ABB IRB 120 Product Manual
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ABB IRB 120 Product Manual

ABB IRB 120 Product Manual

Articulated robot
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Articulated robot
IRB 120 - 3/0.6

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Summary of Contents for ABB IRB 120

  • Page 1 Product manual Articulated robot IRB 120 - 3/0.6...
  • Page 3 Product manual IRB 120 - 3/0.6 M2004 Document ID: 3HAC035728-001 Revision: B...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents Overview of this manual..............7 Product documentation, M2004 .
  • Page 6 Table of Contents 3 Maintenance 3.1 Introduction ............... 73 3.2 Maintenance schedule and expected component life .
  • Page 7 Table of Contents 6 Decommissioning 6.1 Introduction ..............183 6.2 Environmental information.
  • Page 8 Table of Contents 3HAC035728-001 Revision: B...

  • Page 9: Overview Of This Manual

    • maintenance personnel • repair personnel. Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Continues on next page 3HAC035728-001 Revision: B...
  • Page 10 Detailed illustrations of the robot with reference numbers to the part list. Circuit diagram Reference to the circuit diagram for the robot.. References Reference Document ID Product specification - IRB 120 3HAC035960-001 Product manual - IRC5 3HAC021313-001 Product manual - IRC5 Compact 3HAC035738-001 Product manual - Panel Mounted Controller...
  • Page 11 • Safety chapter- Revised terminology: robot replaced with manipula- tor. • Safety chapter - Information not applicable to IRB 120 in WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 43 removed.
  • Page 12 • Installation chapter - Lifting capacity of roundslings updated. See: Lifting the robot with roundslings on page • Installation chapter - New illustration showing IRB 120 added. See: Suspended mounting on page • Repair chapter - Illustrations xx0900001009 and xx0900000782 updated.

  • Page 13: Product Documentation, M2004

    The manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
  • Page 14 Product documentation, M2004 Continued Operating manuals 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 trouble shooters. The group of manuals includes: •...

  • Page 15: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material, etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the manipulator/controller.
  • Page 16 How to read the product manual 3HAC035728-001 Revision: B...

  • Page 17: Safety

    1 Safety 1.1. Introduction to safety information 1 Safety 1.1. Introduction to safety information Overview The safety information in this manual is divided in two categories: • General safety aspects, important to attend to before performing any service work on the robot.

  • Page 18: General Safety Information

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 19: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the manipulator, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 20 1 Safety 1.2.2.1. Safety risks during installation and service work on manipulators Continued Complete manipulator Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the manipulator! Touching motors and gears may result in burns! With a higher environment temperature, more surfaces on the manipulator will get HOT and may also result in burns.

  • Page 21: Caution - Hot Parts May Cause Burns

    1 Safety 1.2.2.2. CAUTION - Hot parts may cause burns! 1.2.2.2. CAUTION - Hot parts may cause burns! Description During normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity.

  • Page 22: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.3. Safety risks related to tools/workpieces 1.2.2.3. Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

  • Page 23: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.4. Safety risks related to pneumatic/hydraulic systems 1.2.2.4. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy can be present in these systems. After shutdown, particular care must be taken.

  • Page 24: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.5. Safety risks during operational disturbances 1.2.2.5. Safety risks during operational disturbances General • The industrial manipulator is a flexible tool that can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 25: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.6. Risks associated with live electric parts 1.2.2.6. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 26: Safety Actions

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

  • Page 27: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC035728-001 Revision: B...

  • Page 28: Emergency Release Of The Manipulator's Arm

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

  • Page 29: Brake Testing

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

  • Page 30: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC035728-001 Revision: B...

  • Page 31: Safe Use Of The Flexpendant

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

  • Page 32: Work Inside The Manipulator's Working Range

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

  • Page 33: Safety Stops

    1 Safety 1.2.4.1. What is an emergency stop? 1.2.4. Safety stops 1.2.4.1. What is an emergency stop? Definition of emergency stop An emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts and disconnects power from any potentially dangerous functions controlled by the manipulator system.
  • Page 34 1 Safety 1.2.4.1. What is an emergency stop? Continued Emergency stop devices In a manipulator system there are several emergency stop devices that can be operated in order to achieve an emergency stop. There are emergency stop buttons available on the FlexPendant and on the controller cabinet (on the Control Module on a Dual Cabinet Controller).

  • Page 35: Safety Related Instructions

    1 Safety 1.3.1. Safety signals in the manual 1.3 Safety related instructions 1.3.1. Safety signals in the manual Introduction to safety signals This section specifies all dangers that can arise when doing the work described in this manual. Each danger consists of: •...
  • Page 36 1 Safety 1.3.1. Safety signals in the manual Continued Symbol Designation Significance ELECTROSTATIC Warns for electrostatic hazards which could result in DISCHARGE (ESD) severe damage to the product. Electrostatic discharge (ESD) NOTE Describes important facts and conditions. Note Describes where to find additional information or how to do an operation in an easier way.

  • Page 37: Safety Symbols On The Manipulator Labels

    1 Safety 1.3.2. Safety symbols on the manipulator labels 1.3.2. Safety symbols on the manipulator labels Introduction to labels This section describes safety symbols used on labels (stickers) on the manipulator. Symbol are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain additional information such as values.
  • Page 38 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Product manual Read the product manual for details. xx0900000813 Before dismantling see product manual xx0900000816 Do not dismantle Dismantling this part can cause injury. xx0900000815 Extended rotation This axis has extended rotation (working area) compared to standard.
  • Page 39 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 Brake release buttons xx0900000820 Lifting bolt xx0900000821 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed.
  • Page 40 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Mechanical stop xx0900000824 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level.

  • Page 41: Danger - Moving Manipulators Are Potentially Lethal

    1 Safety 1.3.3. DANGER - Moving manipulators are potentially lethal! 1.3.3. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the manipulator.

  • Page 42: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.4. DANGER - First test run may cause injury or damage! 1.3.4. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity, such as repair, installation, or maintenance.

  • Page 43: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! 1.3.5. WARNING - The unit is sensitive to ESD! Description ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.
  • Page 44 1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! Continued IRC5 Compact Controller xx0900000315 Wrist strap button 3HAC035728-001 Revision: B...

  • Page 45: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    1 Safety 1.3.6. WARNING - Safety risks during work with gearbox lubricants (oil or grease) 1.3.6. WARNING - Safety risks during work with gearbox lubricants (oil or grease) Description When handling the gearbox lubricants, there is a risk of both personal injury and product damage occurring! The following safety information must be regarded before performing any work with lubricants in the gearboxes! Warnings and elimination...
  • Page 46 1 Safety 1.3.6. WARNING - Safety risks during work with gearbox lubricants (oil or grease) 3HAC035728-001 Revision: B...

  • Page 47: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot at the working site. More detailed technical data can be found in the Product specification for the robot, such as: •...

  • Page 48: Unpacking

    Checking the pre-requisites for installation Installation craftsmen working with an ABB robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 49 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Loads on foundation, robot Endurance load Max. load at Force Mounting position (in operation) (emergency stop) Force Fxy Floor & Suspended ±265 ±515 Wall ±470 ±735 Force Fz Floor -265 ±200 -265 ±365 Suspended 265 ±200 265 ±365...
  • Page 50 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Protection classes, robot The table shows the protection class of the robot: Robot version Protection class Standard IP 30 IP 30 - the first index indicates: • Protection against human/tool contact. "3" = a tool bigger than or equal to 2,5 mm in diameter.

  • Page 51: Working Range And Type Of Motion

    2 Installation and commissioning 2.2.2. Working range and type of motion 2.2.2. Working range and type of motion Working range The figures show the working ranges of the robot. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). Working range The illustration shows the unrestricted working range of the robot.
  • Page 52 The turning radius of robot is shown in the figure. xx0900000157 Robot variant Pos. A Pos. B Pos. C IRB 120-3/0.6 R121 R580 R169.4 Minimum turning radius axis 1. Robot motion The table specifies the types and ranges of motion in every axes.

  • Page 53: Risk Of Tipping/Stability

    2 Installation and commissioning 2.2.3. Risk of tipping/Stability 2.2.3. Risk of tipping/Stability Risk of tipping When the robot is not fastened to the foundation , the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.

  • Page 54: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting the robot with roundslings 2.3 On-site installation 2.3.1. Lifting the robot with roundslings Introduction This procedure details how to lift the robot using roundslings. Required equipment Equipment Note Overhead crane Roundslings (Circle) Length: 3 m Lifting capacity: 100 kg Lifting tool, set The set includes:...
  • Page 55 2 Installation and commissioning 2.3.1. Lifting the robot with roundslings Continued Lifting Attach the roundslings as shown in the figure. xx0900000496 Bracket Lifting instructions Use this procedure to lift the robot in a safe way. Action Note CAUTION! The robot weighs 25 kg. All lifting equipment must be sized accordingly! CAUTION! Attempting to lift the robot in any other...
  • Page 56 2 Installation and commissioning 2.3.1. Lifting the robot with roundslings Continued Action Note WARNING! Personnel must not, under any circum- stances, be present under the suspended load! 4. Move the robot to its most stable position. Detailed in section: • Risk of tipping/Stability on page 51 DANGER! Turn off all electric power, hydraulic and...

  • Page 57: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. Manually releasing the brakes Introduction to manually releasing the brakes This section describes how to release the holding brakes of each axis´ motor. This can be done in three ways: •...
  • Page 58 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Using the brake release unit when the robot is connected to the controller Use this procedure to release the holding brakes using the internal brake release unit in the controller cabinet. Action Note 1.
  • Page 59 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Using the brake release unit with an external power supply Use this procedure to release the holding brakes, when the robot is not connected to the controller. Action Note NOTE! Be careful not to interchange the 24V and 0V pins.

  • Page 60: Orienting And Securing The Robot

    2 Installation and commissioning 2.3.3. Orienting and securing the robot 2.3.3. Orienting and securing the robot Introduction This section details how to orient and secure the robot to the foundation or base plate in order to run the robot safely. The requirements made on the foundation are shown in sections: •...
  • Page 61 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Specification, attachment screws and pins The table specifies the type of securing screws and washers to be used to secure the robot to the foundation or base plate. It also specifies the type of pins to be used. Securing parts/Facts Dimension Note...
  • Page 62 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Action Info 9. Tighten the bolts in a criss-cross pattern to ensure that the base is not distorted. Securing robot on a mounting plate When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts.

  • Page 63: Fitting Equipment On Robot

    Make sure the required mounting holes are accessible when planning the robot cell. NOTE! Never drill a hole in the robot without first consulting ABB! Maximum loads The table shows the maximum permitted loads for any extra equipment fitted in the holes intended for this purpose.
  • Page 64 2 Installation and commissioning 2.3.4. Fitting equipment on robot Continued Fitting equipment on base and upper arm The illustration shows the fitting holes available for fitting extra equipment on the base and upper arm of the robot. ± 0 .1 5 xx0900000203 Load area base, max load 0.5 kg (on each side) Load area upper arm, max load 0.3 kg...
  • Page 65 2 Installation and commissioning 2.3.4. Fitting equipment on robot Continued Fitting equipment on mounting flange The illustration shows the mechanical interface for the mounting flange. xx0900000204 3HAC035728-001 Revision: B...

  • Page 66: Suspended Mounting

    2 Installation and commissioning 2.3.5. Suspended mounting 2.3.5. Suspended mounting General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the robot in a suspended position is basically the same as for floor mounting. NOTE! With suspended installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can...
  • Page 67 2 Installation and commissioning 2.3.5. Suspended mounting Continued xx1000000126 Pos 1 Floor mounted Pos 2 Mounting angle 45° Pos 3 Mounting angle 90° Pos 4 Mounting angle 180° Defining the parameter in the software, RobotWare 5.0 The value of the system parameter Gravity beta must be redefined when changing the mounting angle of the robot.

  • Page 68: Loads

    Specification. The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant. Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC035728-001 Revision: B...

  • Page 69: Restricting The Working Range

    2 Installation and commissioning 2.4.1. Introduction 2.4 Restricting the working range 2.4.1. Introduction General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. This section describes how to install hardware that restricts the working range.

  • Page 70: Mechanically Restricting The Working Range

    2 Installation and commissioning 2.4.2. Mechanically restricting the working range 2.4.2. Mechanically restricting the working range Location of mechanical stops The figures shows where the mechanical stops are placed on the robot. xx1000000002 Mechanical stop axis 1 (base) Mechanical stop axis 1 (swing plate) xx0900000583 Mechanical stop axis 3 (upper arm) Mechanical stops axis 2 (swing housing)
  • Page 71 2 Installation and commissioning 2.4.2. Mechanically restricting the working range Continued xx1000000003 Mechanical stop axis 3 (lower arm) Mechanical stops axis 2 (lower arm) 3HAC035728-001 Revision: B...

  • Page 72: Electrical Connections

    2 Installation and commissioning 2.5.1. Robot cabling and connection points 2.5 Electrical connections 2.5.1. Robot cabling and connection points Introduction Connect the robot and the controller to each other after securing them to the foundation. The lists specify which cables to use for each respective application. Connection point locations For information about the connection point locations, see the chapter Circuit diagram.

  • Page 73: Customer Connections On Robot

    2 Installation and commissioning 2.5.2. Customer connections on robot 2.5.2. Customer connections on robot Introduction The customer cables are integrated in the robot and the connectors are placed on the upper arm housing and at the base. Connectors The tables describes the connectors on base and upper arm housing. Connectors, base Position Description...
  • Page 74 2 Installation and commissioning 2.5.2. Customer connections on robot Continued Customer connections The location of the customer connections on the base and at the upper arm housing, are shown in the figures: Customer connections, base xx0900000639 Customer connections, base. Connection Description Number Value R1.CP/CS Customer power/signal...

  • Page 75: Maintenance

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

  • Page 76: Maintenance Schedule And Expected Component Life

    3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected component life 3.2.1. Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the manipulator: •...

  • Page 77: Maintenance Schedule

    3 Maintenance 3.2.2. Maintenance schedule 3.2.2. Maintenance schedule General The robot, consisting of robot and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component.

  • Page 78: Expected Component Life

    3 Maintenance 3.2.3. Expected component life 3.2.3. Expected component life General The life of any component depends on how hard it is run, and it can vary greatly. Expected component life Component Expected life Note Cable harness 30,000 hours Not including: Normal usage •...

  • Page 79: Inspection Activities

    3 Maintenance 3.3.1. Inspection, robot cabling 3.3 Inspection activities 3.3.1. Inspection, robot cabling Location, robot cabling The robot cabling comprises the cabling between the robot and controller cabinet. Required equipment Equipment Note Standard toolkit The content is defined in the section Standard toolkit on page 191.

  • Page 80: Inspecting Mechanical Stops

    3 Maintenance 3.3.2. Inspecting mechanical stops 3.3.2. Inspecting mechanical stops Location of mechanical stops The mechanical stops on axes 1, 2 and 3 are located as shown in the figures. xx1000000002 Mechanical stop axis 1 (base) Mechanical stop axis 1 (swing plate) xx0900000583 Mechanical stop axis 3 (upper arm) Mechanical stops axis 2 (swing housing)
  • Page 81 3 Maintenance 3.3.2. Inspecting mechanical stops Continued xx10000000003 Mechanical stop axis 3 (lower arm) Mechanical stops axis 2 (lower arm) Required equipment Equipment Note Mechanical stop, axis 1 For art. no. see: • Spare parts - Axes 1 and 2 on page 195 Mechanical stop, axes 2-3 For art.
  • Page 82 3 Maintenance 3.3.2. Inspecting mechanical stops Continued Inspecting mechanical stops Use this procedure to inspect mechanical stops on axes 1, 2 and 3. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Inspect the mechanical stops. See the figures in: •...

  • Page 83: Inspecting Dampers

    3 Maintenance 3.3.3. Inspecting dampers 3.3.3. Inspecting dampers Location of dampers The location of dampers are shown in the figures. xx0900000579 Damper, axis 1 Mechanical stop axis 1 (swing plate) xx0900000582 Damper, axis 3 Dampers, axis 2 Required equipment Equipment Art.
  • Page 84 3 Maintenance 3.3.3. Inspecting dampers Continued Inspecting dampers Use this procedure to inspect the dampers. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Check all dampers for damage such as: See the figure in: •...

  • Page 85: Inspecting Timing Belts

    3 Maintenance 3.3.4. Inspecting timing belts 3.3.4. Inspecting timing belts Location of timing belts Axes 3 and 5 are fitted with timing belts. These are located as shown in the figures. xx0900000610 Timing belt, axis 3 Timing belt pulley (2 pcs) Lower arm cover xx0900000611 Wrist side cover...
  • Page 86 3 Maintenance 3.3.4. Inspecting timing belts Continued Required equipment Equipment Note Standard toolkit The content is defined in the section Standard toolkit on page 191. Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required.

  • Page 87: Inspecting Plastic Covers

    3 Maintenance 3.3.5. Inspecting plastic covers 3.3.5. Inspecting plastic covers Location of plastic covers Plastic covers are located as shown in the figure. xx0900000607 Lower arm cover (2 pcs) Wrist side cover (2 pcs) Wrist support Housing cover Tilt cover Continues on next page 3HAC035728-001 Revision: B...
  • Page 88 3 Maintenance 3.3.5. Inspecting plastic covers Continued Inspecting plastic covers Use this procedure to inspect the plastic covers on the robot. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Check the plastic covers for: •...

  • Page 89: Replacement/Changing Activities

    3 Maintenance 3.4.1. Type of grease in gearboxes 3.4 Replacement/changing activities 3.4.1. Type of grease in gearboxes Introduction The gearboxes of the robot contains grease. This section describes: • Location of gearboxes on page 87 • Type and amount of grease on page Location of gearboxes The gearboxes are located as shown in the figure: xx0900000612...
  • Page 90 3 Maintenance 3.4.1. Type of grease in gearboxes Continued Type and amount of grease The type and amount of grease in the gearboxes are described in the table: Gearbox Art. no. Type of grease Amount Note Axis 1 3HAC031695-001 Harmonic grease 58 grams Unit conversion: 4B No.2...

  • Page 91: Replacing The Battery Pack

    3 Maintenance 3.4.2. Replacing the battery pack 3.4.2. Replacing the battery pack Location of the battery pack The location of the battery pack is inside the base cover as shown in the figure. xx0900000588 Cable strap Battery pack Base cover Required equipment Equipment Note...
  • Page 92 3 Maintenance 3.4.2. Replacing the battery pack Continued Removing the battery pack Use this procedure to remove the battery pack. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the base cover from the robot by The battery pack is located inside the removing its attachment screws.

  • Page 93: Cleaning Activities

    3 Maintenance 3.5.1. Cleaning, robot 3.5 Cleaning activities 3.5.1. Cleaning, robot WARNING! Turn off all electrical power supplies to the manipulator before entering the manipulators work space! General To secure high uptime it is important that the robot is cleaned regularly. The frequency of cleaning depends on the environment that the robot is working in.
  • Page 94 3 Maintenance 3.5.1. Cleaning, robot 3HAC035728-001 Revision: B...

  • Page 95: Repair

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

  • Page 96: General Procedures

    4 Repair 4.2.1. Mounting instructions for seals 4.2 General procedures 4.2.1. Mounting instructions for seals General This section details how to mount different types of seals onto the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 97 If the flange surfaces are defective, the parts may not be used because leakage could occur. 2. Clean the surfaces properly and in accordance with ABB recommendations. 3. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 98: Cable Harness

    4 Repair 4.3.1. Removing the cable harness 4.3 Cable harness 4.3.1. Removing the cable harness Introduction These procedures describes how to remove the complete cable harness in: 1. the wrist - Removing the cable harness in the wrist on page 97 2.
  • Page 99 4 Repair 4.3.1. Removing the cable harness Continued Required equipment Equipment Note Standard toolkit The content is defined in the section Standard toolkit on page 191. Other tools and procedures may be These procedures include references to the tools required. See references to these required.
  • Page 100 4 Repair 4.3.1. Removing the cable harness Continued Action Info 4. Remove the tilt cover. xx0900000901 Parts: • A: Attachment screws(4 pcs) • B: Tilt cover • C: Motor axis 6 5. Unscrew the attachment screw securing the clamp at motor axis 5. xx0900000912 Parts: •...
  • Page 101 4 Repair 4.3.1. Removing the cable harness Continued Action Info 7. Remove the wrist housing (plastic). xx0900000900 Parts: • A: Attachment screws (3 pcs) • B: Wrist housing (plastic) 8. Remove the connector cover. xx0900000902 Parts: • A: Attachment screw •...
  • Page 102 4 Repair 4.3.1. Removing the cable harness Continued Action Info 11. Remove the connector support at axis 6. TIP! When removing the connector support rotate axis 5 to a 90° position. This is the most convenient position to remove the attachment screws.
  • Page 103 4 Repair 4.3.1. Removing the cable harness Continued Action Info 15. Cut the cable straps. xx0900001009 Parts: • A: Cable straps 16. Disconnect: • customer contact R2.CS • air hose. Continues on next page 3HAC035728-001 Revision: B...
  • Page 104 4 Repair 4.3.1. Removing the cable harness Continued Removing the cable harness in the upper arm housing Use this procedure to remove the cable harness in the upper arm housing. Action Info 1. Unscrew the attachment screws securing the cable bracket in the housing. xx0900001018 Parts: •...
  • Page 105 4 Repair 4.3.1. Removing the cable harness Continued Action Info 5. Unscrew the attachment screws securing the two cable brackets on each side of motor axis 4. xx0900001023 Parts: • A: Cable bracket • B: Cable bracket 6. Pull the cable harness out of the upper arm housing.
  • Page 106 4 Repair 4.3.1. Removing the cable harness Continued Removing the cable harness in the lower arm Use this procedure to remove the cable harness in the lower arm. Action Info 1. Remove the lower arm covers. xx0900000848 Parts: • A: Attachment screws (4 + 4 pcs) •...
  • Page 107 4 Repair 4.3.1. Removing the cable harness Continued Action Info 5. Detach the lower arm plate from the motor cover. xx0900000851 Parts: • A: Cable harness • B: Holes for attachment screws (4 pcs) • C: Motor cover • D: Lower arm plate 6.
  • Page 108 4 Repair 4.3.1. Removing the cable harness Continued Removing the cable harness in the base Use this procedure to remove the cable harness in the base. Action Info 1. Pull the cable harness out through the swing housing. 2. Separate the lower and upper arms as well See section: as the swing housing from the base.

  • Page 109: Refitting The Cable Harness

    4 Repair 4.3.2. Refitting the cable harness 4.3.2. Refitting the cable harness Introduction These procedures describes how to refit the complete cable harness in: 1. the base - Refitting the cable harness in the base on page 108 2. the lower arm - Refitting the cable harness in the lower arm on page 110 3.
  • Page 110 4 Repair 4.3.2. Refitting the cable harness Continued Required equipment Equipment Note Standard toolkit The content is defined in the section Standard toolkit on page 191. Other tools and procedures may be required. These procedures include references to See references to these procedures in the step- the tools required.
  • Page 111 4 Repair 4.3.2. Refitting the cable harness Continued Action Info 10. Secure the cable harness to the cable Tightening torque: 1 Nm. holder with the attachment screws. xx0900000884 Parts: • A: Swing plate • B: Cable holder • C: Attachment screws (2 pcs) •...
  • Page 112 4 Repair 4.3.2. Refitting the cable harness Continued Refitting the cable harness in the lower arm Use this procedure to refit the cable harness in the lower arm. Action Info 1. Fit the cable guide. Tightening torque: 1 Nm. xx0900000857 Parts: •...
  • Page 113 4 Repair 4.3.2. Refitting the cable harness Continued Action Info 4. Reconnect connectors: • R2.MP3 • R2.ME3. 5. Push the cable harness in through the upper arm housing. Refitting the cable harness in the upper arm housing Use this procedure to refit the cable harness in the upper arm housing. Action Info 1.
  • Page 114 4 Repair 4.3.2. Refitting the cable harness Continued Refitting the cable harness in the wrist Use this procedure to refit the cable harness in the wrist. Action Info 1. Reconnect: • customer contact R2.CS • air hoses. 2. Secure the cable harness with cable straps. xx0900001009 Parts: •...
  • Page 115 4 Repair 4.3.2. Refitting the cable harness Continued Action Info 6. Refit the attachment screw securing the Tightening torque: 1 Nm. clamp at motor axis 6. xx0900001000 Parts: • A: Attachment screw • B: Clamp 7. Refit the connector cover. Tightening torque: 1 Nm.
  • Page 116 4 Repair 4.3.2. Refitting the cable harness Continued Action Info 9. Refit connector support at axis 5. Tightening torque: 1 Nm. xx0900000888 Parts: • A: Attachment screws (2 pcs) • B: Connector support 10. Refit the attachment screw securing the Tightening torque: 1 Nm.
  • Page 117 4 Repair 4.3.2. Refitting the cable harness Continued Action Info 12. Refit the remaining plastic covers: Tightening torque: 1 Nm • wrist side cover • housing cover and • lower arm cover. 13. Recalibrate the robot. See chapter: • Calibration DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 118: Replacing The Encoder Interface Board

    4 Repair 4.3.3. Replacing the Encoder Interface board 4.3.3. Replacing the Encoder Interface board Introduction This procedure describes how to replace the Encoder Interface board. Location of the Encoder Interface board xx0900000842 Base cover Plate Encoder Interface Board (EIB board) Bracket Battery pack Cable strap...
  • Page 119 4 Repair 4.3.3. Replacing the Encoder Interface board Continued Removing the EIB board Use this procedure to remove the EIB board. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the base cover. See the figure in : •...
  • Page 120 4 Repair 4.3.3. Replacing the Encoder Interface board Continued Action Info 5. Push the cable harness main carefully into the base. CAUTION! Arrange the cable harness inside correctly in a way that: • it is not damaged in the continued refitting process •...

  • Page 121: Plastic Covers

    4 Repair 4.4.1. Replacing plastic covers 4.4 Plastic covers 4.4.1. Replacing plastic covers Introduction The section describes how to replace the plastic covers on the robot. Location of the plastic covers xx0900000607 Lower arm cover (2 pcs.) Wrist side cover (2 pcs.) Wrist housing (plastic) Housing cover Tilt cover...
  • Page 122 4 Repair 4.4.1. Replacing plastic covers Continued Required equipment Equipment Note Standard tools The content is defined in the section Standard toolkit on page 191. Other tools and procedures may be These procedures include references to the required. See references to these tools required.
  • Page 123 4 Repair 4.4.1. Replacing plastic covers Continued Refitting plastic covers Use this procedure to refit the plastic covers. Action Info 1. Before fitting the plastic cover, check it for If the plastic cover is cracked or has cracks or any other damage. any other damage it must be replaced with a new one.

  • Page 124: Upper Arm

    4 Repair 4.5.1. Replacing the upper arm 4.5 Upper arm 4.5.1. Replacing the upper arm Introduction This procedure describes how to replace the upper arm. Location of upper arm The upper and lower arms are located as shown in the figure. xx0900000924 Upper arm, complete with wrist Attachment screws (16 pcs)
  • Page 125 4 Repair 4.5.1. Replacing the upper arm Continued Required equipment Equipment Note Standard toolkit The content is defined in the section Standard toolkit on page 191. Other tools and procedures may be These procedures include references to the required. See references to these tools required.
  • Page 126 4 Repair 4.5.1. Replacing the upper arm Continued Action Info 7. Remove the wrist housing (plastic). xx0900000900 Parts: • A: Attachment screws (3 pcs) • B: Wrist housing (plastic) 8. Remove the cable harness in the upper arm See section: housing.
  • Page 127 4 Repair 4.5.1. Replacing the upper arm Continued Action Info 12. Unscrew the attachment screws securing the lower arm plate to the motor cover. xx0900000851 Parts: • A: Cable harness • B: Holes for attachment screws (4 pcs) • C: Motor cover •...
  • Page 128 4 Repair 4.5.1. Replacing the upper arm Continued Refitting the upper arm Use this procedure to refit the upper arm. Action Info 1. Check that: • All assembly surfaces are clean and without damages. 2. Remove old residues of Loctite from the See: assembly surfaces on gearbox axis 3 and •...
  • Page 129 4 Repair 4.5.1. Replacing the upper arm Continued Action Info 8. Refit the lower arm covers. Tightening torque: 1 Nm. xx0900000848 Parts: • A: Attachment screws (4+4 pcs) • B: Lower arm covers (1+1) 9. Secure the cable harness in the upper arm See section: housing.
  • Page 130 4 Repair 4.5.1. Replacing the upper arm Continued Action Info 13. Refit the cable harness in the wrist. See section: • Refitting the cable harness on page 107 14. Refit the wrist housing (plastic). Tightening torque: 1 Nm. xx0900000900 Parts: •...

  • Page 131: Lower Arm

    4 Repair 4.6.1. Replacing the lower arm 4.6 Lower arm 4.6.1. Replacing the lower arm Introduction This procedure describes how to replace the lower arm. Gearbox axis 3 is included in the lower arm. Location of the lower arm The lower arm is located as shown in the figure. xx0900000859 Swing housing Gearbox axis 2...
  • Page 132 4 Repair 4.6.1. Replacing the lower arm Continued Removing the lower arm Use this procedure to remove the lower arm. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the lower arm covers on both sides of the robot.
  • Page 133 4 Repair 4.6.1. Replacing the lower arm Continued Refitting the lower arm Use this procedure to refit the lower arm. Action Info 1. Check that: • all assembly surfaces are clean and without damages. 2. Remove old residues of Loctite from the See: assembly surfaces on gearbox axis 2 and •...
  • Page 134 4 Repair 4.6.1. Replacing the lower arm Continued Action Info 9. Refit the lower arm covers. Tightening torque: 1 Nm. xx0900000848 Parts: • A: Attachment screws (4+4 pcs) • B: Lower arm cover 10. Recalibrate the robot. See chapter: • Calibration.

  • Page 135: Motors And Motors With Gearboxes

    Gearbox axis 1 is a part of motor axis 1 when ordered as a spare part. The procedure below describes the replacement of motor and gearbox axis 1 as one unit. For further information, please contact ABB. Location of motor axis 1 with gearbox The motor axis 1 with gearbox is located as shown in the figure.
  • Page 136 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Removing motor axis 1 with gearbox Use this procedure to remove motor axis 1 with gearbox. Action Info NOTE! If the robot is fitted in a suspended postion it must first be dismounted from this position.
  • Page 137 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Action Info 7. Cut the cable straps securing the cable harness to the swing plate. xx0900000884 Parts: • A: Swing plate • B: Cable holder • C: Attachment screws (2 pcs) •...
  • Page 138 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Action Info 10. Remove the cable guide. xx0900000800 Parts: • A: Attachment screws (3 pcs) • B: Cable guide • C: Base 11. Remove the base cover. xx0900000829 Parts: • A: Base cover •...
  • Page 139 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Action Info 15. Remove the attachment screws securing the gearbox to the support. xx0900001054 Parts: • A: Attachment screws (12 pcs) 16. Remove the motor axis 1 with gearbox carefully. CAUTION! Lift motor and gearbox by holding the support in order not to damage any parts.
  • Page 140 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Refitting motor and gearbox axis 1 Use this procedure to refit both motor and gearbox axis 1. Action Info 1. Check that: • all assembly surfaces are clean and without damages •...
  • Page 141 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Action Info 4. Fit the cable guide. Tightening torque: 2 Nm. xx0900000800 Parts: • A: Attachment screws (3 pcs) • B: Cable guide • C: Base 5. Reconnect connectors: • R2.MP1 •...
  • Page 142 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Action Info 9. Fit the base cover. Tightening torque: 4 Nm. xx0900000829 Parts: • A: Base cover • B: Attachment screws (4 pcs) 10. Clean the assembly surface on the swing See: plate from old residues of Loctite.
  • Page 143 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Action Info 14. Fit the cable harness to the cable holder. xx0900000884 Parts: • A: Swing plate • B: Cable holder • C: Attachment screws (2 pcs) • D: Cable straps (4 pcs) 15.
  • Page 144 4 Repair 4.7.1. Replacing motor axis 1 with gearbox Continued Action Info DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC035728-001 Revision: B...

  • Page 145: Replacing Motor Axis 2, With Gearbox

    Gearbox axis 2 is a part of motor axis 2 when ordered as a spare part. The procedure below describes the replacement of motor and gearbox axis 2 as one unit. For information how to replace gearbox axis 2, please contact ABB. Location of motor axis 2 with gearbox Motor axis 2 with gearbox is located as shown in the figure.
  • Page 146 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Removing motor axis 2 with gearbox Use this procedure to remove motor axis 2 with gearbox. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 147 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Action Info 4. Disconnect connectors: • R2.MP3 • R2.ME3 xx0900000850 Connectors: • A: R2.ME3 • B: R2.MP3 5. Unscrew the attachment screws securing the cable bracket. xx0900000879 Parts: • A: Cable bracket •...
  • Page 148 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Action Info 7. Unscrew the attachment screws securing the lower arm plate to the motor cover. xx0900000851 Parts: • A: Cable harness • B: Holes for attachment screws (4 pcs) •...
  • Page 149 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Action Info 11. Remove gearbox axis 2 together with the motor. CAUTION! In order not to damage any parts, hold the two items with a firm grip on the support when removing them.
  • Page 150 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Refitting motor axis 2 with gearbox Use this procedure to refit motor axis 2 with gearbox. Action Info 1. Before refitting, check that: • all assembly surfaces are clean and without damages •...
  • Page 151 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Action Info 4. Remove the two bolts with nuts securing motor axis 2 with gearbox while being trans- ported. xx0900001050 Parts: • A: Bolt with nut, used during transport (2 pcs) 5.
  • Page 152 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Action Info 10. Refit the lower arm to the swing housing. Tightening torque: 4 Nm. with its attachment screws and washers. xx0900000859 Parts: • A: Swing housing • B: Gearbox axis 2 •...
  • Page 153 4 Repair 4.7.2. Replacing motor axis 2, with gearbox Continued Action Info 12. Refit the two cable guides. Tightening torque : 1 Nm. xx0900000857 Parts: • A: Cable guides (2 pcs) 13. Refit the lower arm covers. Tightening torque: 2 Nm. xx0900000848 Parts: •...

  • Page 154: Replacing Motor Axis 3

    4 Repair 4.7.3. Replacing motor axis 3 4.7.3. Replacing motor axis 3 Introduction This procedure describes how to replace motor axis 3. How to replace gearbox axis 3 see section: • Replacing gearbox axis 3 on page 169 Location of motor axis 3 The motor axis 3 is located as shown in the figure.
  • Page 155 4 Repair 4.7.3. Replacing motor axis 3 Continued Removing motor axis 3 Use this procedure to replace motor axis 3. Action Info 1. Secure the arm system before removing motor axis 3. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3.
  • Page 156 4 Repair 4.7.3. Replacing motor axis 3 Continued Action Info 5. Disconnect connectors: • R2.MP3 • R2.ME3. xx0900000850 Parts: • A: R2.ME3 • B: R2.MP3 6. Unscrew the attachment screws securing the cable bracket. xx0900000879 Parts: • A: Cable bracket •...
  • Page 157 4 Repair 4.7.3. Replacing motor axis 3 Continued Action Info 9. Unscrew the attachment screws securing the motor axis 3. xx0900000875 Parts: • A: Cable harness • B: Motor axis 3 • C: Lower arm side support • D: Attachment screws (2 pcs) •...
  • Page 158 4 Repair 4.7.3. Replacing motor axis 3 Continued Refitting motor axis 3. Use this procedure to refit motor axis 3. Action Info 1. Check that: • all assembly surfaces are clean and without damages • motor and gearbox are clean and undamaged.
  • Page 159 4 Repair 4.7.3. Replacing motor axis 3 Continued Action Info 5. Move the motor to a position where a good Timing belt tension: F=18-19.8N. timing belt tension is reached. NOTE! Do not strech the timing belt too much! 6. Secure the motor axis 3 with its attachment Tightening torque: 5.5 Nm.
  • Page 160 4 Repair 4.7.3. Replacing motor axis 3 Continued Action Info 10. Secure the connectors with cable straps. NOTE! Put the strap tie on the side in order to make the lower arm cover fit well. xx0900000849 Parts: • A: Cable straps (2 pcs) 11.

  • Page 161: Replacing Motor Axis 4, With Gearbox

    4 Repair 4.7.4. Replacing motor axis 4, with gearbox 4.7.4. Replacing motor axis 4, with gearbox Introduction Motor axis 4 is delivered as part of the upper arm when ordered as a spare part. How to replace the complete upper arm is described in section: •...

  • Page 162: Replacing Motor Axis 5

    4 Repair 4.7.5. Replacing motor axis 5 4.7.5. Replacing motor axis 5 Introduction This procedure describes how to replace: • motor axis 5 with pulley. Location of motor axis 5 The motor axis 5 is located as shown in the figure. xx0900000890 Attachment screws, wrist side covers (3+3 pcs) Wrist side cover...
  • Page 163 4 Repair 4.7.5. Replacing motor axis 5 Continued Removing motor axis 5 with pulley Use this procedure to remove motor axis 5 with pulley. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 164 4 Repair 4.7.5. Replacing motor axis 5 Continued Action Info 4. Remove the connector support. xx0900000888 Parts: • A: Attachment screws (2 pcs) • B: Connector support 5. Cut the cable straps. xx0900001009 Parts: • A: Cable straps (2 pcs) 6.
  • Page 165 4 Repair 4.7.5. Replacing motor axis 5 Continued Refitting motor axis 5 Use this procedure to refit motor axis 5. Action Info 1. Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 2.
  • Page 166 4 Repair 4.7.5. Replacing motor axis 5 Continued Action Info 8. Refit the connector support. Tightening torque: 1 Nm. xx0900000888 Parts: • A: Attachment screws (2 pcs) • B: Connector support 9. Refit the clamp with its attachment screw. Tightening torque: 1 Nm. xx0900000887 Parts: •...
  • Page 167 4 Repair 4.7.5. Replacing motor axis 5 Continued Action Info 11. Refit the wrist side covers. Tightening torque: 1 Nm. xx0900000886 Parts: • A: Wrist side covers (2 pcs) 12. Recalibrate the robot. See chapter: • Calibration. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 168: Replacing Motor Axis 6

    122. Motor axis 6 is a part of the upper arm when ordered as a spare part. For more information how to replace motor axis 6, please contact ABB. Location of motor axis 6 Motor axis 6 is located as shown in the figure.

  • Page 169: Gearboxes

    4 Repair 4.8.1. Replacing gearbox axis 1 4.8 Gearboxes 4.8.1. Replacing gearbox axis 1 Introduction The gearbox axis 1 is delivered as a part of motor axis 1. For information how to replace motor with gearbox axis 1, see section Replacing motor axis 1 with gearbox on page 133.

  • Page 170: Replacing Gearbox Axis 2

    4 Repair 4.8.2. Replacing gearbox axis 2 4.8.2. Replacing gearbox axis 2 Introduction The gearbox axis 2 is delivered as a part of motor axis 2. For information how to replace motor with gearbox axis 2, see section Replacing motor axis 2, with gearbox on page 143.

  • Page 171: Replacing Gearbox Axis 3

    Overview Gearbox axis 3 is delivered as a part of the lower arm. For more information how to replace gearbox axis 3, please contact ABB. Location of gearbox axis 3 Gearbox axis 3 is located as shown in the figure.

  • Page 172: Replacing Gearbox Axis 4

    Gearbox axis 4 is delivered as part of the upper arm. How to replace the upper arm see: • Replacing the upper arm on page 122 For more information how to replace gearbox axis 4, please contact ABB. 3HAC035728-001 Revision: B...

  • Page 173: Replacing Gearbox Axis 5

    Gearbox axis 5 is delivered as a part of the upper arm. How to replace the upper arm is decribed in section Replacing the upper arm on page 122. For more information how to replace gearbox axis 5, please contact ABB. Location of gearbox axis 5 Gearbox axis 5 is located as shown in the figure. xx0900001041...

  • Page 174: Replacing Gearbox Axis 6

    The gearbox axis 6 is delivered as part of the upper arm. How to replace the upper arm is described in section Replacing the upper arm on page 122. For more information how to replace gearbox axis 6, please contact ABB. Location of gearbox axis 6 Gearbox axis 6 is located as shown in the figure: xx0900000910...

  • Page 175: Calibration

    5 Calibration 5.1. Introduction 5 Calibration 5.1. Introduction Introduction This chapter is a short description how to use the calibration pins and the synchronization marks on the robot. 3HAC035728-001 Revision: B...

  • Page 176: Calibrating Axes 1 - 6

    5 Calibration 5.2. Calibrating axes 1 - 6 5.2. Calibrating axes 1 - 6 Introduction This section describes how to calibrate the robot and how to use the calibration pins when calibrating. NOTE! Only fine calibration can be done on the robot. NOTE! Calibration can be done in the following ways: •...
  • Page 177 5 Calibration 5.2. Calibrating axes 1 - 6 Continued Calibration, axis 3. (Rotate axis 3 75.8°) Calibration pins, axis 3 Calibration, axis 4. (Rotate axis 4 -174.7°) Calibration pins, axis 4 Calibration, axis 5-6. (Rotate axis 5 -90° and axis 6 90°) Calibration pin, axis 5-6 Calibration tool, axis 5-6 Required equipment...
  • Page 178 5 Calibration 5.2. Calibrating axes 1 - 6 Continued Action Note 4. Release the brakes. How to release the brakes see section: • Manually releasing the brakes on page 55 5. Rotate axes 4, 5 and 6 manually until the two See the figure in: calibration pins of each axis are in contact with •...
  • Page 179 5 Calibration 5.2. Calibrating axes 1 - 6 Continued Action Info 8. After calibration is done use the FlexPendant to jog each axis to zero degree. 9. The synchronisation marks on axis 1 shall now See section: be matched. • Synchronization marks axes 1- 6 on page 180 Calibration of axis 2 separately...
  • Page 180 5 Calibration 5.2. Calibrating axes 1 - 6 Continued Action Info 3. Release the brakes. See section: • Manually releasing the brakes on page 55 4. Rotate axis 3 manually until the two calibration See figure 3 in: pins are in contact with each other. •...
  • Page 181 5 Calibration 5.2. Calibrating axes 1 - 6 Continued Calibration of axes 5 and 6 using the calibration tool Use this procedure when calibrating axes 5 and 6 separately. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 182: Synchronization Marks Axes 1-6

    5 Calibration 5.3. Synchronization marks axes 1-6 5.3. Synchronization marks axes 1-6 Introduction This section specifies the position of the synchronization marks. How to calibrate the robot is described in section Calibrating axes 1 - 6 on page 174. NOTE! These synchronization marks can not be used for updating encoder revolution.
  • Page 183 5 Calibration 5.3. Synchronization marks axes 1-6 Continued xx0900000575 The figure shows the synchronization marks on axes 4-6. Synchronization mark, axis 4 Synchronization mark, axis 5 Synchronization mark, axis 6 3HAC035728-001 Revision: B...
  • Page 184 5 Calibration 5.3. Synchronization marks axes 1-6 3HAC035728-001 Revision: B...

  • Page 185: Decommissioning

    6 Decommissioning 6.1. Introduction 6 Decommissioning 6.1. Introduction Introduction This section contains information to consider when taking a product, robot or controller, out of operation. It deals with how to handle potentially dangerous components and potentially hazardous materials. General All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit are installed.

  • Page 186: Environmental Information

    6 Decommissioning 6.2. Environmental information 6.2. Environmental information Hazardous material The table specifies some of the materials in the robot and their respective use throughout the product. Dispose of the components properly to prevent health or environmental hazards. Material Example application Batteries, NiCad or Lithium Encoder Interface Board Copper...

  • Page 187: Reference Information

    7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC035728-001 Revision: B...

  • Page 188: Applicable Safety Standards

    7 Reference information 7.2. Applicable safety standards 7.2. Applicable safety standards Standards, EN ISO The manipulator system is designed in accordance with the requirements of: Standard Description EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for...
  • Page 189 7 Reference information 7.2. Applicable safety standards Continued Other standards Standard Description ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems ANSI/UL 1740 Safety Standard for Robots and Robotic Equipment (option 429-1) CAN/CSA Z 434-03 Industrial Robots and Robot Systems - General Safety Require- ments (option 429-1) 3HAC035728-001 Revision: B...

  • Page 190: Unit Conversion

    7 Reference information 7.3. Unit conversion 7.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 0,035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment 1 Nm...

  • Page 191: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.

  • Page 192: Weight Specifications

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

  • Page 193: Standard Toolkit

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

  • Page 194: Special Tools

    7 Reference information 7.7. Special tools 7.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section Standard toolkit on page 191, and of special tools, listed directly in the instructions and also gathered in this section.

  • Page 195: Lifting Equipment And Lifting Instructions

    7 Reference information 7.8. Lifting equipment and lifting instructions 7.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.
  • Page 196 7 Reference information 7.8. Lifting equipment and lifting instructions 3HAC035728-001 Revision: B...

  • Page 197: Spare Parts

    8 Spare parts 8.1. Spare parts - Axes 1 and 2 8 Spare parts 8.1. Spare parts - Axes 1 and 2 Spare parts axes 1-2 Link to Illustration axes 1-2 on page 196. Item Description Spare part no. Base with mechanical stop 3HAC035896-001 Rotational AC motor, including gearbox (axes 1 &...
  • Page 198 8 Spare parts 8.1. Spare parts - Axes 1 and 2 Continued Illustration axes 1-2 Link to Spare parts axes 1-2 on page 195. xx0900000498 3HAC035728-001 Revision: B...

  • Page 199: Spare Parts - Axis 3

    8 Spare parts 8.2. Spare parts - Axis 3 8.2. Spare parts - Axis 3 Spare parts, axis 3 Link to Illustration, spare parts axis 3 on page 198. Item Description Spare part no. Lower arm with mechanical stop 3HAC035901-001 (Including gearbox axis 3) Motor unit with timing belt wheel 3HAC031904-001...
  • Page 200 8 Spare parts 8.2. Spare parts - Axis 3 Continued Illustration, spare parts axis 3 Link to Spare parts, axis 3 on page 197. xx0900000493 3HAC035728-001 Revision: B...

  • Page 201: Spare Parts - Lower Arm, Side Support

    8 Spare parts 8.3. Spare parts - Lower arm, side support 8.3. Spare parts - Lower arm, side support Spare parts, lower arm side support Link to Illustration, Lower arm side support on page 200. Item Description Spare part no. Lower arm, side support 3HAC031894-001 Cable protection cover axis 3...
  • Page 202 8 Spare parts 8.3. Spare parts - Lower arm, side support Continued Illustration, Lower arm side support Link to Spare parts, lower arm side support on page 199. xx0900000500 3HAC035728-001 Revision: B...

  • Page 203: Spare Parts - Upper Arm Unit

    8 Spare parts 8.4. Spare parts - Upper arm unit 8.4. Spare parts - Upper arm unit Spare parts upper arm unit Lint to Illustration, upper arm unit on page 202. Item Description Spare part no. Upper arm with wrist, mechanical 3HAC035914-001 (Motor axes 4 and 6 with gearbox included) Arc shaft cover...
  • Page 204 8 Spare parts 8.4. Spare parts - Upper arm unit Continued Illustration, upper arm unit Link to Spare parts upper arm unit on page 201. xx0900000544 3HAC035728-001 Revision: B...

  • Page 205: Spare Parts - Wrist Unit

    8 Spare parts 8.5. Spare parts - Wrist unit 8.5. Spare parts - Wrist unit Spare parts. wrist unit Link to Illustration, spare parts wrist unit on page 204. Item Description Spare parts no. Carrier ring 3HAC031653-001 Motor unit with timing belt pulley 3HAC037303-001 Timing belt 3HAC031828-001...
  • Page 206 8 Spare parts 8.5. Spare parts - Wrist unit Continued Illustration, spare parts wrist unit Link to Spare parts. wrist unit on page 203. xx0900000551 3HAC035728-001 Revision: B...

  • Page 207: Spare Parts - Cable Harness

    8 Spare parts 8.6. Spare parts - Cable harness 8.6. Spare parts - Cable harness Introduction The spare parts in this section covers cable harness. Description Spare part no. Cable harness main 3HAC032095-001 Cable harness EIB 3HAC032076-001 Cable harness CP/CS 3HAC032296-001 EIB DSQC401 3HAC032243-001...
  • Page 208 8 Spare parts 8.6. Spare parts - Cable harness 3HAC035728-001 Revision: B...

  • Page 209: Circuit Diagram

    IRC5 with Drive System 04 3HAC024480-004 IRC5 with Drive System 09 3HAC024480-005 IRC5 Panel Mounted Controller 3HAC026871-005 IRC5 Compact 3HAC031403-003 Manipulators Product Article numbers for circuit diagrams IRB 120 3HAC031408-003 IRB 140 3HAC6816-3 IRB 260 3HAC025611-001 IRB 360 3HAC028647-009 IRB 660 3HAC025691-001 IRB 1410...
  • Page 210 9 Circuit diagram 9.1. About circuit diagrams 3HAC035728-001 Revision: B...

  • Page 211: Index

    Index brakes safety testing function 27 brake testing 27 emergency stop 31 ESD 41 carbon dioxide extinguisher 25 fence dimensions 24 connection fire extinguishing 25 external safety devices 16 FlexPendant 29 introduction 15 manipulator system 16 danger levels 33 moving manipulators 39 reduced speed function 28 release manipulator arm 26 emergency stop...
  • Page 212 Index validity and responsibility 16 wall mounting 64 3HAC035728-001 Revision: B...
  • Page 214 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000...

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