ABB IRB 920 Product Manual
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ABB IRB 920 Product Manual

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Table of Contents

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ROBOTICS
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IRB 920

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Summary of Contents for ABB IRB 920

  • Page 1 ROBOTICS Product manual IRB 920...
  • Page 2 Trace back information: Workspace 22A version a22 Checked in 2022-03-21 Skribenta version 5.5.019...
  • Page 3 Product manual IRB 920T-6/0.45 IRB 920T-6/0.55 IRB 920T-6/0.65 OmniCore Document ID: 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Adjusting the working range ..............3.4.2 Mechanically restricting the working range ........... Electrical connections ..................3.5.1 Robot cabling and connection points ............3.5.2 Customer connections ................Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 6 5.7.4 Replacing the axis-4 motor sub-assembly ............ Gearboxes ....................... 5.8.1 Replacing the axis-1 gear unit sub-assembly ..........5.8.2 Replacing the axis-2 gear unit sub-assembly ..........Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 7 Standard toolkit ....................Special tools ....................Lifting accessories and lifting instructions .............. 10 Spare parts 1001 10.1 Spare part lists and illustrations ................1001 Index 1003 Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    Standard • Clean Room Product manual scope The manual covers all variants and designs of the IRB 920. Some variants and designs may have been removed from the business offer and are no longer available for purchase. Usage This manual should be used during: •...
  • Page 10 Overview of this manual Continued References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - IRB 920 3HAC075722-001 Product specification - IRB 920 3HAC075723-001 Circuit diagram - IRB 920 3HAC075152-014...

  • Page 11: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 12 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 13: How To Read The Product Manual

    Likewise, certain work methods or general information that is valid for several product models, can be illustrated with illustrations that show a different product model than the one that is described in the current manual. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 14 This page is intentionally left blank...

  • Page 15: Safety

    The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.

  • Page 16: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 17: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 18 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 19: Safety Symbols On Manipulator Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 20 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 21 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 22 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 23 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 24 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 25: Robot Stopping Functions

    For more information see: • Product manual - OmniCore C30 • Product manual - OmniCore C90XT • Product manual - OmniCore E10 Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 26: Safety During Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 27 Water • Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 28 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 29: Safety During Operation

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 30: Safety During Maintenance And Repair

    90 °C. Hot oil or grease Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 31 Operating temperatures are listed in Operating conditions, robot on page See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 32 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 33: Emergency Release Of The Robot Axes

    When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 34: Brake Testing

    For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 35: Safety During Troubleshooting

    The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.

  • Page 36: Safety During Decommissioning

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 37: Manipulator Description

    2.1 About IRB 920 Introduction The IRB 920 is one of ABB Robotics latest generation of 4-axis robot, with a payload of 6 kg, designed based on industrial robot platform. The robot has an open structure that is especially adapted for flexible use, and can communicate extensively with external systems.

  • Page 38: Technical Data

    The weight does not include additional options, tools and other equipment fitted on the robot. Loads on foundation, robot xx2000001168 Force in any direction in Plane XY Force along Axis Z Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 39 Application manual - Control- time to have a ler software OmniCore, section Motion Process lower resonance Mode. frequency than recommended. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 40 Manipulator, protection type Clean Room ISO Class 5 According to IEC 60529. The protection class of the ballscrew area is IP20. For more information, please contact ABB. Environmental information The product complies with IEC 63000. Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances.

  • Page 41: Robot Dimensions

    Robots with protection class IP54 (option 3350-540) or with protection type Clean Room (option 3351-5) xx2100002391 *: For Clean Room only. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 42 190 mm 290 mm 290 mm 390 mm 390 mm 596.5 mm 716.5 mm 596.5 mm 716.5 mm 596.5 mm 716.5 mm Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 43 390 mm 610.8 mm 728.7 mm 610.8 mm 728.7 mm 610.8 mm 728.7 mm 165.7 mm 150.7 mm 165.7 mm 150.7 mm 165.7 mm 150.7 mm Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 44: Working Range

    0.65_0.18 0.65_0.3 180 mm 300 mm 180 mm 300 mm 180 mm 300 mm (Axis3) 450 mm 550 mm 650 mm Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 45 0.65_0.3 190 mm 290 mm 390 mm 260 mm 150.9 mm 167.8 mm 231.5 mm ±150° (Axis1) ±145° (Axis2) ±400° (Axis4) Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 46 145 mm 250 mm 145 mm 250 mm (Axis3) 450 mm 550 mm 650 mm 190 mm 290 mm 390 mm Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 47 Robots with protection class Value for restricted working range. IP54 (option 3350-540) or with protection type Clean Room (option 3351-5) 145 mm/250 mm Axis 4 ±400° Default value. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 48: Information Labels

    ABB logo (Small size) Rating label Calibration label UL label WEEE label Read manual and caution Clean Room label Only for robots with protection type Clean Room. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 49: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 50 This page is intentionally left blank...

  • Page 51: Installation And Commissioning

    Safety on page 15 before performing any installation work. Note Always connect the IRB 920 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...

  • Page 52: Unpacking

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • Be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work. • Conform to all national and local codes.

  • Page 53: Risk Of Tipping/Stability

    How to use the transportation bracket is described further in Transportation bracket on page WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 54: Transportation Bracket

    Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws. Remove the bracket. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 55: On-Site Installation

    Introduction This procedure is a brief guide when installing the robot for the first time. Also see Pre-installation procedure on page First installation Use these procedures to install the IRB 920. Action Note Transport the manipulator to its intended location.

  • Page 56: Test Run After Installation, Maintenance, Or Repair

    Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 57: Lifting The Robot

    Grasping location Grasp the robot with one hand supporting at the housing and the other hand holding the base. xx2000001156 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 58 Be careful so that the robot does not bump into something while lifting and transporting. It could damage the robot. Secure the robot on a workbench according to section Orienting and securing the robot on page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 59: Lifting Robot With Lifting Accessories

    Overhead crane Roundsling, 2 m Length: 2 m. Lifting capacity: 100 Roundsling, 2.5 m Length: 2.5 m. Lifting capacity: 2,000 kg. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 60 For Clean Room robots, it is important not to rub against the paint of the robot while perform- ing any service work on the robot. CAUTION The weight of the IRB 920 robot is 22 kg All lifting accessories used must be sized ac- cordingly. WARNING Personnel must not, under any circumstances, be present under the suspended load.
  • Page 61 Lifting capacity for the lifting chain is specified in Required tools and equip- ment on page Valid for IRB 920T-6/0.55 xx2000001144 Valid for IRB 920T-6/0.65 xx2000001153 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 62 Remove the robot attachment screws (if the Screw: M12x35 (robot installation dir- robot is fastened). ectly on foundation) (4 pcs) Raise the overhead crane to lift the robot. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 63: Manually Releasing The Brakes

    Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 64 If they are mixed up, damage can be caused to internal electrical components. xx2000001136 Use the brake releasing button as described in Releasing the brakes on page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 65: Orienting And Securing The Robot

    The foundation surface must be clean and un- figuration, base on page painted. CAUTION The weight of the IRB 920 robot is IRB 920T-6/0.45: 22 kg IRB 920T-6/0.55: 23 kg IRB 920T-6/0.65: 24 kg All lifting accessories used must be sized accord- ingly.
  • Page 66 Hole configuration, base This illustration shows the hole configuration used when securing the robot. Illustration for rear outlet cable version: 4x 13.5 xx2000001147 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 67 3 Installation and commissioning 3.3.5 Orienting and securing the robot Continued Illustration for undeneath outlet cable version: 13.5 (136.8) xx2000001148 Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 68: Loads Fitted To The Robot, Stopping Time And Braking Distances

    The performance of the motor brake depends on if there are any loads attached to the robot. See Product specification - Robot stopping distances according to ISO 10218-1. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 69: Lamp

    This function is NOT valid when connecting to OmniCore E10. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 70: Installation Of Signal Lamp (Option)

    The X15 connector provides MON_LAMP output signals for use. For more details, see chapter Descriptions for connectors in OmniCore product manuals. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 71 Further information about how to set up I/O system may be found in Technical reference manual - System parameters. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 72: Fitting Equipment On The Robot (Robot Dimensions)

    The dimensions for fitting the end effector is shown in the following figure. Note Mounting of other equipment on the IRB 920 may damage the gearboxes. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C...
  • Page 73 Robots with protection class IP54 (option 3350-540) or with protection type Clean Room (option 3351-5) 38,5 xx2100002394 *: For Clean Room only. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 74 When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 75: Restricting The Working Range

    Part of the casting or fixed on the casting and can not /should not be removed. Can be installed in a different position to ensure a reduced working range. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 76: Mechanically Restricting The Working Range

    The figures shows where the axis-1 mechanical stop is placed on the robot. xx2000001159 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 77 Replacing the bellows. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...

  • Page 78: Electrical Connections

    An O-ring is needed for the robots with protection type Clean Room and protection class IP54. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 79 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 80 15 m 3HAC067449-003 It is recommended to always use the CP/CS cable provided by ABB. If users still require to do wiring by their own, make sure to use R1.C1 connector in M12 A-code 12p female type. It is the responsibility of the users to guarantee the safety of the system when self-prepared cables and connectors are used.

  • Page 81: Customer Connections

    Hose for compressed air is also integrated into the manipulator. There are 4 inlets at the base (R1/8”)) and 4 outlets (M5) on the outer arm. xx2000001161 xx2100002441 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 82 M12 CPCS Male angled connector 3HAC066099-001 kits Ethernet M12 Ethernet Cat5e Male straight 3HAC067413-001 connector kits M12 Ethernet Cat5e Male angled 3HAC067414-001 connector kits Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 83 Protection covers for C2/SMB connector on the base and C1/C2 connector on the process hub Protection cover for C1 connector on the base Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 84 3 Installation and commissioning 3.5.2 Customer connections Continued Protection plug for exhaust port connector on the base Only available for protection type Clean Room. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 85: Maintenance

    Note If the IRB 920 is connected to power, always make sure that the IRB 920 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.

  • Page 86: Service Information System (Sis)

    Such information of the ball screw spline unit of the IRB 920 is reported as axis 3 in the SIS system. When a service message is reported for axis 3 of the IRB 920, an inspection on the ball screw spline unit is required.

  • Page 87: Maintenance Schedule And Expected Component Life

    4.3.1 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 920: • Calendar time: specified in months regardless of whether the system is running or not.

  • Page 88: Maintenance Schedule

    Expected component life on page 90 Maintenance schedule Maintenance activities Reference Cleaning the robot Cleaning the IRB 920 on page108 Check for abnormal wear or Inspecting the robot contamination. Inspecting the robot cabling on Inspecting the robot harness...
  • Page 89 The battery is to be replaced at given maintenance interval or at battery low alert. iv Not needed separately if already included in the application. Recommended test interval is within the range 8-48 hours. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 90: Expected Component Life

    Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 91: Inspection Activities

    • air pressure supply to the robot, before entering the safeguarded space. Inspect the labels, located as shown in the figures. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 92 Continued Action Note Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 1001. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 93: Inspecting The Robot Cabling

    • the cabling to motors 1 and 2. Look for abrasions, cuts or crush damage. Replace the cabling if wear or damage is detected. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 94: Inspecting The Ball Screw Spline Unit

    Replacing the bellows. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 95 Make sure the payload is disassembled or tooling is properly supported; otherwise, fast downward movements of axis 3 may cause severe hits. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 96 106. Replace the ball screw spline unit if wear or dam- Replacing the ball screw on age is detected. page 488. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 97: Inspecting Axis-3 Mechanical Stops

    Replacing the bellows. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 98 See Cut the paint or surface on the robot before repla- cing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 99 Replace if any mechanical stop is: • bent • loose • damaged. Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 100: Inspecting Timing Belts

    Always read the section "General procedures" before doing any repair work. Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 101 4.4.5 Inspecting timing belts Continued Location of timing belts The timing belts are located as shown in the figures. Axis Location xx2100001015 xx2100001024 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 102 4 Maintenance 4.4.5 Inspecting timing belts Continued Axis Location xx2100001020 xx2100001022 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 103 New timing belt Used timing belt New timing belt Axis 1 51.1 Axis 2 64.7 Axis 3 36.6 Axis 4 36.3 Axis 4-2 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 104 Use a sonic tension meter to measure the Timing belt tension on page 103. timing belt tension. Adjust the belt tension if needed! Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 105: Replacement/Changing Activities

    Replacing the battery pack Replacing the battery pack is accessible after removing the SMB from the base, Replacing the SMB unit and battery unit on page 193. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 106: Lubrication Activities

    Article number Note 24 VDC power supply Used to release the motor brakes. Required consumables Consumable Article number Note Grease THK AFA Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 107 Move the shaft up and down several times while pressing the brake release button to smooth out the grease on the shaft. Wipe off excessive grease. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 108: Cleaning Activities

    4.7.1 Cleaning the IRB 920 General To secure high uptime it is important that the IRB 920 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the IRB 920.
  • Page 109 Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...
  • Page 110 This page is intentionally left blank...

  • Page 111: Repair

    Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 920, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 112: General Procedures

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 113: Mounting Instructions For Bearings

    Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 114 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 115: Mounting Instructions For Sealings

    If the sealing is without dust lip, just lubricate the main lip with a thin layer of grease. xx2000000071 A Main lip B Grease C Dust lip Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 116 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
  • Page 117 Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Make sure that no grease is left on the robot surface. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

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

    Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 119 Clean Room/Hygienic. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 120: Cable Harness

    The main harness is located as shown in the figure. xx2100001029 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 121 If no previous reference values exist, and routine on page 957. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 122 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 123 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 124 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 125 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 126 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 127 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 128 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 129 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 130 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 131 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 132 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 133 Removing the axis-1 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 134 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 135 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 136 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 137 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws on the base to the ground. Lay down the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 138 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002434 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 139 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 140 Disconnecting the connectors for axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 141 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 142 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 143 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 144 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 145 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 146 For robots with protection type Clean Room (op- tion 3351-1) Remove the one way valve by unscrewing it. xx2200000281 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 147 For undeneath outlet cable version: CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2100001206 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 148 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 149 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 150 Cut the paint or surface on the robot before replacing parts on page 118. Lay the main harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 151 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 152 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100000945 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 153 For robots with protection class IP54 (option 3350-540) Screws: Hex socket head cap screw M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2100002433 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 154 For robots with protection type Clean Room (op- tion 3351-1) Refit the one way valve by screwing it into the main harness assembly. xx2200000281 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 155 Clean Room (option 3351-1) Screws: Hex socket head cap screw M3x30 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 1.2 Nm ±10% xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 156 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 157 5.3.1 Replacing the main harness Continued Action Note Apply grease to the internal harness, cover all moving area of the harness. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 158 Secure the base plate/ rear plate to the base with the screws. xx2100002434 For undeneath outlet cable version: For robots with protection class IP30 (option 3350-300) xx2100001202 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 159 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 160 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 161 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 162 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 163 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 164 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 165 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 166 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 167 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 168 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 169 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 170 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 171 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 172 Refitting the axis-2 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 173 Refit the screws. xx2100000943 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002451 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 174 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 175: Replacing The Process Hub

    The process hub is located as shown in the figure. xx2100001009 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 176 Preparations before removing the process hub Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 177 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 178 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 179 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 180 IP54 (option 3350-540) For robots with protection type Check the gasket and replace it if needed. Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 181 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the air hoses from the L-shaped con- nectors. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 182 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100001034 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 183 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 184 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 185 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 186 Reconnect the connector. • R2.PB • R2.LAMP See the number markings on the connectors for help to find the corresponding connector. xx2100001030 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 187 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 188 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 189 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 190 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 191 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 192 5 Repair 5.3.2 Replacing the process hub Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 193: Replacing The Smb Unit And Battery Unit

    The SMB unit and battery unit are located as shown in the figure. xx2100001010 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 194 Preparations before removing the SMB unit and battery unit Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 195 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 196 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 197 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 198 Cut the paint or surface on the robot before replacing parts on page 118. Separate the battery unit from the SMB assembly by cutting the cable straps. xx2100001035 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 199 Refit the SMB package to the SMB cover with the Screws: Hex socket head cap screws. screw M3x5 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.8 Nm xx2100001036 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 200 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100000945 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 201 For robots with protection class IP54 (option 3350-540) Screws: Hex socket head cap screw M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2100002433 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 202 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 203: Base

    The base is located as shown in the figure. xx2100001011 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 204 If no previous reference values exist, and routine on page 957. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 205 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 206 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 207 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 208 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 209 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 210 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 211 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 212 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 213 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 214 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 215 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 216 Removing the axis-1 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 217 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 218 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 219 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 220 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws on the base to the ground. Lay down the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 221 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002434 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 222 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 223 Disconnecting the connectors for axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 224 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 225 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 226 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 227 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 228 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 229 Removing the pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 230 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws and washers. Remove the motor. xx2100001038 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 231 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 232 118. For robots with protection type Clean Room (op- tion 3351-1) Remove the air exhaust by unscrewing the locking xx2200000280 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 233 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 234 M5x16 12.9 Lafre 2C2B/FC6.9 (16 pcs) Refit the screws. Washers: Plain washer 11x5.3x1.2 Steel (16 pcs) Tightening torque: 8.5 Nm±10% xx2100001039 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 235 4.2x9x2 steel (3 pcs) tightened. Tightening torque: 2.8 Nm ±10% xx2100001038 Timing belt A1: 3HAC070449-001 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 236 Refitting the pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 237 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 238 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 239 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 240 Screws: Hex socket head cap with the screw. screw M3x5 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.5 Nm ±10% xx2100000947 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 241 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000951 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 242 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100000945 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 243 For robots with protection class IP54 (option 3350-540) Screws: Hex socket head cap screw M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2100002433 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 244 For robots with protection type Clean Room (op- tion 3351-1) Refit the one way valve by screwing it into the main harness assembly. xx2200000281 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 245 Clean Room (option 3351-1) Screws: Hex socket head cap screw M3x30 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 1.2 Nm ±10% xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 246 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 247 5 Repair 5.4.1 Replacing the base Continued Action Note Apply grease to the internal harness, cover all moving area of the harness. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 248 Secure the base plate/ rear plate to the base with the screws. xx2100002434 For undeneath outlet cable version: For robots with protection class IP30 (option 3350-300) xx2100001202 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 249 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 250 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 251 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 252 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 253 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 254 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 255 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 256 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 257 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 258 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 259 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 260 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 261 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 262 Refitting the axis-2 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 263 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 264 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 265 5 Repair 5.4.1 Replacing the base Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 266: Replacing The Axis-1 Timing Belt

    The axis-1 timing belt is located as shown in the figure. xx2100001015 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 267 Remove the robot from the wall or enough space. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 268 Removing the process hub screws Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 269 Removing the top cover and the flange with bearing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 270 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the screws on the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 271 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 272 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 273 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 274 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 275 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 276 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 277 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 278 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 279 Removing the axis-1 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 280 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 281 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 282 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 283 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws on the base to the ground. Lay down the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 284 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002434 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 285 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 286 Disconnecting the connectors for axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 287 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 288 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 289 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 290 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 291 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 292 Removing the pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 293 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws and washers. Remove the motor. xx2100001038 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 294 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Put the timing belt into the pulley on the gear. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 295 During the measurement, make sure that all inter- ferences that may affect the force are removed. Pay attention to the force application direction. xx2100001043 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 296 M4x10 12.9 Lafre Secure the screws on the pulley protection cover 2C2B/FC6.9 (8 pcs) to the base. Tightening torque: 0.8 Nm xx2100001037 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 297 For undeneath outlet cable version: CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2100001206 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 298 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 299 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 300 Cut the paint or surface on the robot before replacing parts on page 118. Lay the main harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 301 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 302 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100000945 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 303 For robots with protection class IP54 (option 3350-540) Screws: Hex socket head cap screw M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2100002433 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 304 For robots with protection type Clean Room (op- tion 3351-1) Refit the one way valve by screwing it into the main harness assembly. xx2200000281 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 305 Clean Room (option 3351-1) Screws: Hex socket head cap screw M3x30 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 1.2 Nm ±10% xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 306 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 307 5.4.2 Replacing the axis-1 timing belt Continued Action Note Apply grease to the internal harness, cover all moving area of the harness. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 308 Secure the base plate/ rear plate to the base with the screws. xx2100002434 For undeneath outlet cable version: For robots with protection class IP30 (option 3350-300) xx2100001202 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 309 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 310 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 311 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 312 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 313 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 314 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 315 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 316 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 317 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 318 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 319 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 320 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 321 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 322 Refitting the axis-2 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 323 Refit the screws. xx2100000943 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002451 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 324 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 325: Inner Arm

    The inner arm is located as shown in the figure. xx2100001012 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 326 Handheld dynamometer Used for measuring the timing belt tension. Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 327 Do not lay down the robot during the transporta- tion, always keep it straight. If the robot lay down in any situation, the grease may come out from gearbox. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 328 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 329 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 330 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 331 IP54 (option 3350-540) For robots with protection type Check the gasket and replace it if needed. Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 332 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the air hoses from the L-shaped con- nectors. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 333 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100001034 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 334 Disconnecting the connectors for axis-3 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 335 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 336 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 337 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 338 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000940 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 339 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 340 Removing the axis-2 timing belt Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 341 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws on the axis -2 gear inside the outer arm. xx2100001049 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 342 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 343 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 344 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 345 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 346 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws on the base to the ground. Lay down the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 347 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002434 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 348 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 349 Disconnecting the connectors for axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 350 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 351 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 352 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 353 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 354 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 355 Removing the pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 356 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws and washers. Remove the motor. xx2100001038 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 357 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 358 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 359 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 360 Check the O-ring and replace it if needed. When the gear unit is in the right position, you can hear a clear "Click". Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 361 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 362 When the gear unit is in the right position, you can hear a clear "Click". Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 363 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 364 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Put the timing belt into the pulley on the gear. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 365 During the measurement, make sure that all inter- ferences that may affect the force are removed. Pay attention to the force application direction. xx2100001043 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 366 M4x10 12.9 Lafre Secure the screws on the pulley protection cover 2C2B/FC6.9 (8 pcs) to the base. Tightening torque: 0.8 Nm xx2100001037 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 367 For undeneath outlet cable version: CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2100001206 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 368 Route the cabling behind the axis-1 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 369 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 370 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000951 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 371 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100000945 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 372 For robots with protection class IP54 (option 3350-540) Screws: Hex socket head cap screw M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2100002433 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 373 For robots with protection type Clean Room (op- tion 3351-1) Refit the one way valve by screwing it into the main harness assembly. xx2200000281 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 374 Clean Room (option 3351-1) Screws: Hex socket head cap screw M3x30 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 1.2 Nm ±10% xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 375 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 376 5.5.1 Replacing the inner arm Continued Action Note Apply grease to the internal harness, cover all moving area of the harness. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 377 Secure the base plate/ rear plate to the base with the screws. xx2100002434 For undeneath outlet cable version: For robots with protection class IP30 (option 3350-300) xx2100001202 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 378 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 379 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 380 Pay attention to the force application direction. If the ball screw will interfere with the handheld dynamometer, adjust the ball screw manually. xx2100001125 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 381 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 382 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 383 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 384 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 385 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 386 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 387 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 388 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 389 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 390 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 391 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 392 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 393 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 394 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 395 Refitting the axis-2 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 396 Refit the screws. xx2100000943 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002451 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 397 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 398: Outer Arm

    Replacing the bellows. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 399 Preparations before removing the upper mechanical stopper Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 400 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Loose the locking screws. xx2100002398 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 401 Removing the extension shaft for Clean Room/ IP54 robots Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 402 For robots with protection class IP54 (option 3350- 540) Check the gasket for the extension shaft and re- place it if needed. xx2100002421 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 403 Be careful when you do any work that may cause this. xx1800002859 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 404 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 405 Be careful when you do any work that may cause this. xx1900002012 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900002011 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 406 For robots with protection class IP54 (option 3350- 540) Check the gasket for the extension shaft and re- place it if needed. xx2100002421 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 407 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 408 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 409 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Move the ball screw to lower position. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 410 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Loose the locking screws. xx2100002404 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 411 Removing the shaft for Clean Room/ IP54 robots Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 412 Removing the lower mechanical stopper Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 413 Be careful when you do any work that may cause this. xx1800002861 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 414 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 415 The flat side is on the upper side. Clean Room (option 3351-1) For 180 mm ball screw xx2100002425 For 300 mm ball screw Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 416 IP30 (option 3350-300) xx1800002860 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900001642 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 417 For robots with protection type Clean Room (op- tion 3351-1) Tightening torque: 0.4 Nm ±10% Secure the shaft to the ball screw with the screws. xx1900001616 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 418 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Install the flange with bearing to the shaft. xx2100002407 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 419 M3x8 (2 pcs) For robots with protection type Clean Room (op- tion 3351-1) Tightening torque: 0.4 Nm ±10% Refit the locking screws. xx2100002404 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 420 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 421: Replacing The Bellows

    The bellows are located as shown in the figure. xx2100002397 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 422 If no previous reference values exist, and routine on page 957. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 423 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 424 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 425 Note For robots with protection class IP54 (option 3350- 540) Clean the bellow from the glue if it will be reused. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 426 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Install the bellow to the extension shaft. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 427 540) For robots with protection type Clean Room (op- tion 3351-1) Install the flange with bearing to the extension shaft. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 428 M3x8 (2 pcs) For robots with protection type Clean Room (op- tion 3351-1) Tightening torque: 0.4 Nm ±10% Refit the locking screws. xx2100002398 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 429 Removing the lower cover and the flange with bearing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 430 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the screws on the flange with bearing. xx2100002406 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 431 Note For robots with protection class IP54 (option 3350- 540) Clean the bellow from the glue if it will be reused. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 432 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Install the bellow to the shaft. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 433 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 434 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Refit the lower cover to the ball screw. xx2100002405 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 435 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 436: Replacing The Pulley On The Ball Screw Upper Position

    The pulley is located as shown in the figure. xx2100001016 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 437 Preparations before removing the pulley Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 438 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 439 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 440 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 441 IP54 (option 3350-540) For robots with protection type Check the gasket and replace it if needed. Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 442 Loosen the screws of the axis-3 motor sub-as- sembly to let the axis-3 timing belt free. xx2100001078 Remove the timing belt. xx2100001079 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 443 Be careful when you do any work that may cause this. xx1800002859 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 444 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 445 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 446 Be careful when you do any work that may cause this. xx1900002012 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900002011 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 447 Refit the timing belt to the pulley on the ball screw Timing belt A3: and the motor. Ensure that the belt runs correctly 3HAC070464-001 in the grooves. xx2100001079 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 448 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 449 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 450 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 451 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 452 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 453 5.6.3 Replacing the pulley on the ball screw upper position Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 454: Replacing The Pulley On The Ball Screw Lower Position

    The pulley is located as shown in the figure. xx2100001017 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 455 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 456 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 457 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 458 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 459 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 460 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 461 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002407 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 462 Clean the bellow gasket from the glue if it will be reused. Note Be careful when removing the bellow gaskets. If any broken, replace it. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 463 Remove the shaft from the mechanical stopper. Note xx1900001616 The shaft is glued to the ball screw. Be careful with the glue when removing the shaft. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 464 Loosen the screws of the axis-3 motor sub-as- sembly to let the axis-3 timing belt free. xx2100001078 Remove the timing belt. xx2100001079 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 465 IP30 (option 3350-300) xx1800002860 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900001642 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 466 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws and washers on the ball screw flange. xx2100001082 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 467 Be careful when you do any work that may cause this. xx2100001084 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 468 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 469 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 470 Refit the belt to the pulley. Timing belt, A4-2: Ensure that the belt runs correctly in the grooves. 3HAC070471-001 xx2100001086 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 471 Pre-tighten the screws at 0.5Nm and slide the ball screw up and down for five times. Then tighten the screws at 3.8Nm to secure it. xx2100001082 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 472 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 473 The flat side is on the upper side. Clean Room (option 3351-1) For 180 mm ball screw xx2100002425 For 300 mm ball screw Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 474 IP30 (option 3350-300) xx1800002860 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900001642 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 475 Washers: Plain washer machining 4.2x9x2 steel (4 pcs) Tightening torque: 2.6 Nm ±10% xx2100001078 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 476 Make sure that the ball screw is supported with something. The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 477 New belt:180 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 478 For robots with protection type Clean Room (op- tion 3351-1) Tightening torque: 0.4 Nm ±10% Secure the shaft to the ball screw with the screws. xx1900001616 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 479 For robots with protection class IP54 (option 3350- 540) Apply the glue to the outer arm. xx2100002409 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 480 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 481 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Refit the lower cover to the ball screw. xx2100002405 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 482 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 483 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 484 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 485 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 486 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 487 5.6.4 Replacing the pulley on the ball screw lower position Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 488: Replacing The Ball Screw

    Location of the ball screw The ball screw is located as shown in the figure. xx2100001019 IP30 Clean Room/IP54 xx2100001019 xx2100002431 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 489 Replacing the bellows. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 490 Do not lay down the robot during the transporta- tion, always keep it straight. If the robot lay down in any situation, the grease may come out from gearbox. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 491 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 492 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 493 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 494 For robots with protection class IP54 (option 3350- 540) Check the gasket for the extension shaft and re- place it if needed. xx2100002421 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 495 IP54 (option 3350-540) For robots with protection type Check the gasket and replace it if needed. Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 496 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the lower cover from the ball screw. xx2100002405 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 497 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 498 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 499 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 500 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 501 Removing the ball screw with the flange Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 502 Remove the screws and washers on the ball screw flange. xx2100001082 Insert the special tool into the ball screw shaft. IRB 920 special tool:3HAC077249- xx2100001129 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 503 Loosening the transmission module screws Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 504 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 505 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 506 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screw. xx1800002858 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 507 Be careful when you do any work that may cause this. xx2100001089 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 508 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 509 Refitting the ball screw lower nut Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 510 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 511 Be careful when you do any work that may cause this. Refit the screws. xx2100001090 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 512 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 513 Be careful when you do any work that may cause this. xx1900002012 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900002011 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 514 CAUTION With the inserting of the ball screw shaft, remove the special tool along with the ball screw shaft carefully. xx2100001083 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 515 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 516 The flat side is on the upper side. Clean Room (option 3351-1) For 180 mm ball screw xx2100002425 For 300 mm ball screw Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 517 IP30 (option 3350-300) xx1800002860 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900001642 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 518 Make sure that the ball screw is supported with something. The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 519 Make sure that the ball screw is supported with something. The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 520 New belt:180 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 521 Washers: Plain washer machining 4.2x9x2 steel (4 pcs) Tightening torque: 2.6 Nm ±10% xx2100001078 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 522 3351-1) Install the shaft to the ball screw at 40.2 mm pos- ition to the lower of the ball screw. xx1900001617 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 523 For robots with protection type Clean Room (op- tion 3351-1) Insert the O-ring to the shaft. Note Replace the o-ring if needed. xx1900001615 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 524 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Install the bellow to the shaft. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 525 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 526 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Refit the lower cover to the ball screw. xx2100002405 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 527 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 528 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 529 For robots with protection type Clean Room (op- tion 3351-1) Insert the O-ring to the extension shaft. Note Replace the o-ring if needed. xx2100002419 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 530 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 531 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 532 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 533 5 Repair 5.6.5 Replacing the ball screw Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 534: Replacing The Axis-2 Timing Belt

    The axis-2 timing belt is located as shown in the figure. xx2100001024 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 535 Preparations before removing the axis-2 timing belt Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 536 Removing the process hub screws Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 537 Removing the top cover and the flange with bearing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 538 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the screws on the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 539 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 540 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 541 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 542 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 543 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 544 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 545 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 546 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 547 Removing the gear-2 pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 548 118. Remove the screws and washers. Remove the motor. Move the internal harness out of the way. xx2100001046 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 549 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 550 Pay attention to the force application direction. If the ball screw will interfere with the handheld dynamometer, adjust the ball screw manually. xx2100001125 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 551 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 552 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 553 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 554 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 555 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 556 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 557 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 558 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 559 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 560 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 561 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 562 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 563 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 564 5 Repair 5.6.6 Replacing the axis-2 timing belt Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 565: Replacing The Axis-3 Timing Belt

    The axis-3 timing belt is located as shown in the figure. xx2100001020 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 566 Preparations before removing the axis-3 timing belt Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 567 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 568 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 569 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 570 IP54 (option 3350-540) For robots with protection type Check the gasket and replace it if needed. Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 571 Loosen the screws of the axis-3 motor sub-as- sembly to let the axis-3 timing belt free. xx2100001078 Remove the timing belt. xx2100001079 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 572 Washers: Plain washer machining 4.2x9x2 steel (4 pcs) Tightening torque: 2.6 Nm ±10% xx2100001078 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 573 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 574 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 575 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 576 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 577 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 578 5 Repair 5.6.7 Replacing the axis-3 timing belt Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 579: Replacing The Axis-4 Second Timing Belt

    The axis-4 second timing belt is located as shown in the figure. xx2100001021 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 580 Preparations before removing the axis-4 second timing belt Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 581 Removing the process hub screws Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 582 Removing the top cover and the flange with bearing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 583 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the screws on the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 584 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 585 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 586 Make sure that the ball screw is supported with something. The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 587 118. Removing the screws of the ball screw flange to make enough space for removing the axis-4 second timing belt. xx2100001082 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 588 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 589 Refit the timing belt to the transmission module. xx2100001093 Timing belt, A4-2: 3HAC070471-001 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 590 Tightening torque: 2.6 Nm ±10% Place the axis-4 second timing belt through the ball screw flange. Secure with the screws without fully tightened. xx2100001091 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 591 Make sure that the ball screw is supported with something. The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 592 The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Hang a strong strap to the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 593 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 594 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 595 New belt:110 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 596 Refit the screws. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 597 For robots with protection type Clean Room (op- tion 3351-1) Tightening torque: 0.8 Nm ±10% Refit the screws to the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 598 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 599 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 600 5 Repair 5.6.8 Replacing the axis-4 second timing belt Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 601: Replacing The Axis-4 Timing Belt

    The axis-4 timing belt is located as shown in the figure. xx2100001022 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 602 Preparations before removing the axis-4 timing belt Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 603 Removing the process hub screws Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 604 Removing the top cover and the flange with bearing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 605 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the screws on the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 606 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 607 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 608 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 609 118. Removing the screws of the transmission module assembly. xx2100001091 Take out the transmission module assembly with the axis-4-2 timing belt. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 610 Removing the axis-4 timing belt Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 611 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 612 Tightening torque: 2.6 Nm ±10% xx2100001095 Hang a strap to the motor and hold the transmis- sion module. Note Just tighten the tool. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 613 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 614 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 615 Refit the belt to the pulley. Timing belt, A4-2: Ensure that the belt runs correctly in the grooves. 3HAC070471-001 xx2100001086 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 616 Adjusting the axis-4 second timing belt tension Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 617 New belt:180 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 618 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 619 Washers: Plain washer machining 4.2x9x2 steel (4 pcs) Tightening torque: 2.6 Nm ±10% xx2100001078 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 620 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 621 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 622 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 623 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 624 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 625 5 Repair 5.6.9 Replacing the axis-4 timing belt Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 626: Replacing The Transmission Module

    The transmission module is located as shown in the figure. xx2100001018 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 627 Preparations before removing the transmission module Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 628 Removing the process hub screws Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 629 Removing the top cover and the flange with bearing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 630 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the screws on the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 631 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 632 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 633 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 634 118. Removing the screws of the transmission module assembly. xx2100001091 Take out the transmission module assembly with the axis-4-2 timing belt. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 635 Removing the axis-4 motor sub-assembly Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 636 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 637 Timing belt, A4-1: 3HAC070470-001 Refit the timing belt to the motor. Ensure that the belt runs correctly in the grooves. xx2100001097 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 638 Tightening torque: 2.6 Nm ±10% xx2100001095 Hang a strap to the motor and hold the transmis- sion module. Note Just tighten the tool. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 639 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 640 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 641 Refit the belt to the pulley. Timing belt, A4-2: Ensure that the belt runs correctly in the grooves. 3HAC070471-001 xx2100001086 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 642 Adjusting the axis-4 second timing belt tension Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 643 New belt:180 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 644 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 645 Washers: Plain washer machining 4.2x9x2 steel (4 pcs) Tightening torque: 2.6 Nm ±10% xx2100001078 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 646 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 647 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 648 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 649 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 650 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 651 5 Repair 5.6.10 Replacing the transmission module Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 652: Replacing The Outer Arm

    The outer arm is located as shown in the figure. xx2100001013 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 653 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 654 Removing the process hub screws Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 655 Removing the top cover and the flange with bearing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 656 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the screws on the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 657 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 658 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 659 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002407 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 660 Clean the bellow gasket from the glue if it will be reused. Note Be careful when removing the bellow gaskets. If any broken, replace it. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 661 Remove the shaft from the mechanical stopper. Note xx1900001616 The shaft is glued to the ball screw. Be careful with the glue when removing the shaft. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 662 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the air hoses from the L-shaped con- nectors. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 663 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100001034 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 664 Disconnecting the connectors for axis-3 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 665 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 666 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 667 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 668 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000940 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 669 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 670 Removing the axis-2 timing belt Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 671 Make sure that the ball screw is supported with something. The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 672 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 673 Removing the ball screw with the flange Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 674 Remove the screws and washers on the ball screw flange. xx2100001082 Insert the special tool into the ball screw shaft. IRB 920 special tool:3HAC077249- xx2100001129 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 675 Removing the transmission module assembly Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 676 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 677 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 678 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 679 Cut the paint or surface on the robot before replacing parts on page 118. Insert the main harness through the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 680 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 681 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 682 CAUTION With the inserting of the ball screw shaft, remove the special tool along with the ball screw shaft carefully. xx2100001083 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 683 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 684 The flat side is on the upper side. Clean Room (option 3351-1) For 180 mm ball screw xx2100002425 For 300 mm ball screw Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 685 IP30 (option 3350-300) xx1800002860 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx1900001642 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 686 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 687 The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Tighten the screws of the ball screw flange. xx2100001082 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 688 Pay attention to the force application direction. xx2100001127 Fasten the screws on the transmission module to Tightening torque: 2.6 Nm ±10% the recommended tightening torque. xx2100001087 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 689 Refit the timing belt to the pulley on the ball screw Timing belt A3: and the motor. Ensure that the belt runs correctly 3HAC070464-001 in the grooves. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 690 New belt:110 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. xx1800002887 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 691 Washers: Plain washer machining 4.2x9x2 steel (4 pcs) Tightening torque: 2.6 Nm ±10% xx2100001078 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 692 Refit the axis-2 timing belt onto the pulley on the axis-2 gearbox. xx2100001048 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 693 Fasten the screws to the recommended tightening Tightening torque: 2.3 Nm ±10% torque. xx2100001176 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 694 Align all the cable ferrules so that the cable is in a natural bending position to avoid twisting. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 695 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 696 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 697 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 698 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 699 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 700 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 701 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 702 Note Fulfill the gaps on the ball screw in this contacted zone to make a sealing structure. xx1900001805 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 703 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Install the bellow to the shaft. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 704 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 705 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Refit the lower cover to the ball screw. xx2100002405 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 706 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 707 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 708 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 709 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 710 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 711 5 Repair 5.6.11 Replacing the outer arm Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 712: Motors

    The axis-1 motor sub-assembly is located as shown in the figure. xx2100001014 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 713 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 714 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 715 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 716 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 717 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 718 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 719 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 720 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 721 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 722 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 723 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 724 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 725 Removing the axis-1 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 726 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 727 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 728 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 729 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws on the base to the ground. Lay down the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 730 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002434 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 731 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 732 Disconnecting the connectors for axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 733 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 734 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 735 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 736 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 737 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 738 Removing the pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 739 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws and washers. Remove the motor. xx2100001038 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 740 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 741 4.2x9x2 steel (3 pcs) tightened. Tightening torque: 2.8 Nm ±10% xx2100001038 Timing belt A1: 3HAC070449-001 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 742 Refitting the pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 743 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 744 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 745 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 746 Screws: Hex socket head cap with the screw. screw M3x5 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.5 Nm ±10% xx2100000947 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 747 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000951 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 748 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100000945 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 749 For robots with protection class IP54 (option 3350-540) Screws: Hex socket head cap screw M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2100002433 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 750 For robots with protection type Clean Room (op- tion 3351-1) Refit the one way valve by screwing it into the main harness assembly. xx2200000281 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 751 Clean Room (option 3351-1) Screws: Hex socket head cap screw M3x30 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 1.2 Nm ±10% xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 752 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 753 5.7.1 Replacing the axis-1 motor sub-assembly Continued Action Note Apply grease to the internal harness, cover all moving area of the harness. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 754 Secure the base plate/ rear plate to the base with the screws. xx2100002434 For undeneath outlet cable version: For robots with protection class IP30 (option 3350-300) xx2100001202 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 755 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 756 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 757 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 758 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 759 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 760 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 761 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 762 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 763 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 764 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 765 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 766 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 767 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 768 Refitting the axis-2 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 769 Refit the screws. xx2100000943 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002451 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 770 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 771: Replacing The Axis-2 Motor Sub-Assembly

    The axis-2 motor sub-assembly is located as shown in the figure. xx2100001023 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 772 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 773 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 774 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 775 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 776 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 777 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 778 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 779 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 780 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 781 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 782 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 783 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 784 Removing the gear-2 pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 785 118. Remove the screws and washers. Remove the motor. Move the internal harness out of the way. xx2100001046 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 786 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 787 Refit the axis-2 timing belt onto the pulley on the axis-2 gearbox. xx2100001048 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 788 Fasten the screws to the recommended tightening Tightening torque: 2.3 Nm ±10% torque. xx2100001176 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 789 Align all the cable ferrules so that the cable is in a natural bending position to avoid twisting. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 790 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 791 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 792 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 793 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 794 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 795 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 796 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 797 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 798 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 799 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 800 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 801 5 Repair 5.7.2 Replacing the axis-2 motor sub-assembly Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 802: Replacing The Axis-3 Motor Sub-Assembly

    The axis-3 motor sub-assembly is located as shown in the figure. xx2100001025 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 803 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 804 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 805 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 806 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the flange with bearing. xx2100002402 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 807 IP54 (option 3350-540) For robots with protection type Check the gasket and replace it if needed. Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 808 Removing the axis-3 motor sub-assembly Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 809 Separating the flange from axis-3 motor sub-assembly Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 810 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 811 Refit the timing belt to the pulley on the ball screw Timing belt A3: and the motor. Ensure that the belt runs correctly 3HAC070464-001 in the grooves. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 812 New belt:110 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. xx1800002887 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 813 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 814 Refit the screws. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002427 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 815 For robots with protection type Clean Room (op- tion 3351-1) Tightening torque: 0.8 Nm ±10% Refit the screws to the flange with bearing. xx2100002401 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 816 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 817 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 818 5 Repair 5.7.3 Replacing the axis-3 motor sub-assembly Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 819: Replacing The Axis-4 Motor Sub-Assembly

    The axis-4 motor sub-assembly is located as shown in the figure. xx2100001026 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 820 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 821 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 822 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 823 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 824 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 825 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 826 Make sure that the ball screw is supported with something. The sudden drop of the ball screw due the lost of the axis-3 motor may cause danger. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 827 118. Removing the screws of the ball screw flange to make enough space for removing the axis-4 second timing belt. xx2100001082 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 828 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 829 (2 pcs) Move the internal harness out of the way. Tightening torque: 2.6 Nm ±10% Refit the screws and washers. xx2100001094 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 830 Tightening torque: 2.6 Nm ±10% xx2100001095 Hang a strap to the motor and hold the transmis- sion module. Note Just tighten the tool. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 831 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 832 Refit the belt to the pulley. Timing belt, A4-2: Ensure that the belt runs correctly in the grooves. 3HAC070471-001 xx2100001086 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 833 Adjusting the axis-4 second timing belt tension Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 834 New belt:180 If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 835 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 836 Washers: Plain washer machining 4.2x9x2 steel (4 pcs) Tightening torque: 2.6 Nm ±10% xx2100001078 Hang a strap to the hook on the motor. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 837 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 838 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 839 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 840 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 841 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 842 5 Repair 5.7.4 Replacing the axis-4 motor sub-assembly Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 843: Gearboxes

    The axis-1 gear unit sub-assembly is located as shown in the figure. xx2100001027 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 844 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 845 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 846 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 847 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 848 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 849 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 850 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 851 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 852 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 853 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 854 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 855 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 856 Removing the axis-1 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 857 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 858 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 859 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 860 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws on the base to the ground. Lay down the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 861 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002434 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 862 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 863 Disconnecting the connectors for axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 864 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 865 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 866 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 867 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 868 Replace the gasket if needed. For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 869 Removing the pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 870 Cut the paint or surface on the robot before replacing parts on page 118. Remove the screws and washers. Remove the motor. xx2100001038 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 871 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 872 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 873 When the gear unit is in the right position, you can hear a clear "Click". Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 874 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 875 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Put the timing belt into the pulley on the gear. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 876 During the measurement, make sure that all inter- ferences that may affect the force are removed. Pay attention to the force application direction. xx2100001043 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 877 M4x10 12.9 Lafre Secure the screws on the pulley protection cover 2C2B/FC6.9 (8 pcs) to the base. Tightening torque: 0.8 Nm xx2100001037 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 878 For undeneath outlet cable version: CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2100001206 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 879 Route the cabling behind the axis-1 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 880 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 881 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000951 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 882 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100000945 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 883 For robots with protection class IP54 (option 3350-540) Screws: Hex socket head cap screw M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2100002433 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 884 For robots with protection type Clean Room (op- tion 3351-1) Refit the one way valve by screwing it into the main harness assembly. xx2200000281 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 885 Clean Room (option 3351-1) Screws: Hex socket head cap screw M3x30 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 1.2 Nm ±10% xx2100002436 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 886 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 887 5.8.1 Replacing the axis-1 gear unit sub-assembly Continued Action Note Apply grease to the internal harness, cover all moving area of the harness. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 888 Secure the base plate/ rear plate to the base with the screws. xx2100002434 For undeneath outlet cable version: For robots with protection class IP30 (option 3350-300) xx2100001202 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 889 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 890 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 891 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 892 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 893 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 894 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 895 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 896 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 897 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 898 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 899 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 900 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 901 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 902 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 903 Refitting the axis-2 cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 904 Refit the screws. xx2100000943 For robots with protection class IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100002451 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 905 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 906: Replacing The Axis-2 Gear Unit Sub-Assembly

    The axis-2 gear unit sub-assembly is located as shown in the figure. xx2100001028 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 920 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 907 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 908 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 909 IP54 (option 3350-540) For robots with protection type Clean Room (option 3351-1) xx2100000932 Insert the process hub to the outer arm. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 910 For robots with protection class IP54 (option 3350- 540) For robots with protection type Clean Room (op- tion 3351-1) Remove the top cover from the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 911 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 912 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 913 The connector clip has to be pressed (1) and pushed forward (2) to separate the R1.C2 (for C2 cabling). xx1800002943 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 914 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP2 • R2.FB2 xx2100000934 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 915 Cut the paint or surface on the robot before replacing parts on page 118. Disconnect the connectors. • R2.MP3 • R2.FB3 xx2100000936 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 916 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. xx2100000939 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 917 Pull out the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 918 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 919 Removing the gear-2 pulley protection cover Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 920 118. Remove the screws and washers. Remove the motor. Move the internal harness out of the way. xx2100001046 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 921 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 922 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 923 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 924 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 925 Check the O-ring and replace it if needed. When the gear unit is in the right position, you can hear a clear "Click". Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 926 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 927 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 928 Pay attention to the force application direction. If the ball screw will interfere with the handheld dynamometer, adjust the ball screw manually. xx2100001125 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 929 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 930 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Lay the internal harness in a natural state without distortion. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 931 The harness are not visible due to the cleanness requirements of the illustration. They are still ex- isting inside the cable ferrule in the actual situ- ation. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 932 Route the cabling on the axis-4 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 933 Route the cabling on the axis-3 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 934 Route the cabling behind the axis-2 motor. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 935 Route and secure the cabling with cable straps if needed. CAUTION Correct cable routing is highly important. If the cables are routed incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 936 CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 937 The air hoses with the same number connect to the same Y-shaped connector. xx2100001032 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 938 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 939 118 Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 940 Refit the top cover to the ball screw. The top surface of the cover should be flush with the top end of the ball screw. xx2100002399 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 941 After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. Insert the process hub from the outer arm cover. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 942 Cut the paint or surface on the robot before replacing parts on page 118. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 943 Recalibrate the robot. Calibration is detailed in section Calibration on page 945. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 944 5 Repair 5.8.2 Replacing the axis-2 gear unit sub-assembly Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 945: Calibration

    Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.

  • Page 946: Calibration Methods

    Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 920. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: •...
  • Page 947 References Article numbers for the calibration tools are listed in the section Special tools on page 997. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 948: When To Calibrate

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

  • Page 949: Synchronization Marks And Axis Movement Directions

    6.2.1 Synchronization marks and synchronization position for axes Introduction This section shows the position of the synchronization marks and the synchronization position for each axis. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 950 6 Calibration 6.2.1 Synchronization marks and synchronization position for axes Continued Synchronization marks, IRB 920 xx2000001163 Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 951: Calibration Movement Directions For All Axes

    Positive directions are shown in the graphic below. Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below. Manual movement directions xx2100000931 Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 952: Updating Revolution Counters

    When all axes are positioned, update the Step 2 - Updating the revolution counter revolution counter. with the FlexPendant on page 955. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 953 This will further affect the calibration position of axis 3. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 954 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 955 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 976. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 956: Calibrating With Axis Calibration Method

    FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
  • Page 957 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
  • Page 958 New calibration values have to be downloaded to SafeMove, and a new SafeMove calibration has to be done. Make sure that the user rights admit to change the safety settings and to synchronize SafeMove. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 959: Calibration Tools For Axis Calibration

    There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
  • Page 960 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.

  • Page 961: Installation Locations For The Calibration Tools

    Replace damaged parts with new. Spare part Article number Note Protective plug for bushing 3HAC054431-005 Replace if damaged or missing. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 962: Axis Calibration - Running The Calibration Procedure

    WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
  • Page 963 For RobotWare 7, the mechanical unit page is displayed only if there is more than one mechan- ical unit available. The calibration method used at ABB factory for The FlexPendant will give all inform- each axis is shown, as well as calibration method ation needed to proceed with Axis used for the robot during last field calibration.
  • Page 964 Axis Calibration routine. When a warning message is displayed, tap Acknowledge to confirm the unsynchronized state and continue Axis Calibration procedure. CAUTION SafeMove must be synchronized after the calibration is completed. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 965 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC059487-001. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 966: Reference Calibration

    6.4.5 Reference calibration Brief introduction to Reference Calibration Note Only axes 1 and 2 of the IRB 920 can be calibrated with the reference calibration routine. Reference calibration is a faster method compared to Fine calibration, as it refers to a previously made calibration.
  • Page 967 The requirement to do manual tuning is that there is a known accurate position, that worked accurately before the repair (step 5, see Brief introduction to Reference Calibration on page 966). Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 968: Calibrating The Robot

    6 Calibration 6.5.1 Calibration position 6.5 Calibrating the robot 6.5.1 Calibration position Calibration position The table below specifies the axis positions. Axis 2 mm 0° Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 969: Calibrating Axis 1 And Axis 2

    6.5.2 Calibrating axis 1 and axis 2 6.5.2 Calibrating axis 1 and axis 2 Calibrating axis 1 and axis 2 Axes 1 and 2 of the IRB 920 are calibrated using the Axis Calibration method. See Calibrating with Axis Calibration method on page 956.

  • Page 970: Calibrating Axis 3 And Axis 4

    Calibration position of axis 3 and axis 4 The figure shows axis 3 and axis 4 in calibration position. The axes 3 and 4 are calibrated together. xx2000001165 Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 971 Make sure the payload is disassembled or tooling is properly supported; otherwise, fast downward movements of axis 3 may cause severe hits. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 972 The calibration summary for the selected mechan- ical unit is displayed. On the right pane tap Calibration Methods. Tap Calibration Parameters. The calibration parameters are displayed. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 973 Jog axes 3 and 4 to zero degree using the Flex- Pendant. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 974 In this case, update the revolution counters for axis 3 and axis 4 (axis 4 is coupled with axis 3). See Updating revolution counters on page 952. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 975: Verifying The Calibration

    949. Write down the values on a new label and stick it on top of the calibration label. The label is located on the base. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 976: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 949 date the revolution counters. Updating revolution counters on page 952. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 977: Troubleshooting

    Check: been installed • the configuration files • connectors • options and their configuration • changes in the robot working space/movements. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 978 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 979: Oil And Grease Stains On Motors And Gearboxes

    "cooling periods" into the your local ABB representative. application. • Overpressure created inside gearbox. Inspect all sealings and gaskets between motor and gearbox. Replace broken parts. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 980: Mechanical Noise Or Dissonance

    Bearings inside motors are not to be re- placed individually, but the complete motor is replaced. Make sure the bearings are fitted correctly. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 981 Investigate whether it chased from your local ABB representat- is possible to program small "cooling ive. periods" into the application. • Overpressure created inside gearbox. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 982: Manipulator Collapses On Power Down

    Remove the motor from the gearbox to in- If found faulty, the motor must be replaced spect it from the drive side. as a complete unit. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 983: Motor Temperature Too High

    The ways could be but not limited to op- tor utilization. timizing robot movement cycle, adjusting acc, dec as well as external force, adding wait time, and introducing alternative path/RAPID, etc. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 984 This page is intentionally left blank...

  • Page 985: Decommissioning

    These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 986: Environmental Information

    8.2 Environmental information 8.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
  • Page 987 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of IRB 920 according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".

  • Page 988: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 989: Reference Information

    9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 990: Applicable Standards

    Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices) EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus- trial robots — Part 1: Robots Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 991: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 992: Screw Joints

    9.4 Screw joints 9.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
  • Page 993 Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 994 Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Lubricated with Molycote 1000, Gleitmo 603 or equivalent Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 995: Weight Specifications

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

  • Page 996: Standard Toolkit

    Torque wrench 0.3-45 Nm Torque wrench 56 Nm±5.6 Nm For securing robot to foundation. Small screwdriver T-handle with ball head Small cutting plier Plastic mallet Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.

  • Page 997: Special Tools

    Special tools Note If the replacing procedure is not listed in the table below, only standard tools are needed for the procedure. Continues on next page Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 998 9 Reference information 9.7 Special tools Tools and equipment with spare part number: (These tools can be ordered from ABB) 24 VDC power supply 3HAC055412-001 Calibration toolbox, Axis Calibration Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot.

  • Page 999: Lifting Accessories And Lifting Instructions

    The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 920 3HAC075721-001 Revision: C © Copyright 2022 ABB. All rights reserved.
  • Page 1000 This page is intentionally left blank...

This manual is also suitable for:

Irb 920 seriesIrb 920-6/0.55Irb 920-6/0.65Irb 920t-6/0.45Irb 920t-6/0.55Irb 920t-6/0.65

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