std/F Item 111, 112,
180, 159, 161,
160 and 182
incl.
Gleitmo 610
158 6 9ADA 334-7 Spring washer, conical 8.4x18x2
159 1 3HAB 3732-13 Sealing ring (V-ring) 99x10.5
160 1 3HAC 7842-1 / Rot. ac motor with pinion
3HAC 021757-001
161 1 3HAB 3772-24 O-ring 29x3
162 2 3HAC 7841-1 / Rot. ac motor with pinion
3HAC 021758-001
Gleitmo 610
164 1 3HAC 6773-1 Motor Console axes 5-6
165 5 9ADA 183-13 Hex. socket head cap screw M5x12
166 3 3HAA 2356-15 Washer SRKB 5.3x15x1.2
167 1 3HAC 7367-1 Cable holder
168 1 3HAC 8572-1 Clamp
169 2 3HAC 6779-1 Timing belt
170 1 3HAC 6777-1 Timing Belt Pulley Z2/5
171 1 3HAC 6778-1 Timing Belt Pulley Z2/6
172 1 3HAC 7939-1 Clamping unit
173 1 3HAC 7391-1 Belt shield
174 1 3HAC 10473-1 Cover armhousing spare Item 175 incl.
175 1 3HAC 7867-1 Gasket upper arm cover
177 1 3HAC 6761-1 Cable guide
178 1 3HAC 7561-3 Dustcap for receptacles 12p
30 3HAC 023297-001 Revision: -


179 2 2125 2052-178 Distance bolt M5X55
180 1 3HAC 6598-1 Hose nipple G 1/4"
181 1 3HAB 8964-1 Damper axis 5
182 550 ml 3HAC 0860-1 Lubricating oil Optimol
Optigear BM
100
183 1 3HAC 10466-3 Upper arm, spare CR
184 1 3HAC 10475-4 Wrist, spare CR
185 1 3HAC 10479-3 Axis 4 complete, spare CR
186 1 3HAC 10439-3 Cover armhousing, spare CR
187 1 3HAC 11922-1 Slip strip
3HAC 023297-001 Revision: - 31

32 3HAC 023297-001 Revision: -

3 Foldouts
3.1. Introduction
3 Foldouts
3.1. Introduction
Overview
The foldouts in this chapter refer to the part list.
3HAC 023297-001 Revision: - 33

1 33 15 32 18 27 8 13 34 35 36 37 38 39 3 31 20 19
R1/4
21 22 23 28 3
Inside of cover
4 5 7 16 35 Nm 17 6 11 9 26 29 31
24 8 12
10
Inside of base
2 3 30 25
Base complete
Foldout 1
51 62 56 70 8 57 71 58 52 53 32 65 25 25 72 31
A
62
52 15,5 Nm A (1 : 2)
31 55
52
53
52 54 53 52 51 69
53
54
63
64
68 50 ax.1 1,2 litre

ax.2 1,0 litre
67
61 61 60 63 31 59 31 63 63
Foldout 2
0,4 litre
67 100 114 104 105 64 3 103 101 115 8 113 102 116
Do not loosen
these screws
Do not loosen
these screws
3 110 109 18
66
17 16 35 Nm 108 107 112 111 4,1 Nm 106
Lower arm complete with cables

Lower arm (shown without cables) (shown without cover)
Foldout 3
0,35 litre oil (at oil change).
0,30 litre oil (New wrist)

0,2 litre oil
182 151 184 152 180 182 156 185 176
159
162 162 164 163 4,1 Nm 112
169 170 171 172 3 Nm 173
153 28 Nm
154 181
108 35 Nm 6 Nm
157 158 161 112 111 160
112 4,1 Nm 163

Upper arm (shown without cables)
112 4,1 Nm 111 166 165 6 Nm 4,1 Nm

169 112 163
175 8 174 186 12
Foldout 4
177 179
168
167
150 183 20 165
187
Upper arm with cables

178 (shown without cover)
155
Upper arm complete
Foldout 5
4 Circuit diagram
4.1. Introduction
4 Circuit diagram
4.1. Introduction
Overview
This chapter includes the circuit diagram for the robot.
3HAC 023297-001 Revision: - 35

Circuit Diagram
CONTENTS
Page
Manipulator, diagram 3HAC 6816-3, Rev. 0 ..............................................................101-108
IRB 140
Manipulator Circuit Diagram 3HAC 6816-3
LIST OF CONTENTS
IRB 140 No. of Sheets 8 Sheet no. 101

CONNECTION POINT LOCATIONS

SERIAL MEASUREMENT BOARD

MOTOR AXIS 1 - 3

FEEDBACK AXIS 1 - 3

MOTOR AXIS 4 - 6

FEED-BACK AXIS 4 - 6

CUSTOMER CONNECTIONS

IRC5-IRB140 Prod Man 3HAC023297-001 - References - Rev - en PDF

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Product manual (part 2 of 2), reference information

Document ID: 3HAC 023297-001

© Copyright 2004 ABB All right reserved.

2 Spare part / part list 27

3HAC 023297-001 Revision: - 3

4 3HAC 023297-001 Revision: -

About this manual

Who should read this manual?

3HAC 023297-001 Revision: - 5

6 3HAC 023297-001 Revision: -

Product documentation, M2000/M2000A

Controller hardware option manual

3HAC 023297-001 Revision: - 7

Product documentation, M2004

8 3HAC 023297-001 Revision: -

• How to use the application

3HAC 023297-001 Revision: - 9

10 3HAC 023297-001 Revision: -

3HAC 023297-001 Revision: - 11

1.2. Applicable Safety Standards

Standards, safety fence

Standards, robot cell

12 3HAC 023297-001 Revision: -

1.3. Unit conversion

3HAC 023297-001 Revision: - 13

1.4. Screw joints

Gleitmo treated screws

Screws lubricated in other ways

Lubricant Art. no.

14 3HAC 023297-001 Revision: -

• Only use correctly calibrated torque keys.

Tightening torque (Nm)

Tightening torque Tightening torque Tightening torque

Tightening torque (Nm) Tightening torque (Nm)

3HAC 023297-001 Revision: - 15

Tightening torque Tightening torque Tightening torque

16 3HAC 023297-001 Revision: -

1.5. Weight specifications

3HAC 023297-001 Revision: - 17

1.6. Document references

Product specification, robot

Document name Document ID

Product manuals, controller

Document name Document ID

Document name Document ID Note

Document name Document ID Note

18 3HAC 023297-001 Revision: -

Document name Document ID Note

3HAC 023297-001 Revision: - 19

1.7. Standard toolkit

Qty Art. no. Tool

20 3HAC 023297-001 Revision: -

1.8. Performing a leak-down test

Equipment, etc. Art. no. Note

Step Action Note/Illustration

3HAC 023297-001 Revision: - 21

1.9. Lifting equipment and lifting instructions

22 3HAC 023297-001 Revision: -

1.10. Mounting instructions for bearings

Equipment, etc. Art. no. Note

Assembly of all bearings

Assembly of tapered bearings

3HAC 023297-001 Revision: - 23