Page 1 ROBOTICS Product manual CRB 15000...
Page 2 Trace back information: Workspace 23B version a17 Checked in 2023-06-29 Skribenta version 5.5.019...
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
Testing the FlexPendant connection ............3.5.4 Working closely with the robot in a safe way ..........Configuring the software ..................3.6.1 Information about software for the CRB 15000 ..........3.6.2 Lead-through ..................Product manual - CRB 15000 3HAC077389-001 Revision: L...
Page 6 Table of contents 3.6.3 The SafeMove configurator app on FlexPendant ........... 3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 ......3.6.5 Configuration of SafeMove using Visual SafeMove in RobotStudio ....3.6.6 Information about Collaborative Speed Control add-in ........3.6.7 Speed control ..................
Page 7 Joint units ......................5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) ........5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) ..5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) ........5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) ..
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Page 9: Overview Of This Manual
The robot described in this manual has the following protection types: • Standard Product manual scope The manual covers all variants and designs of the CRB 15000. 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 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. • be trained to respond to emergencies or abnormal situations. References Documentation referred to in the manual, is listed in the table below.
Page 11 Removed the troubleshooting for issue of RED flashing status on Scalable I/O device and failure to move the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 12 Updated requirement and procedure descriptions for manually releasing the brakes. Published in release 23B. The following updates are made in this revision: • Added new variants CRB 15000-10/1.52 and CRB 15000-12/1.27. • Added pin assignment on XG1 connector of SafetyIO-based laser scanner.
Page 13: 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 14 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
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Page 17: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
Page 18 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 19: Requirements On Personnel
Use personal protective equipment, as stated in the instructions. Risk of entanglement Loose clothing should not be worn and long hair should be tied up to reduce the risk for entanglement. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 20: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 21 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 22: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 23 Using the brake release tool will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 24 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 25 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Lifting bolt xx0900000821 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 26 Stored energy Warns that this part contains stored energy. Used in combination with Do not disassemble symbol. xx0900000825 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 27 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 28: Robot Stopping Functions
• Product manual - OmniCore C30 Reasons for selection of stops in CRB 15000 For nearly all safety functions in CRB 15000, a category 1 stop is defined. Exceptions are only allowed: • When there is a technical fault in the system, or •...
Page 29: Safety During Installation And Commissioning
Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 30 Specific information for GoFa robots The CRB 15000 collaborative robot is designed to be able to work safely alongside humans and even share tasks with them. It is vital for the user of the robot to operate it in a safe way, setting up the necessary safety configurations, and ensure that appropriate risk reduction measures are implemented.
Page 31: Safety During Operation
If necessary, to prevent burns, allow touch surfaces to cool down before working closely with the robot. The following figure takes the CRB 15000-12/1.27 as an example to show the locations of touch surfaces. All the other surfaces are considered as non-touch surfaces.
Page 32 1 Safety 1.5 Safety during operation Continued Arm side interface Tubular Tubular covers Housing cover Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 33: Safety During Maintenance And Repair
Follow the instructions in section Maintenance on page 183. Related information See also the safety information related to installation and operation. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 34: Emergency Release Of The Robot Axes
1.6.2 Emergency release of the robot axes Description How to release the brakes is described in the section: • Manually releasing the brakes on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 35: 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 36: 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 37: Safety During Decommissioning
See section Decommissioning on page 1077. If the robot is decommissioned for storage, take extra precaution to reset safety devices to delivery status. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
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Page 39: Manipulator Description
2.1 About CRB 15000 Introduction The CRB 15000 robot is a flexible, agile 6-axis articulated robot, available in three variants spanning various options for payload from 5 kg to 12 kg, wrist reach from 0.95 m to 1.52 m (flange reach from 1.05 m to 1.62 m), and designed specifically for manufacturing industries that use flexible robot-based automation.
Page 40: Technical Data
Loads on foundation, robot The illustration shows the directions of the robots stress forces. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 41 ±145 Nm / ±200 Nm / ±210 Nm ±334 Nm / ±720 Nm / ±690 Nm Valid for CRB 15000-5/0.95. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 42 Disturbances from other machinery will affect the robot and the tool accuracy. The robot has resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified, Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 43 Valid for CRB 15000-5/0.95. iii Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27. iv Depending on climate and robot running conditions, condensation may occur on the inside of plastic covers. The condensation will disappear over time by itself, alternatively the user can open the covers and run a program for 12 hours to accelerate the process.
Page 45: Safety Data
The SISTEMA/ABB FSDT libraries contains details for the safety functions. Performance level for OmniCore C30 for CRB 15000 The OmniCore C30 for CRB 15000 controller safety system has a safety category 3 with performance level PL d according to EN ISO 13849-1:2015 and thus fulfils the safety performance requirement of the robot safety standard EN ISO 10218-1:2011.
Page 46 Sufficient space must be provided around the robot to prevent an operator from being trapped. The falling distance and maximum speed are dependent on the robot pose, so this must be validated. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 47: Working Range
22° 0° pos6 -230.2 272.7 180° 85° 0° pos7 -179 180° -158° 0° pos8 198.1 287.6 180° -225° 0° Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 48 -625.3 -307 180° 9.8° pos6 442.6 180° 85° pos7 925.3 -307 180° -170.2° pos8 596.9 326.5 180° -225° Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 49 -78.4° pos5 -674 -369 180° 11.6° pos6 -193 276.8 180° 85° pos7 -369 180° -168.4° pos8 370.6 180° -225° Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 50 2 Manipulator description 2.4 Working range Continued Top view of working range CRB 15000-5/0.95 +180° R199.4 R173.1 -180° R951 xx2100000122 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 51 2 Manipulator description 2.4 Working range Continued CRB 15000-10/1.52 +180° R352.6 R1632.3 R296.3（A） -180° xx2300000577 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 52 Simulation in RobotStudio is recom- mended. Axis 2 ±180° Axis 3 -225°/+85° Axis 4 ±180° Axis 5 ±180° Axis 6 ±270° Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 53: 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
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Page 55: Installation And Commissioning
Safety on page 17 before performing any installation work. Note Always connect the CRB 15000 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 56: 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 57: Risk Of Tipping/Stability
3.2.2 Risk of tipping/stability Risk of tipping CRB 15000-5/0.95 is delivered lying flat in the delivery package, while CRB 15000-10/1.52 and CRB 15000-12/1.27 are delivered in standing position in the package. The robot cannot stand on its own without being secured to the foundation.
Page 58 Axis 1 0° Axis 2 -15° Axis 3 -225° Axis 4 0° Axis 5 -30° Axis 6 0° Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 59 Axis 3 +85° Axis 4 0° Axis 5 +15° Axis 6 0° WARNING The robot is mechanically unstable if not secured to the foundation. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 60: 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 CRB 15000. Action Note Transport the manipulator to its intended location.
Page 61: Lifting The Robot
Introduction This section describes how to lift the robot and transport it to the installation site. For CRB 15000-5/0.95, two persons are always required when lifting and securing the robot. For CRB 15000-10/1.52 and CRB 15000-12/1.27, lifting accessories, such as lifting roundslings, shall be prepared for the lifting and securing.
Page 62 3 Installation and commissioning 3.3.2.1 Orienting and securing the robot Continued Hole configuration, base CRB 15000-5/0.95 This illustration shows the hole configuration used when securing CRB 15000-5/0.95. + 0,012 6 H7 xx2000002366 Circular hole for locating pin Elongated hole for locating pin...
Page 63 This illustration shows the hole configuration used when securing CRB 15000-10/1.52. H7 + 0.012 xx2300000382 Circular hole for locating pin Elongated hole for locating pin Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 64 Make sure the installation site for the robot con- forms to the specifications in section Technical data on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 65 Lifting and securing the robot (-5/0.95) Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minim- um of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury.
Page 66 WARNING The robot is mechanically unstable if not se- cured to the foundation. CAUTION The weight of the CRB 15000 robot is up to 51 All lifting accessories used must be sized ac- cordingly. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 67 Personnel must not, under any circumstances, be present under the suspended load. Raise the overhead crane to lift the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 68 Washers: 23/10.5/2.5 mm Steel Tighten the bolts in a crosswise pattern to en- Tightening torque: 32 Nm ±10% sure that the base is not distorted. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 69: Manually Releasing The Brakes
Make sure that the arm is secured against col- lapsing under gravity and that no personnel is at risk of getting hit by the arm moving downwards. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 71: Manually Releasing The Brakes With The External Tool
Note The spare parts related to the brake release function using the external tool are discontinued from Q2 2023. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 72 The manipulator needs to be powered and motors in state Motors OFF. Do not release the brakes in automatic operating mode. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 73 1063. Put back the tool in its holder and store on specified location close to the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 75: Installation Of Brake Release Tool
The storage location must be well known for all personnel working with or nearby the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 76 3 Installation and commissioning 3.3.5 Installation of brake release tool Continued Securing the brake release tool holder Securing with screws xx2100000403 Securing with cable ties xx2100000404 Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 77: Setting The System Parameters For An Inverted Or A Tilted Robot
Gravity Alpha must be redefined. The value of Gravity Alpha should then be ±π/2 (±1.570796). Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 78 Examples of mounting angles tilted around the X axis (Gravity Alpha) The following illustration shows the IRB 120, but the same principle applies for all robots. 0° xx2100000297 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 79 The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 80: 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 the product specification for the robot, listed in References on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 81: Fitting Equipment On The Robot (Robot Dimensions)
Robot dimensions The figure shows the dimension of the robot. CRB 15000-5/0.95 xx2000002368 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 82 3 Installation and commissioning 3.3.8 Fitting equipment on the robot (robot dimensions) Continued CRB 15000-10/1.52 1297 1217 1107 xx2300000646 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 83 3 Installation and commissioning 3.3.8 Fitting equipment on the robot (robot dimensions) Continued 1235 1155 1045 xx2300000647 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 84 Note If the gasket screws on the upper arm cover of CRB 15000-5/0.95 are replaced with hex spacers, then the IP54 is no longer fulfilled. Before fitting equipment to the robot upper arm, special considerations must be taken: •...
Page 85 Housing and lower arm For CRB 15000-10/1.52 and CRB 15000-12/1.27, extra loads can also be mounted on robot housing and lower arm. Definitions of dimensions and masses are shown Holes for fitting extra equipment on page Maximum allowed arm load depends on center of gravity of arm load and robot payload.
Page 86 Upper arm, CRB 15000-10/1.52 4 x M3 SECTION A-A xx2300000989 Upper arm, CRB 15000-12/1.27 4 x M3 SECTION A-A xx2300000990 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 87 Housing and lower arm, CRB 15000-12/1.27 2 x M4 4xM4 2 x R10 DETAIL G 2 x M4 DETAIL F xx2300000755 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 88 Example of suitable hex Bossard, article number: Bossard, article number: spacer 304318041152 304325041152 Keystone, article number: Bossard, article number: 24289~24294 304330041152 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 89 Also note the thread depth on the tool flange. Using too long screws may damage the tool flange and cause the tool to be improperly fastened, which is a safety hazard. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 90: Test Run After Installation, Maintenance, Or Repair
If maintenance or repair has been done, verify the function of the part that was main- tained. Verify the application in the operating mode manual reduced speed. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 91: Installation Of Laser Scanner
3.3.10 Installation of laser scanner Overview The safety separation technology and speed control for CRB 15000 is based on the connection and communication of one or two safety laser scanners in the robot. Laser scanner(s) provides a timely and continuous monitor on the activities within its scanning area and forms a protective field.
Page 92 1 PROFIsafe-based laser scanner (option 3051-1), with PLC connected OmniCore controller Laser Scanner blue white black brown 24V + 0V PROFIsafe PROFIsafe xx2100000160 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 93 OmniCore controller white blue black brown PROFIsafe PROFIsafe 24V+ 0V Laser Scanner2 white blue black brown PROFIsafe 24V+ 0V xx2200000298 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 94 1 SafetyIO-based laser scanner (option 3051-2) Power Laser Scanner OmniCore controller white blue black brown 24V+ 0V xx2200000299 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 95 If there are additional scalable I/O devices available, install and configure the additional devices by following the detailed procedures in Application manual - Scalable I/O. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 96 Universal output 1 White with yellow Universal output 2 Yellow with brown Voltage 0 V DC White with grey Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 97 164 RobotWare 7.6 or Configuration of two SafetyIO-base later laser scanners (RobotWare 7.6 or later) on page 169 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 98 (RobotWare 7.10 or later and OmniCore acting as Master) on page 156 Configuration of two PROFIsafe-based laser scanners (Ro- botWare 7.10 or later and OmniCore acting as Master) on page 160. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 99: Electrical Connections
Robot cable Signal cable length Article number Hybrid floor cable 7 m 3HAC073212-002 Hybrid floor cable 15 m 3HAC073212-003 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 100 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 101: Customer Connections On The Manipulator
Stresses above the limitation may cause permanent damage to the manipulator. Rated 24V, max 30V iii Rated 24V, max 30V Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 102 The R1.MP on the base is used for transferring DC bus, EtherCat and customer signals (CP/CS). xx2100000228 xx2100002065 The connector can be rotated 330° clockwise. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 103 Note Always inspect the connector for dirt or damage before connecting it. Clean or replace any damaged parts. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 104 200 mm wire, M10x0.75 Pin3 Pin1 1: CS Pair_1 + straight 2: CS Pair_1 - 3: CS Pair_2 + M8x1 4: CS Pair_2 - xx2100000219 Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 105: Arm-Side Interface
SafeMove. The tool and payload must be configured before configuring the arm-side interface. See Operating manual - OmniCore. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 106 Stand by state Green Program running Yellow, steady Lead through/programming mode Yellow, blinking Brake release signal is activated Error Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 107 For more information on RAPID, see Technical reference manual - RAPID Instructions, Functions and Data types and Technical reference manual - RAPID Overview. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 108 FlexPendant is connected, see Testing the FlexPendant connection on page 110. Note In RobotWare 7.2, the light ring configuration cannot be changed, only disabled. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 109: Using The Arm-Side Interface
If the buttons are not responding, close the ASI Setting app and reopen it. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 110: Testing The Flexpendant Connection
3 Inspect on which robot the light ring is affected. Note This technique should also be used to verify a Robot Control Mate connection before starting work. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 111: Working Closely With The Robot In A Safe Way
Constrained collisions can be either transient, if the robot can give way (at least partially), or quasi-static. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 112 2 To prevent unexpected motion, initiated by additional clients: Do not add additional clients to the robot to control program execution. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 113 Finally, if risks in automatic mode cannot be sufficiently reduced by these or other means, use of the arm-side interface shall be restricted to manual mode. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 114: Configuring The Software
The configuration of emergency stops is stop category 1 and cannot be changed. Collision detection As default CRB 15000 will have collision detection active at stand still. It also has another stop ramp compared to other robots to be able to release clamping forces.
Page 115 3 Installation and commissioning 3.6.1 Information about software for the CRB 15000 Continued With the FlexPendant, a user can verify local presence with the three-position enabling device. For robots without a connected FlexPendant, system input signals can be used to verify local presence.
Page 116 3 Installation and commissioning 3.6.1 Information about software for the CRB 15000 Continued Some typical examples of singularity positions for GoFa are shown here. Typical arm singularities Typical wrist singularities xx2300000099 xx2300000098 xx2300000101 xx2300000100 For more information about singularity, see Technical reference manual - RAPID Overview, section Singularities.
Page 117: Lead-Through
The Lead-through lock section is disabled for the Axis 1-6 mode. 4 Gently pull the robot arm to the desired position. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 118 If the load is lighter than the defined load, the effect will be the same as if you are pulling the robot arm upwards. For the CRB 15000, there is a button for updating/refreshing the load while lead-through is active.
Page 119 4 Tap and hold the Press and Hold Align button. The robot is aligned to the selected coordinate system. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 120: The Safemove Configurator App On Flexpendant
The configuration follows the same principles as when using Visual SafeMove in RobotStudio but the functionality is not as extensive. For more information about transient contact, quasi-static contact, and body areas, Guidelines for transient and quasi-static contact, CRB 15000 on page 132. Overview of the user interface The user interface consists of a configurator and a 3D model that visualizes the robot with the configured encapsulations and zones.
Page 121 A sphere or capsule encapsulation can be modified in dimension and position. A lozenge capsule can be modified in dimension, position, and rotation. xx2100000712 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 122 The Synchronization tab is used to manually set the current joint positions for the robot. For more information about synchronization, see Application manual - Functional safety and SafeMove. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 123 Use the following procedure to load and apply the template configuration to the robot controller. 1 Select Enable Edit Mode to edit the safety configuration. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 124 1 Select Enable Edit Mode to edit the safety configuration. 2 If no configuration is loaded, load an empty configuration or a template configuration. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 125 The green dot in the 3D visualization shows where the new vertex is located. Use the arrows to change the position (index). Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 126 4 To add a supervision to a safe zone, tap to select the safe zone in the 3D view, then tap Add. 5 Select a supervision function or guide. xx2100000713 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 127 5 Review the suggested supervisions. 6 When the supervision is applied, the data is transferred to Tool Speed Supervision and Tool Force Supervision. For more details, see Guidelines for transient and quasi-static contact, CRB 15000 on page 132. Continues on next page...
Page 128 The Standstill Supervision functionality is not active by default. It can be added, modified, and deactivated. The CRB 15000 has support for both stop category 0 and stop category 1 for Standstill Supervision. For other stops, only stop category 1 is available.
Page 129 The validation should verify that the following is configured correctly: • All I/O settings and signals used for safety interlocking including connected functionality • All Stop configuration functions Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 130 1 Log in as a user with the grant Safety Services. 2 In the Settings app, select the Safety Controller, and then Configuration. 3 Select the check box Validated. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 131 3 Select the check box Locked. Concluding steps After the validation is concluded, turn on the the SafeMove Assistant functionality, with the system parameter Disable SafeMove Assistant. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 132: Guidelines For Transient And Quasi-Static Contact, Crb 15000
3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 About Human Contact Supervision The CRB 15000 robot is designed with collaborative applications in focus, where occasional contact between the human and the robot are foreseen. This is according to ISO/TS 15066.
Page 133 3 Installation and commissioning 3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 Continued Body model As defined in ISO/TS 15066, the body model is a representation of the human body consisting of individual body segments characterized by biomechanical properties.
Page 134 3 Installation and commissioning 3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 Continued Conclusion The values calculated in the Human Contact Supervision function are conservative. However, if the risk assessment for the final application shows that these values can be changed to a higher value, for example, by using padding on the arm, then the values can be changed in the settings for the tool force supervision and tool speed supervision.
Page 135: Configuration Of Safemove Using Visual Safemove In Robotstudio
2 Click Pre Logic view in the Safe IO Configuration page. 3 Click New expression and create the following expressions. • ISH_Activate_SST • ISH_Activate_TSP • ISH_Delay_SST Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 136 DELAY(ISH_Enabler_Delay_SST,Protect- ingArea1,(ISH_AtUser_Period_ms_Until_SST / ISH_SMctrl_Frequency),ISH_Count- Delay_SST,ISH_Delayed_SST) Valid for scenarios with 2 PROFIsafe-based laser scanners connected DELAY(ISH_Enabler_Delay_SST,Protect- ingAreaSM,(ISH_AtUser_Period_ms_Until_SST / ISH_SMctrl_Frequency),ISH_Count- Delay_SST,ISH_Delayed_SST) Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 137 (ROB_1) and click Capsule in the Visual SafeMove ribbon tab to create two capsule geometries for the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 138 1 In the Visual SafeMove ribbon tab, choose Create Safe Zone from the Safe Zone list. 2 Create three zones and rename as follows: • Transient_Contact_Zone • Quasi_Static_Contact_Zone_1 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 139 Violation action Stop category Category1Stop Signal No signal Settings Checked the Include upper arm geometry and Allow inside check boxes. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 140 1 In the Visual SafeMove ribbon tab, click Controller in the Configuration group. 2 Click Write to controller. The configurations are uploaded to the controller after the controller restarts. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 141: Information About Collaborative Speed Control Add-In
10 Select Apply to confirm and save the changes. The add-in is displayed in the controller overview if it is successfully added to the controller. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 142: Speed Control
Device slot mapping (default) ProtectingArea ProfiSafe OmniCore_Internal WarningArea ProfiSafe OmniCore_Internal ProtectingAreaSST ProfiSafe OmniCore_Internal WarningAreaTSP ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 143 RobotStudio or the OmniCore controller. • In the RobotWare installation folder in RobotStudio: ...\DistributionPackages\ABB.RobotWare-x.x.x-xxx\RobotPackages \RobotControl_x.x.xxx\utility\service\GSDML\ • On the OmniCore Controller: ...\products\RobotControl_x.x.x\utility\service\GSDML\ Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 144 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 145 7 Create monitoring cases and assign the fields that are to be monitored to each monitoring cases in Configuration > Monitoring cases. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 146 1 Make some initial preparations. 2 Configure system parameters. 3 Set the input and output size and name of the PROFINET internal device. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 147 3 Installation and commissioning 3.6.7.1 Configuration of one PROFINET-base laser scanner (RobotWare 7.5 or earlier) Continued For CRB 15000, required settings for communication between laser scanner, PLC and OmniCore controller are predefined in the configuration file. 4 Set up safety user grants.
Page 148: Configuration Of One Profisafe-Based Laser Scanner (Robotware 7.6 Or Later And Plc Acting As Master)
ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable • The PROFINET device name of the controller must be set to omnicoreprofisafe. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 149 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 150 3 and 2, respectively, and for the SDO are set to 5 and 4, respectively. • Make sure the address for the SDO signal is the first address of SDO 8 bytes slot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 151 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 152: Configuration Of Two Profisafe-Based Laser Scanners (Robotware 7.6 Or Later And Plc Acting As Master)
ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable • The PROFINET device name of the controller must be set to omnicoreprofisafe. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 153 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 154 Add the controller to the PLC by adding the DI 8 bytes, DO 8 bytes, SDI 8 bytes and SDO 8 bytes modules. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 155 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 156: Configuration Of One Profisafe-Based Laser Scanner (Robotware 7.10 Or Later And Omnicore Acting As Master)
The mappings are only for examples. Refer to the cut-off setting defined in the Safety Designer software and enter the actual value. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 157 The RAPID program is displayed in the right pane. b Find the parameter Scanner1 and modify its value to the user-defined laser scanner name. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 158 1 Connect the laser scanner to the PC using a network cable. See the physical connection in Connecting the laser scanner(s) on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 159 2 In the Controller tab, click Safety, then select Visual SafeMove. 3 In the Visual SafeMove window, configure SafeMove function as instructed Configuration of SafeMove using Visual SafeMove in RobotStudio on page 135. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 160: Configuration Of Two Profisafe-Based Laser Scanners
The mappings are only for examples. Refer to the cut-off setting defined in the Safety Designer software and enter the actual value. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 161 The RAPID program is displayed in the right pane. b Find the parameters Scanner1 and Scanner2, and modify their values to the user-defined laser scanner names. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 162 1 Connect the laser scanner to the controller using a network cable. See the physical connection in Connecting the laser scanner(s) on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 163 2 In the Controller tab, click Safety, then select Visual SafeMove. 3 In the Visual SafeMove window, configure SafeMove function as instructed Configuration of SafeMove using Visual SafeMove in RobotStudio on page 135. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 164: Configuration Of One Safetyio-Base Laser Scanner (Robotware 7.6 Or Later)
Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3 and ABB_Scalable_IO_0_DI4. For definition of WarningArea, see Configuring the laser scanner on page 165. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 165 Make sure the scanner IP address is in the same network segment with the PC used for configuring the scanner. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 166 3 Connect the logic power supply to connector X4 of the scalable I/O device via pin locations PWR and GND. 4 Connect the Ethernet cable from the robot controller to connector X5. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 167 Make sure the user logged in have access grants to lock safety controller configurations, safety services and software synchronization. 2 Tap SafeMove on the home page. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 168 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 169: Configuration Of Two Safetyio-Base Laser Scanners (Robotware 7.6 Or Later)
Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3, ABB_Scalable_IO_0_DI4, ABB_Scalable_IO_0_DI7 and ABB_Scalable_IO_0_DI8. For definition of WarningArea, see Configuring the laser scanner on page 170. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 170 Make sure the scanner IP addresses are in the same network segment with the PC used for configuring the scanner. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 171 1 Make sure that the laser scanner and scalable I/O device is connected as instructed in previous configuration procedure of laser scanner. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 172 If there are additional scalable I/O devices available, install and configure the additional devices by following the detailed procedures in Application manual - Scalable I/O. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 173 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 174: Speed Control Strategies
3.6.7.8 Speed control strategies General The speed control of CRB 15000 is affected by several factors, such as, the RobotWare version, the speed setting in the FlexPendant, the speed setting in motion instruction and the SpeedRefresh value. Users in different protection fields defined for laser scanner to monitor and perform different program execution actions may result in different movement speed.
Page 175 3 Installation and commissioning 3.6.7.8 Speed control strategies Continued Users in Warning area xx2100000513 SafeMove triggered but SST/TSP not configured xx2100000514 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 176 3 Installation and commissioning 3.6.7.8 Speed control strategies Continued Strategies (RobotWare 7.6 or later) Users in Protecting area xx2200000302 Users in Warning area xx2200000303 Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 177: Use Cases Of Safety Configurations
SafeMove configurations also affect the speed control on the robot to achieve further safety. SafeMove is still functional after the SpeedHandling function in RAPID program is deactivated. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 178 Use the following procedure to change the speed limit based on risk assessment of the final application: 1 In RobotStudio, open the RAPID program InternalSpeedHandling_User in task T_ROB1. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 179 4 In the left pane of the window, choose Global_TSP under the Tool Speed Supervisions from the navigation tree. xx2200000438 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 180 1 Open the RobotStudio. 2 Log in the controller using the Admin account and request the write access. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 181 6 Apply the configuration to the controller by clicking Write to Controller in the Controller group in the Configuration category. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
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Page 183: Maintenance
Note If the CRB 15000 is connected to power, always make sure that the CRB 15000 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.
Page 184: Maintenance Schedule And Expected Component Life
4.2.1 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 CRB 15000: • Calendar time: specified in months regardless of whether the system is running or not.
Page 185: Maintenance Schedule
Replace if damage or cracks are detected. Not needed separately if already included in the application. Recommended test interval is within the range 8-48 hours. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 186: Inspection Activities
See article numbers in Robot cabling and connection points on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 187 1.4 Nm M3x8 12.9 Lafre 2C2B/FC6.9 Housing top cover Hex socket head cap screw 0.45 Nm M3x8 12.9 Lafre 2C2B/FC6.9 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 188 M3x12 12.9 Lafre 2C2B/FC6.9 Base M10x35 8.8 32 Nm ±10% Tightening torques, CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000758 xx2300000757 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 189 M3x12 12.9 Lafre 2C2B/FC6.9 Axis-6 flange Hex socket head cap screw 1.9 Nm M3x12 12.9 Lafre 2C2B/FC6.9 Base M10x35 8.8 32 Nm ±10% Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 190: Inspecting The Cable Harness
4 Maintenance 4.3.2 Inspecting the cable harness 4.3.2 Inspecting the cable harness Location of cable harness Cable harness, CRB 15000-5/0.95 The figures show the location for the cable harness of CRB 15000-5/0.95. xx2100000056 xx2100000057 xx2100000058 xx2100000059 Spare part Spare part number...
Page 191 Cable harness, joint 4 3HAC073206-001 Cable harness, joint 5 3HAC073206-001 Cable harness, joint 6 3HAC073208-001 Cable harness, transition joint-5 and joint- 3HAC083726-001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 192 10/1.52) Cable harness, joint 1 (CRB 15000- 3HAC080959-001 12/1.27) Cable harness, joint 2 3HAC080960-001 Cable harness, joint 3 3HAC080965-001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 193 Required equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 1087. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 194 CAUTION section Tightening torques to be inspected on page 187. Be careful not to squeeze any cabling during the refitting procedure. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 195: Cleaning Activities
Always check that all protective covers are fitted to the robot before cleaning. • Do not use compressed air to clean the robot. • Do not use solvents that are not approved by ABB to clean the robot. • Do not remove any covers or other protective devices before cleaning the robot.
Page 196: Testing Activities
Note The spare parts related to the brake release function using the external tool are discontinued from Q2 2023. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 197 Look for damage to the magnet. Replace the tool if damaged. • See troubleshooting section Brake release tool does not work on page 1063. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 198: Running The Cyclic Brake Check Routine
Use of such a configuration must be justified by risk assessment. • The method described in Brake testing on page 35 can be used to check that the brakes still function correctly. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 199: Testing The Functionality Of The Joint Electronics
Testing the joint electronics Action Note Turn off power to the controller and then turn the power on again. Verify that the robot starts as expected. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
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Page 201: Repair
CRB 15000-5/0.95 is illustrated. Report replaced units Note When replacing a part on the CRB 15000, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 202: General Procedures
Check the sealing to ensure that: • The sealing is of the correct type. • There is no damage on the main lip. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 203 Mount the sealing correctly with a mounting tool. Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 204 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. Tighten the screws evenly when fastening the flange joint.
Page 205: Cable Harness
2 Loosen the robot from the foundation and lay it down on its back. • For CRB 15000-5/0.95, this step requires two persons. • For CRB 15000-10/1.52 and CRB 15000-12/1.27, the robot requires to be lifted using lifting roundslings. 3 Remove the base cover. 4 Replace the cabling.
Page 206 5.3.1 Replacing the base cabling Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 207 Laying down the robot (-5/0.95) Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minimum of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury. Continues on next page...
Page 208 Laying down the robot (-10/1.52 and -12/1.27) Action Note CAUTION The weight of the CRB 15000 robot is up to 51 All lifting accessories used must be sized ac- cordingly. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 209 Do not stretch the roundsling too much. Loosen the robot base from the foundation by removing the foundation attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 210 Remove the bottom cover by removing the attach- Valid for CRB 15000-5/0.95 ment screws. xx2000002007 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000760 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 211 Snap loose and disconnect the connectors: • J1.DC+ • J1.DC- • J1.CS • J1.CP xx2100000426 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 212 Removing the base cabling Action Note Remove the attachment screws. xx2100000406 Pull out the cabling from the base. xx2100000407 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 213 Secure the base connector with the attachment Hex socket head cap screw: M3x8 screws. 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm. xx2100000406 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 214 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2100000425 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 215 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-64 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002016 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 216 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.2 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2000002007 xx2100000268 Refitting the base cover (-10/1.52 and -12/1.27)
Page 217 Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2300000760 Lifting and securing the robot (-5/0.95)
Page 218 WARNING The robot is mechanically unstable if not se- cured to the foundation. CAUTION The weight of the CRB 15000 robot is up to 51 All lifting accessories used must be sized ac- cordingly. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 219 Personnel must not, under any circumstances, be present under the suspended load. Raise the overhead crane to lift the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 220 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 221: Replacing The Axis-1 Cabling
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 222 CRB 15000-10/1.52 and CRB 15000-12/1.27. Cable tie gun EVO 7i HellermannTyton 110-77001 or similar Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 223 15000-10/1.52 and CRB 15000- 12/1.27. Replace if damaged. Grease 3HAC042536-001 Shell Gadus S2 Cleaning agent Isopropanol Flange sealant Loctite 574 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 224 Removing the lower arm covers (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 226 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 227 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 228 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 229 Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 230 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 231 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 232 New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 233 Handle the as- sembly with care. xx2000001958 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 234 Action Note Remove the swing attachment screws. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 235 Snap loose and disconnect the connectors: • J1.DC+ • J1.DC- • J1.CS • J1.CP xx2000002010 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 236 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 237 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 238 Axis 6: No significance. xx2100000044 CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 239 Disconnecting the cabling between the lower arm and the swing Action Note Remove the functional earth cable by removing the screw. xx2000001936 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 240 Removing the lower and upper arm assembled Action Note Remove the cable bracket by removing the four screws. xx2000001939 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 241 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 242 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 243 Make sure that all supplies for electrical power are turned off. Remove the cover by removing the screws. xx2300000814 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 245 The weight of the complete swing and base together is xxx WARNING Personnel must not, under any circumstances, be present under the suspended load. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 246 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000787 xx2300000788 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 247 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000790 Remove the lifting aid. xx2300000778 xx2300000776 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 248 Note Valid for CRB 15000-10/1.52 Remove the swing transition. xx2300000817 Valid for CRB 15000-10/1.52 Remove the swing flange. xx2300000818 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 249 Remove the swing attachment screws. Valid for CRB 15000-10/1.52 CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 250 Action Note Cut the cable ties. xx2000002012 Remove the functional and protective earth cables by removing the screw. xx2000002011 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 251 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 252 Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 253 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 254 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 255 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 256 Assembly direction for the cable tie is shown in Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 257 D1.DC- to Ground • D1.X4 to X4 • D1.X2 to X2 • D1.X5 to X5 • DR.X8 to X8 xx2000002009 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 258 Tightening torque: 0.8 Nm. xx2000002011 Secure the cabling with cable ties. Cable ties (4 pcs) xx2000002012 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 259 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.2 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2000002007 xx2100000268...
Page 260 Separate the new swing parts by removing the pre-assembling screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 261 M4x25 12.9 Lafre Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs) CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 262 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 263 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001961 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 264 Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws. xx2000001956 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 265 Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 266 M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 267 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 268 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 269 Refit the inner cover with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm. xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 270 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000001932 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 271 Refit the cover with the four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 272 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002048 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 273 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 274 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 275 Assembly direction for the cable tie is shown in Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 276 D1.DC- to Ground • D1.X4 to X4 • D1.X2 to X2 • D1.X5 to X5 • DR.X8 to X8 xx2000002009 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 277 Tightening torque: 0.8 Nm. xx2000002011 Secure the cabling with cable ties. Cable ties (4 pcs) xx2000002012 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 278 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2300000760 Securing the base...
Page 279 CAUTION Do not use the pre-assembling screws of swing parts for securing. xx2300000817 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 280 Pre-tighten the screws crosswise firstly. Valid for CRB 15000-12/1.27 CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 281 Always use guide pins in pairs. For joint units on axes 1 and 2 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2300000791 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 282 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 283 The joint unit is properly placed when no gaps between the block and both lifting aid and swing. xx2300000794 Remove the guide pins. xx2300000795 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 284 Washers: 23/10.5/2.5 mm Steel (4 pcs). Tightening torque: 32 Nm ±10%. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 285 12.9 Lafre 2C2B/FC6.9, 16 pcs Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 286 12.9 Lafre 2C2B/FC6.9, 16 pcs CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 287 Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001946 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 288 Removing the lower arm covers (-10/1.52 and -12/1.27) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 289 Fit the o-ring to cover groove. O-ring: 3HAC061327-074 (for CRB 15000-10/1.52 and CRB 15000- Replace if damaged. 12/1.27) xx2300000816 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 290 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 291: Replacing The Axis-2 Cabling
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 292 Note Cable ties O-ring 3HAC061327-044 Lower arm, inner cover of CRB 15000-5/0.95. 1 pcs / cover. Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 293 CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 295 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 296 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 297 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 298 Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 299 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 300 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 301 New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 302 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 303 Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 304 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002060 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 305 Make sure that all supplies for electrical power are turned off. Remove the lower cover of lower arm by removing the screws. xx2300000812 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 306 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 307 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 308 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 309 Make sure that all supplies for electrical power are turned off. Remove the cover by removing the screws. xx2300000814 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 310 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 312 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 313 Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 314 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 315 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 316 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 317 Assembly direction for the cable tie is shown in Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 318 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 319 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. xx2000002153 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 320 Remove the guide pins and secure the remaining two attachment screws. xx2100000295 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 321 • J2.DC+ to J2.DC+ • J2.DC- to J2.DC- • J2.CS to J2.CS • J2.CP to J2.CP xx2000001944 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 322 Refitting the swing cover(-5/0.95) Action Note Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB 15000-5/0.95) Replace if damaged. xx2000001962 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 323 Refit the cover with the four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 324 Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 325 M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 326 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001936 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 327 Hex socket head cap screw: M3x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Secure the cover with four screws. Tightening torque: 0.45 Nm. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 328 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002048 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 329 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 330 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 331 Assembly direction for the cable tie is shown in Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 332 Always use guide pins in pairs. For joint units on axes 1 and 2 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2300000791 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 333 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 334 The joint unit is properly placed when no gaps between the block and both lifting aid and swing. xx2300000794 Remove the guide pins. xx2300000795 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 335 Washers: 23/10.5/2.5 mm Steel (4 pcs). Tightening torque: 32 Nm ±10%. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 336 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 337 Fit the o-ring to cover groove. O-ring: 3HAC061327-074 (for CRB 15000-10/1.52 and CRB 15000- Replace if damaged. 12/1.27) xx2300000816 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 338 Guide pin, M5x150: 3HAC087786- xx2300001021 CAUTION The weight of the complete upper and lower arm together is 18 kg Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 339 12.9 Lafre 2C2B/FC6.9, 16 pcs Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 340 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 341 Remove the lower cover of lower arm by removing the screws. xx2300000812 Remove the lower inner cover by removing the screws. xx2300000813 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 342 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 343: Replacing The Axis-3 Cabling
2 Remove the upper arm and place on a workbench. 3 Remove the housing cover. 4 Remove the axis-3 joint unit. 5 Replace the cabling. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 344 5.3.4 Replacing the axis-3 cabling Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 345 Removing the lower arm covers (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 346 Remove the inner covers by removing the screws. xx2000001947 xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 347 Remove the lower arm covers by removing the screws. xx2300000812 xx2300000829 Remove the inner covers by removing the screws. xx2300000813 xx2300000830 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 348 Loosening the cabling between the lower and upper arm Action Note Remove the functional earth cable by removing the screw. xx2000001964 Cut the cable tie. xx2000001965 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 349 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. xx2000001968 Remove the remaining attachment screws. xx2000001969 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 350 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 351 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 352 Action Note Cut the cable ties. xx2000002066 Remove the functional and protective earth cables by removing the screw. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 353 Remove two attachment screws. Dispose the screws. New screws are included in the spare part delivery of the joint unit. xx2000002070 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 354 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2000002577 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 355 Use two fully attachment screws as removal tools to press the joint unit out of position. xx2300000801 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 356 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 357 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 358 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 359 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 360 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 361 Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 362 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 363 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002072 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 364 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 365 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000804 xx2300000777 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 366 Remove the guide pins. xx2300000809 Secure with four attachment screws and pre- tighten the screws crosswise. xx2300000810 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 367 D3/4.DC+ to DC+ • D3/4.DC- to Ground • D3.X4 to X4 • D3/4.X2 to X2 • D3.X5 to X5 xx2000002068 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 368 Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 369 For robots with RobotWare earlier than 7.10 Cable ties Secure the brake release cable with a cable tie. xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 370 Do not leave the cover in location without being secured with the attachment screws. Remove the insert. xx2300000834 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 371 Hex socket head cap flange screw: attachment screws but two. M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. xx2000001969 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 372 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001964 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 373 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 374 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. xx2000001947 xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 375 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075 Replace if damaged. O-ring: 3HAC061327-044 Grease: 3HAC042536-001 (Shell Gadus S2) xx2300000832 xx2300000831 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 376 12.9 Lafre 2C2B/FC6.9 (3 pcs) x 2 Secure the cover with three screws. Tightening torque: 1.4 Nm. xx2300000812 xx2300000829 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 377 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 378: Replacing The Axis-4 Cabling
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 379 15000-5/0.95. Replace if damaged. O-ring 3HAC061327-047 Housing cover, used for CRB 15000-10/1.52 and CRB 15000- 12/1.27. Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 381 Valid for CRB 15000-10/1.52 xx2300000838 Valid for CRB 15000-12/1.27 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 382 Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000002021 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 383 Make sure that all supplies for electrical power are turned off. Remove the cover by removing the screws. xx2300000833 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 384 Action Note Cut the cable ties. xx2000002066 Remove the functional and protective earth cables by removing the screw. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 385 • D3/4.DC- xx2000002120 Opening the housing top cover Action Note Remove the cover by removing the four screws. xx2000002075 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 386 Action Note Cut the cable tie. Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 387 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-4 joint unit. Always use guide pins in pairs. xx2000002079 xx2000002080 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 388 Assist the cabling to be removed from the housing while lifting away the complete tubular. Place the tubular on a workbench. xx2000002082 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 389 For robots with RobotWare earlier than 7.10 Tweezers Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 390 Separating the cabling between the tubular and the tilt Action Note Cut the cable ties on joint unit. xx2000002086 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 391 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 392 Disconnect the connectors from the drive board. Tweezers CAUTION Use tweezers to unlock connectors and pull them off. • D4/5.X1 • D4/5.X4 • D4/5.X5 xx2000002088 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 393 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2100000327 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 394 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 395 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 396 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 397 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 398 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 399 Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 400 Note CAUTION Axis-4 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 401 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000326 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 402 Reconnect the connectors to the drive board. • D4/5.X1 to X1 • D4/5.X4 to X4 • D4/5.X5 to X5 xx2000002088 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 403 • J4/5.DC+ to J5/6.DC+ • J4/5.DC- to J5/6.DC- • J4/5.CS to J5/6.CS • J4/5.CP to J5/6.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 404 Secure the cabling to tubular with cable ties. Cable ties (2 pcs) Valid for CRB 15000-5/0.95 xx2000002124 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000842 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 405 If ordering a new axis-4 or axis-5 joint unit spare part, new screws for the tubular cover are included. Tightening torque: 1.6 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 406 Refit the covers with new attachment screws. Hex socket head cap screw: 3HAB3409-224 M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 407 For robots with RobotWare earlier than 7.10 Cable ties Secure the brake release cable with a cable tie. xx2000002084 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 408 Apply flange sealant to the corner of the housing Flange sealant: Loctite 574 mounting surface, as pointed out in the figure. xx2000002094 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 409 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 xx2000002079 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 410 Secure the cabling with a cable tie. Cable ties (1 pcs) Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 411 Refit the cover with the four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.45 Nm xx2000002075 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 412 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 413 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 414 Refit the insert. Insert: 3HAC084002-001 Hex socket head cap screw: M3x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm xx2300000834 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 415 8 Test the brake release (movement without drive power) functionality, see Testing the brake release functionality on page 196. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 416 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 417: Replacing The Axis-5 Cabling
4 Remove the axis-6 joint unit. 5 Remove the axis-5 cover. 6 Remove the axis-5 joint unit. 7 Replace the cabling. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 418 5.3.6 Replacing the axis-5 cabling Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 419 Axis 6: No significance. CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 420 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 421 Separating the cabling between the tubular and the tilt Action Note Cut the cable ties on joint unit. xx2000002086 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 422 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 423 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95 xx2000002126 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000844 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 424 Assist the cabling to be removed while lifting away the complete tilt. Place the tilt on a workbench. xx2000002131 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 425 Cut the cable ties. xx2000002157 Disconnect the CP/CS connectors from the drive board and remove the tool flange. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 426 Press the adapter out of position by using two of the attachment screws as removal tools. xx2000002166 Remove the tool flange adapter. xx2000002167 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 427 ASI.DC+ • ASI.DC- • ASI.X1 xx2100000335 Disconnecting the axis-6 joint unit cabling Action Note Cut the cable ties. xx2000002161 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 428 • D6.DC- • D6.X4 • D6.X2 • D6.X5 CAUTION Use tweezers to unlock connectors and pull them off. xx2000002164 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 429 Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. For joint units on axes 4, 5 and 6. xx2100000328 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 431 For robots with RobotWare earlier than 7.10 Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002134 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 432 • D5.DC- • D4/5.X4 • D5.X2 • D4/5.X5 CAUTION Use tweezers to unlock connectors and pull them off. xx2000002138 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 433 New screws are included in the spare part delivery of the joint unit. xx2100000333 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 434 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 435 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 436 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 437 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 438 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 439 Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 440 Note CAUTION Axis-5 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 441 Fit the transition cable between axis-5 and axis-6 Cable harness, transition joint-5 joint units into the tilt. and joint-6: 3HAC083726-001 xx2100000040 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 442 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002142 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 443 15000-10/1.52 and CRB 15000- 12/1.27) Remove the lifting aid by removing the screws. xx2000002139 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 444 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000002136 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 445 Valid for CRB 15000-5/0.95 Replace if damaged. O-ring: 3HAC061327-051 xx2000001962 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 O-ring: 3HAC061327-051 xx2300000849 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 446 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 Hex socket head cap screw: M3x12 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm xx2000002132 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 447 Note CAUTION Axis-6 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 448 For joint units on axes 4, 5 and 6. xx2000002438 Place the cabling at the slot before refitting the joint unit. xx2100000041 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 449 Torque tighten all screws crosswise. Tightening torque: 1.4 Nm (for CRB 15000-5/0.95) / 1.9 Nm (for CRB 15000-10/1.52 and CRB 15000- 12/1.27) Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 450 Connect the connectors to each other and snap them to the cable holders. • J7.CS to J7.CS • J7.CP to J7.CP xx2000002163 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 451 Refitting the arm-side interface Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002551 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 452 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 Hex socket head cap screw: M3x20 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002550 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 453 Secure with screws. Flange socket head screw: M3x20 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (16 pcs) Tightening torque: 1.8 Nm. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 454 Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Place the tool flange at mounting position and reconnect the CP/CS connectors. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 455 Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. xx2000002146 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 456 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (2 pcs) xx2000002128 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 457 • J4/5.DC+ to J5/6.DC+ • J4/5.DC- to J5/6.DC- • J4/5.CS to J5/6.CS • J4/5.CP to J5/6.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 458 Secure the cabling to tubular with cable ties. Cable ties (2 pcs) Valid for CRB 15000-5/0.95 xx2000002124 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000842 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 459 If ordering a new axis-4 or axis-5 joint unit spare part, new screws for the tubular cover are included. Tightening torque: 1.6 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 460 Refit the covers with new attachment screws. Hex socket head cap screw: 3HAB3409-224 M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 461 For robots with RobotWare earlier than 7.10 Cable ties Secure the brake release cable with a cable tie. xx2000002084 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 462 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 463: Replacing The Axis-6 Cabling
5 Replace the cabling. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 464 Jog the axis on which the joint unit is to be re- placed to home position, to achieve correct cable routing during replacement of the joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 465 Cut the cable ties. xx2000002157 Disconnect the CP/CS connectors from the drive board and remove the tool flange. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 466 Press the adapter out of position by using two of the attachment screws as removal tools. xx2000002166 Remove the tool flange adapter. xx2000002167 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 467 ASI.DC+ • ASI.DC- • ASI.X1 xx2100000335 Disconnecting the axis-6 joint unit cabling Action Note Cut the cable ties. xx2000002161 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 468 • D6.DC- • D6.X4 • D6.X2 • D6.X5 CAUTION Use tweezers to unlock connectors and pull them off. xx2000002164 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 469 Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. For joint units on axes 4, 5 and 6. xx2100000328 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 472 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 473 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 474 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 475 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 476 Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 477 Note CAUTION Axis-6 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 478 For joint units on axes 4, 5 and 6. xx2000002438 Place the cabling at the slot before refitting the joint unit. xx2100000041 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 479 Torque tighten all screws crosswise. Tightening torque: 1.4 Nm (for CRB 15000-5/0.95) / 1.9 Nm (for CRB 15000-10/1.52 and CRB 15000- 12/1.27) Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 480 Connect the connectors to each other and snap them to the cable holders. • J7.CS to J7.CS • J7.CP to J7.CP xx2000002163 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 481 Refitting the arm-side interface Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002551 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 482 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 Hex socket head cap screw: M3x20 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002550 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 483 Secure with screws. Flange socket head screw: M3x20 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (16 pcs) Tightening torque: 1.8 Nm. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 484 Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Place the tool flange at mounting position and reconnect the CP/CS connectors. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 485 Hex socket head cap screw: M3x12 washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs) Spring washer: 7x3.2x0.6 Steel (10 pcs) Tightening torque: 1.8 Nm. xx2000002155 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 486 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 487: Replacing The Axis-5 To Axis-6 Transition Cabling
The replacement procedure is identical to replacing the axis-5 joint unit. Follow procedure Replacing the axis-5 joint unit and the axis-5 to axis-6 transition cabling on page 980. Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 488: Replacing The Brake Release Unit
3 Remove the base cover. 4 Replace the brake release unit. Axis-2/-3/-4/-5 brake release unit 1 Open the joint unit cover. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 489 Base cover, used for CRB 15000- 5/0.95. O-ring 3HAC061327-047 Cover for axis 2/3, used for CRB 15000-5/0.95. Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 490 Prepare a working bench where the robot can be laid down on its back with the base socket outside the table edge. xx2100000414 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 491 Laying down the robot (-5/0.95) Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minimum of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury. Loosen the robot from the foundation.
Page 492 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000760 Removing the brake release unit Action Note Cut the cable tie. xx2100000410 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 493 Remove the brake release cover by removing the two screws. xx2100000416 Remove the brake release board. xx2100000418 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 494 Harmonic Grease 4B No.2 Used to lubricate the seals. xx2100000419 If not already fitted, place the sheet metal inside the cover. xx2100000420 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 495 Fit the brake release cover and secure with two Screws: M2x6 12.9 Gleitmo 605 (2 screws. pcs) Tightening torque: 0.2 Nm. xx2100000416 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 496 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm. xx2100000413 Reconnect the brake release connector DR.X8 to the drive board. xx2100000411 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 497 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAB3772-64 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002016 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 498 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.2 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2000002007 xx2100000268 Lifting and securing the robot (-5/0.95)
Page 499 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 500 Remove the cover. xx2000001932 Removing the brake release unit Action Note Cut the cable tie. xx2100000096 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 501 Remove the brake release cover by removing the two screws. xx2100000095 Disconnect the brake release cable from the board. xx2100000094 Remove the brake release board. xx2100000093 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 502 Fit the brake release board to the sheet metal. xx2100000093 Connect the brake release cable to the board. xx2100000094 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 503 Closing the joint unit cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-047 Replace if damaged. xx2000001962 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 504 Orient the cover for proper arrangement of the brake release cable. xx2000001932 Axis 3: xx2000002023 Axis 4: Tweezers xx2000002085 Axis 5: xx2000002134 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 505 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 506: Upper And Lower Arms
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 507 Jog the robot to the synchronization position. CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 508 Remove the cover by inserting a small flat screwdriver to snap open the locks at each end of the cover. xx2100000267 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 509 Make sure that all supplies for electrical power are turned off. Remove the lower arm covers by removing the screws. xx2300000812 xx2300000829 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 510 Disconnecting the cabling between the lower arm and the swing Action Note Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 511 Cut the cable tie. xx2000001965 Removing the upper arm Action Note Remove the cable bracket by removing the four screws. xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 512 Press the upper arm out of position by using two fully threaded attachment screws as removal tools. xx2100000001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 513 Action Note Remove the cable bracket by removing the four screws. xx2000001939 Secure the weight of the lower arm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 514 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 515 Valid for CRB 15000-5/0.95 Guide pin, M4x120: 3HAC077786- Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 Guide pin, M5x150: 3HAC087786- xx2000001949 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 516 2C2B/FC6.9+PrO-COat111 (16 pcs) Valid for CRB 15000-10/1.52 and CAUTION CRB 15000-12/1.27 Do not mix the flange screws used for CRB 15000- Hex socket head cap screw: M5x30 5/0.95 and the threaded screws used for CRB 12.9 Lafre 2C2B/FC6.9, 16 pcs 15000-10/1.52 and CRB 15000-12/1.27.
Page 517 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001939 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 518 Hex socket head cap flange screw: attachment screws but two. M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. xx2000001969 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 519 Connecting the cabling between the lower arm and swing Action Note Connect the connectors to each other and snap them to the cable holders. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 520 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001964 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 521 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. xx2000001947 xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 522 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075 Replace if damaged. O-ring: 3HAC061327-044 Grease: 3HAC042536-001 (Shell Gadus S2) xx2300000832 xx2300000831 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 523 12.9 Lafre 2C2B/FC6.9 (3 pcs) x 2 Secure the cover with three screws. Tightening torque: 1.4 Nm. xx2300000812 xx2300000829 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 524 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 525 2 Remove the upper arm and place on a workbench. 3 Remove the axis-3 joint unit. 4 Remove the tubular. 5 Replace the housing. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 526 5.4.2 Replacing the housing Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 527 Axis 6: 0° xx2100000002 CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 528 Remove the cover by inserting a small flat screwdriver to snap open the locks at each end of the cover. xx2100000267 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 529 Make sure that all supplies for electrical power are turned off. Remove the lower arm covers by removing the screws. xx2300000812 xx2300000829 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 530 Disconnecting the upper arm cabling Action Note Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 531 Secure the weight of the upper arm. CAUTION The weight of the complete upper arm is 14 kg. Remove two attachment screws. xx2000001967 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 532 Removing the housing cover (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 533 For robots with RobotWare earlier than 7.10 Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 534 Do not leave the cover in location without being secured with the attachment screws. Remove the insert. xx2300000834 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 535 Snap loose and disconnect the connectors: • J4.DC+ • J4.DC- • J4.CS • J4.CP xx2000002067 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 536 For joint units on axes 1, 2 and 3 of CRB 15000-5/0.95 and axis 3 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2000002576 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 537 Handle the as- sembly with care. xx2000002071 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 538 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000802 Remove the lifting aid. xx2300000804 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 539 Action Note Cut the cable tie. Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 540 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-4 joint unit. Always use guide pins in pairs. xx2000002079 xx2000002080 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 541: Replacing The Housing
Action Note Replace the housing. Housing: 3HAC073949-001 (for CRB 15000-5/0.95) / 3HAC087550- 001 (for CRB 15000-10/1.52 and CRB 15000-12/1.27) Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 542 Lift the tubular into mounting position while insert- ing the cabling into the housing. Slide the tubular into place on the guide pins. xx2000002082 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 543 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 xx2000002079 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 544 Secure the cabling with a cable tie. Cable ties (1 pcs) Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 545 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 546 For joint units on axes 1, 2 and 3 of CRB 15000-5/0.95 and axis 3 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2000002438 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 547 Remove the guide pins and secure the remaining two attachment screws. xx2000002070 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 548 For joint units on axes 1, 2 and 3 of CRB 15000-5/0.95 and axis 3 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2300000803 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 549 The joint unit is properly placed when no gaps between the lifting aid and housing. xx2300000808 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 550 Hex socket head cap screw: ment screws. 3HAB3409-262 xx2300000811 Torque tighten all screws crosswise. M4x45 12.9 Lafre 2C2B/FC6.9, 12 Tightening torque: 4.3 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 551 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 552 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 553 Refit the insert. Insert: 3HAC084002-001 Hex socket head cap screw: M3x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm xx2300000834 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 554 Refitting the upper arm Action Note Fit two guide pins to the axis-3 joint. Guide pin, M4x120: 3HAC077786- xx2000001971 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 555 Hex socket head cap flange screw: two screws. M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) xx2000001967 Torque tighten all screws crosswise. Tightening torque: 4.6 Nm Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 556 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001964 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 557 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 558 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. xx2000001947 xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 559 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-075 Replace if damaged. O-ring: 3HAC061327-044 Grease: 3HAC042536-001 (Shell Gadus S2) xx2300000832 xx2300000831 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 560 Tightening torque: 1.4 Nm. xx2300000812 xx2300000829 Concluding procedure Action Note Calibrate the axis-3 joint unit torque sensor. Calibration on page 1051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 561 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 562: Replacing The Tubular
1 Separate the cabling between the housing and the tubular (at the axis-3 joint unit). 2 Remove the complete tubular. 3 Remove the axis-4 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 563 5 Replace the tubular. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 564 15000-5/0.95. Replace if damaged. O-ring 3HAC061327-047 Housing cover, used for CRB 15000-10/1.52 and CRB 15000- 12/1.27. Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 565 • Axis 5: +90° • Axis 6: No significance. xx2100000005 Valid for CRB 15000-10/1.52 xx2300000838 Valid for CRB 15000-12/1.27 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 566 Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000002021 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 567 Make sure that all supplies for electrical power are turned off. Remove the cover by removing the screws. xx2300000833 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 568 Action Note Cut the cable ties. xx2000002066 Remove the functional and protective earth cables by removing the screw. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 569 • D3/4.DC- xx2000002120 Opening the housing top cover Action Note Remove the cover by removing the four screws. xx2000002075 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 570 Action Note Cut the cable tie. Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 571 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-4 joint unit. Always use guide pins in pairs. xx2000002079 xx2000002080 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 572 Assist the cabling to be removed from the housing while lifting away the complete tubular. Place the tubular on a workbench. xx2000002082 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 573 For robots with RobotWare earlier than 7.10 Tweezers Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 574 Separating the cabling between the tubular and the tilt Action Note Cut the cable ties on joint unit. xx2000002086 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 575 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 576 Disconnect the connectors from the drive board. Tweezers CAUTION Use tweezers to unlock connectors and pull them off. • D4/5.X1 • D4/5.X4 • D4/5.X5 xx2000002088 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 577 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2100000327 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 578 Always use guide pins in pairs. xx2000002128 xx2000002129 Remove the remaining attachment screws. xx2000002130 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 579 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 580 Note CAUTION Axis-4 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 581 Remove the guide pins and secure the remaining two attachment screws. xx2000002091 Pre-tighten the screws crosswise. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 582 Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. xx2000002146 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 583 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (2 pcs) xx2000002128 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 584 • J4/5.DC+ to J5/6.DC+ • J4/5.DC- to J5/6.DC- • J4/5.CS to J5/6.CS • J4/5.CP to J5/6.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 585 Secure the cabling to tubular with cable ties. Cable ties (2 pcs) Valid for CRB 15000-5/0.95 xx2000002124 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000842 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 586 If ordering a new axis-4 or axis-5 joint unit spare part, new screws for the tubular cover are included. Tightening torque: 1.6 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 587 Refit the covers with new attachment screws. Hex socket head cap screw: 3HAB3409-224 M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 588 For robots with RobotWare earlier than 7.10 Cable ties Secure the brake release cable with a cable tie. xx2000002084 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 589 Apply flange sealant to the corner of the housing Flange sealant: Loctite 574 mounting surface, as pointed out in the figure. xx2000002094 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 590 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 xx2000002079 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 591 Secure the cabling with a cable tie. Cable ties (1 pcs) Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 592 Refit the cover with the four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.45 Nm xx2000002075 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 593 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 594 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 595 Refit the insert. Insert: 3HAC084002-001 Hex socket head cap screw: M3x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm xx2300000834 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 596 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 597: Replacing The Wrist Housing
2 Separate the cabling between the tubular and the tilt (at the axis-4 joint unit). 3 Remove the tilt and place on a workbench. 4 Remove the axis-6 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 598 6 Replace the wrist housing. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 599 Use these procedures to remove the wrist. Preparations before removing the wrist Action Note Jog the robot to the synchronization position. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 600 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 601 Separating the cabling between the tubular and the tilt Action Note Cut the cable ties on joint unit. xx2000002086 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 602 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 603 Pull out the cabling carefully from the tubular. Valid for CRB 15000-5/0.95 xx2000002126 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000844 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 604 Assist the cabling to be removed while lifting away the complete tilt. Place the tilt on a workbench. xx2000002131 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 605 Cut the cable ties. xx2000002157 Disconnect the CP/CS connectors from the drive board and remove the tool flange. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 606 Press the adapter out of position by using two of the attachment screws as removal tools. xx2000002166 Remove the tool flange adapter. xx2000002167 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 607 ASI.DC+ • ASI.DC- • ASI.X1 xx2100000335 Disconnecting the axis-6 joint unit cabling Action Note Cut the cable ties. xx2000002161 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 608 • D6.DC- • D6.X4 • D6.X2 • D6.X5 CAUTION Use tweezers to unlock connectors and pull them off. xx2000002164 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 609 Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. For joint units on axes 4, 5 and 6. xx2100000328 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 611 For robots with RobotWare earlier than 7.10 Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002134 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 612 • D5.DC- • D4/5.X4 • D5.X2 • D4/5.X5 CAUTION Use tweezers to unlock connectors and pull them off. xx2000002138 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 613 New screws are included in the spare part delivery of the joint unit. xx2100000333 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 614 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 615 Note CAUTION Axis-5 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 616 Fit the transition cable between axis-5 and axis-6 Cable harness, transition joint-5 joint units into the tilt. and joint-6: 3HAC083726-001 xx2100000040 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 617 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002142 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 618 15000-10/1.52 and CRB 15000- 12/1.27) Remove the lifting aid by removing the screws. xx2000002139 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 619 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000002136 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 620 Valid for CRB 15000-5/0.95 Replace if damaged. O-ring: 3HAC061327-051 xx2000001962 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 O-ring: 3HAC061327-051 xx2300000849 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 621 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 Hex socket head cap screw: M3x12 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm xx2000002132 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 622 Note CAUTION Axis-6 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 623 For joint units on axes 4, 5 and 6. xx2000002438 Place the cabling at the slot before refitting the joint unit. xx2100000041 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 624 Torque tighten all screws crosswise. Tightening torque: 1.4 Nm (for CRB 15000-5/0.95) / 1.9 Nm (for CRB 15000-10/1.52 and CRB 15000- 12/1.27) Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 625 Connect the connectors to each other and snap them to the cable holders. • J7.CS to J7.CS • J7.CP to J7.CP xx2000002163 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 626 Refitting the arm-side interface Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002551 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 627 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 Hex socket head cap screw: M3x20 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002550 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 628 Secure with screws. Flange socket head screw: M3x20 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (16 pcs) Tightening torque: 1.8 Nm. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 629 Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Place the tool flange at mounting position and reconnect the CP/CS connectors. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 630 Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. xx2000002146 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 631 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (2 pcs) xx2000002128 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 632 • J4/5.DC+ to J5/6.DC+ • J4/5.DC- to J5/6.DC- • J4/5.CS to J5/6.CS • J4/5.CP to J5/6.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 633 Secure the cabling to tubular with cable ties. Cable ties (2 pcs) Valid for CRB 15000-5/0.95 xx2000002124 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000842 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 634 If ordering a new axis-4 or axis-5 joint unit spare part, new screws for the tubular cover are included. Tightening torque: 1.6 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 635 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 636: Replacing The Tool Flange And Axis-6 Inner Flange
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L ©...
Page 637 Axis 6: 0° CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 638 Cut the cable ties. xx2000002157 Disconnect the CP/CS connectors from the drive board and remove the tool flange. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 639 Press the adapter out of position by using two of the attachment screws as removal tools. xx2000002166 Remove the tool flange adapter. xx2000002167 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 640 Secure with screws. Flange socket head screw: M3x20 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (16 pcs) Tightening torque: 1.8 Nm. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 641 Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Place the tool flange at mounting position and reconnect the CP/CS connectors. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 642 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 643: Replacing The Arm-Side Interface
The arm-side interface is located as shown in the figure. xx2000002549 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 644 Loosen the arm-side interface carefully and dis- connect the connectors from it. • ASI.DC+ • ASI.DC- • ASI.X1 xx2100000335 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 645 Note Do not leave the arm-side interface in location xx2100000335 without being secured with the attachment screws. xx2100000336 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 646 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 647: Swing And Base
6 Remove the axis-1 joint unit. 7 Replace the base. Move the base cabling and axis-1 brake release unit from old to new base. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 648 5.5.1 Replacing the base Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 649 CRB 15000-10/1.52 and CRB 15000-12/1.27. Replace if damaged. O-ring 3HAC061327-047 Cover for axis 2/3, used for CRB 15000-5/0.95. Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 650 Removing the lower arm covers (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 652 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 653 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 654 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 655 Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 656 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 657 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 658 New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 659 Handle the as- sembly with care. xx2000001958 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 660 Action Note Remove the swing attachment screws. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 661 Snap loose and disconnect the connectors: • J1.DC+ • J1.DC- • J1.CS • J1.CP xx2000002010 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 662 Remove two attachment screws. Dispose the screws. New screws are included in the spare part delivery of the joint unit. xx2100000296 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 663 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002014 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 664 Pull out the cabling from the base. xx2100000407 Removing the brake release unit Action Note Remove the brake release unit by removing the screws. xx2100000413 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 665 Make sure that all supplies for electrical power are turned off. Remove the lower cover of lower arm by removing the screws. xx2300000812 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 666 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 667 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 668 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 669 Make sure that all supplies for electrical power are turned off. Remove the cover by removing the screws. xx2300000814 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 671 The weight of the complete swing and base together is xxx WARNING Personnel must not, under any circumstances, be present under the suspended load. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 672 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000787 xx2300000788 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 673 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000790 Remove the lifting aid. xx2300000778 xx2300000776 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 674 Note Valid for CRB 15000-10/1.52 Remove the swing transition. xx2300000817 Valid for CRB 15000-10/1.52 Remove the swing flange. xx2300000818 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 675 Remove the swing attachment screws. Valid for CRB 15000-10/1.52 CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 676 Action Note Cut the cable ties. xx2000002012 Remove the functional and protective earth cables by removing the screw. xx2000002011 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 677 Use tweezers to unlock connectors and pull them off. xx2000002009 Removing the axis-1 joint unit (-10/1.52 and -12/1.27) Action Note Removing the attachment screws. xx2300000770 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 678 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000774 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 679 Removing the base cabling Action Note Remove the attachment screws. xx2100000406 Pull out the cabling from the base. xx2100000407 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 680 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm. xx2100000413 Refitting the base cabling Action Note Insert the cabling into the base. xx2100000408 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 681 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 682 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 683 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2000002008 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 684 D1.DC- to Ground • D1.X4 to X4 • D1.X2 to X2 • D1.X5 to X5 • DR.X8 to X8 xx2000002009 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 685 Tightening torque: 0.8 Nm. xx2000002011 Secure the cabling with cable ties. Cable ties (4 pcs) xx2000002012 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 686 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.2 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2000002007 xx2100000268...
Page 687 Separate the new swing parts by removing the pre-assembling screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 688 M4x25 12.9 Lafre Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs) CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 689 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 690 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001961 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 691 Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws. xx2000001956 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 692 Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 693 M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 694 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 695 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 696 Refit the inner cover with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm. xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 697 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000001932 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 698 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 699 Secure the base connector with the attachment Hex socket head cap screw: M3x8 screws. 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm. xx2100000406 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 700 Always use guide pins in pairs. For joint units on axes 1 and 2 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2300000775 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 701 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000779 xx2300000780 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 702 Secure with four attachment screws and pre- tighten the screws crosswise. xx2300000783 Remove the lifting aid by removing the screws. xx2300000784 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 703 D1.DC- to Ground • D1.X4 to X4 • D1.X2 to X2 • D1.X5 to X5 • DR.X8 to X8 xx2000002009 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 704 Tightening torque: 0.8 Nm. xx2000002011 Secure the cabling with cable ties. Cable ties (4 pcs) xx2000002012 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 705 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2300000760 Securing the base...
Page 706 CAUTION Do not use the pre-assembling screws of swing parts for securing. xx2300000817 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 707 Pre-tighten the screws crosswise firstly. Valid for CRB 15000-12/1.27 CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 708 ESD on page Check the o-rings. O-ring: 3HAC061327-044 Replace if damaged. xx2300000823 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 709 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 710 The joint unit is properly placed when no gaps between the block and both lifting aid and swing. xx2300000794 Remove the guide pins. xx2300000795 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 711 Washers: 23/10.5/2.5 mm Steel (4 pcs). Tightening torque: 32 Nm ±10%. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 712 12.9 Lafre 2C2B/FC6.9, 16 pcs Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 713 12.9 Lafre 2C2B/FC6.9, 16 pcs CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 714 Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001946 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 715 Removing the lower arm covers (-10/1.52 and -12/1.27) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 716 Fit the o-ring to cover groove. O-ring: 3HAC061327-074 (for CRB 15000-10/1.52 and CRB 15000- Replace if damaged. 12/1.27) xx2300000816 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 717 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 718: Replacing The Swing
2 Remove the lower and upper arm undivided. 3 Remove the swing cover. 4 (For CRB 15000-10/1.52 and CRB 15000-12/1.27) Loosen the base from the foundation and lay it down with the torque sensor side upwards. 5 Remove the axis-2 joint unit.
Page 719 Content is defined in section Standard toolkit on page 1087. Required consumables Consumable Article number Note Cleaning agent Isopropanol Flange sealant Loctite 574 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 720 Replace if damaged. O-ring 3HAC061327-075 Lower arm, lower inner cover of CRB 15000-10/1.52 and CRB 15000-12/1.27. Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 721 Removing the lower arm covers (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 723 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 724 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 725 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 726 Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 728 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 729 New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 730 Handle the as- sembly with care. xx2000001958 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 731 Action Note Remove the swing attachment screws. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 732 Make sure that all supplies for electrical power are turned off. Remove the lower cover of lower arm by removing the screws. xx2300000812 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 733 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 734 CRB 15000-10/1.52 and CRB 15000-12/1.27. The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 735 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 736 Make sure that all supplies for electrical power are turned off. Remove the cover by removing the screws. xx2300000814 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 738 The weight of the complete swing and base together is xxx WARNING Personnel must not, under any circumstances, be present under the suspended load. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 739 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000787 xx2300000788 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 740 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000790 Remove the lifting aid. xx2300000778 xx2300000776 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 741 Note Valid for CRB 15000-10/1.52 Remove the swing transition. xx2300000817 Valid for CRB 15000-10/1.52 Remove the swing flange. xx2300000818 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 742 Remove the swing attachment screws. Valid for CRB 15000-10/1.52 CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 743 The torque sensor (on the exposed PCBA) is sensitive to mechanical damage. Handle the as- sembly with care. xx2000001989 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 744 M4x25 12.9 Lafre Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs) CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 745 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. xx2000002153 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 746 Remove the guide pins and secure the remaining two attachment screws. xx2100000295 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 747 • J2.DC+ to J2.DC+ • J2.DC- to J2.DC- • J2.CS to J2.CS • J2.CP to J2.CP xx2000001944 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 748 Refitting the swing cover(-5/0.95) Action Note Fit the o-ring to cover groove. O-ring: 3HAC061327-047 (for CRB 15000-5/0.95) Replace if damaged. xx2000001962 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 749 Refit the cover with the four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 750 Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 751 M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 752 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001936 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 753 Hex socket head cap screw: M3x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Secure the cover with four screws. Tightening torque: 0.45 Nm. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 754 Valid for CRB 15000-10/1.52 O-ring: 3HAC061327-044 Fit the o-ring to groove. Replace if damaged. xx2300000821 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 755 The torque sensor (on the exposed PCBA) is sensitive to mechanical damage. Handle the as- sembly with care. xx2000001989 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 756 Pre-tighten the screws crosswise firstly. Valid for CRB 15000-12/1.27 CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 757 Always use guide pins in pairs. For joint units on axes 1 and 2 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2300000791 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 758 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 759 The joint unit is properly placed when no gaps between the block and both lifting aid and swing. xx2300000794 Remove the guide pins. xx2300000795 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 760 Washers: 23/10.5/2.5 mm Steel (4 pcs). Tightening torque: 32 Nm ±10%. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 761 Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 762 Fit the o-ring to cover groove. O-ring: 3HAC061327-074 (for CRB 15000-10/1.52 and CRB 15000- Replace if damaged. 12/1.27) xx2300000816 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 763 Guide pin, M5x150: 3HAC087786- xx2300001021 CAUTION The weight of the complete upper and lower arm together is 18 kg Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 764 12.9 Lafre 2C2B/FC6.9, 16 pcs Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 765 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 766 Refit the inner cover with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm. xx2300000813 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 767 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 768: Joint Units
5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) 5.6 Joint units 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Location of the axis-1 joint unit The joint unit is located as shown in the figure. xx2000002018 Summary of the replacement procedure This is a brief summary of the replacement procedure, containing the major actions to be performed.
Page 769 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 770 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Removing the joint unit Use these procedures to remove the joint unit. Preparations before removing the joint unit Action Note Jog the robot to the specified position: • Axis 1: 0° (home position) •...
Page 771 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the four lower arm cover screws. xx2000001929 Remove the cover by inserting a small flat screwdriver to snap open the locks at each end of the cover.
Page 772 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Disconnecting the cabling between the lower arm and the swing Action Note Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors.
Page 773 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Removing the lower and upper arm assembled Action Note Remove the cable bracket by removing the four screws. xx2000001939 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an overhead crane.
Page 774 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 775 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the complete arm system from the swing. xx2000001941 Remove the guide pins. xx2000002432 Removing the swing cover (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off.
Page 776 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note CAUTION Valid for CRB 15000-5/0.95 There is cabling connected between the cover and the joint unit drive board. Open the cover with care to avoid damage to the cabling or the connector(s).
Page 777 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Cut the cable ties. xx2000001946 Remove the functional and protective earth cables by removing the screw. xx2000001945 Snap loose and disconnect the connectors: • J2.DC+ • J2.DC- •...
Page 778 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Removing the axis-2 joint unit (-5/0.95) Action Note Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001 sensor side. Screws: M4x35 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage.
Page 779 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Put the cabling at the slot in order not to squeeze it during removal of joint unit. xx2100000045 Press the joint unit out of position using two of the previous attachment screws as removal tools.
Page 780 Action Note Remove the swing attachment screws. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 781 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Tilt the base on to its side and remove the bottom cover by removing the attachment screws. xx2000002007 Disconnecting the axis-1 joint unit cabling Action Note Cut the cable ties.
Page 782 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Disconnect the connectors from the drive board. • D1.X1 from X1 • D1.DC+ from DC+ • D1.DC- from ground • D1.X4 from X4 • D1.X2 from X2 •...
Page 783 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Fit two guide pins to the axis-1 joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. For joint units on axes 1, 2 and 3 of CRB 15000-5/0.95 and axis 3 of...
Page 784 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the lifting aid and guide pins. xx2000001957 Removing the joint cable Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Fit the protection plate to the drive board unit.
Page 785 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the protection plate. xx2100000301 Remove the cable support from the drive board by removing the attachment screws. xx2000002055 Disconnect the two connectors from the torque sensor board.
Page 786 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the joint cable from the hollow shaft from the torque sensor side. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002060 sembly with care.
Page 787 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Secure the cable plate to the joint unit with the Hex socket head cap screw: attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm.
Page 788 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit.
Page 789 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For cable tie, using a cable tie gun. securing joint unit cable. Assembly direction for the cable tie is shown in Cable tie gun EVO 7i the figure.
Page 790 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Preparations before fitting the joint unit (-5/0.95) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page...
Page 791 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. For joint units on axes 1, 2 and 3 of CRB 15000-5/0.95 and axis 3 of...
Page 792 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the guide pins and secure the remaining two attachment screws. xx2100000296 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws.
Page 793 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Connect the connectors to each other and snap them to the cable holders. • J1.DC+ to J1.DC+ • J1.DC- to J1.DC- • J1.CS to J1.CS • J1.CP to J1.CP...
Page 794 Refit the bottom cover with the attachment screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.2 Nm. Note For CRB 15000-5/0.95, fit the cover in correct dir- ection, the protrusion of the cover must face out- wards. xx2000002007 xx2100000268...
Page 795 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Securing the base Action Note Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4 foundation with the attachment screws and pcs). washers. Washers: 23/10.5/2.5 mm Steel (4 pcs).
Page 796 M4x25 12.9 Lafre Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs) CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 797 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Clean the mounting surface of the joint unit and Cleaning agent: Isopropanol the mating surface on the casting with isopropan- Flange sealant: Loctite 574 Joint unit mounting surface is pointed out in the figure.
Page 798 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Fit two guide pins to the joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. For joint units on axes 1, 2 and 3 of CRB 15000-5/0.95 and axis 3 of...
Page 799 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Secure the joint unit with new attachment screws. Flange socket head screw with glue: 3HAB3413-435 M4x35 12.9 Lafre 2C2B/FC6.9+PrO-COat111, with NYPLAS glue , 12 pcs Used for joint unit of CRB 15000- 5/0.95.
Page 800 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Refitting the lower and upper arm assembled (-5/0.95) Action Note Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786- xx2000001949 Remove any old residuals of flange sealant from...
Page 801 M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 802 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Connecting the axis-2 joint unit cabling Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page Reconnect the connectors to the drive board.
Page 803 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001946 Connecting the cabling between the lower arm and swing Action Note Connect the connectors to each other and snap them to the cable holders.
Page 804 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001936 Refitting the lower arm covers (-5/0.95)
Page 805 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note Snap the lower arm cover into place. Hex socket head cap screw: M3x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Secure the cover with four screws. Tightening torque: 0.45 Nm.
Page 806 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Action Note For robots with RobotWare earlier than 7.10 Cable ties Secure the brake release cable with a cable tie. xx2000001931 Refit the cover with the four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs)
Page 807 5 Repair 5.6.1 Replacing the axis-1 joint unit (CRB 15000-5/0.95) Continued Concluding procedure Action Note Calibrate the joint unit torque sensor. Calibration on page 1051 1 On the FlexPendant, go to the Code app and call the calibration procedure using PP to Routine, not by using Call Routine.
Page 808: Replacing The Axis-1 Joint Unit (Crb 15000-10/1.52 And Crb 15000-12/1.27)
5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Location of the axis-1 joint unit The joint unit is located as shown in the figure.
Page 809 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Spare part Article number Note Joint unit 3HAC087472-001 Used for CRB 15000-10/1.52 and CRB 15000-12/1.27. New O-rings 3HAC061327-044 and cable tie 3HAC075545-001 are included in the delivery.
Page 810 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Removing the joint unit Use these procedures to remove the joint unit. Preparations before removing the joint unit Action Note Jog the robot to the specified position: xxx •...
Page 811 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the lower inner cover by removing the screws. xx2300000813 Disconnecting the cabling between the lower arm and the swing Action Note Remove the functional earth cable by removing the screw.
Page 812 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Removing the lower and upper arm assembled Action Note Remove the cable bracket by removing the four screws. xx2000001939 Secure the weight of the upper and lower arm.
Page 813 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove two attachment screws and fit two guide Guide pin, M5x150: 3HAC087786- pins to the axis-2 joint unit. Always use guide pins in pairs.
Page 814 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the complete arm system from the swing. xx2000001941 Remove the guide pins. xx2000002432 Removing the swing cover and insert (-10/1.52 and -12/1.27) Action...
Page 815 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note CAUTION Valid for CRB 15000-5/0.95 There is cabling connected between the cover and the joint unit drive board. Open the cover with care to avoid damage to the cabling or the connector(s).
Page 816 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the functional and protective earth cables by removing the screw. xx2000001945 Snap loose and disconnect the connectors: • J2.DC+ • J2.DC- • J2.CS •...
Page 817 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Loosen the robot base from the foundation by removing the foundation attachment screws. Lay the robot down with the torque sensor side upwards on a working bench. Do not damage the base socket.
Page 818 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Place the two semicircular blocks surrounding the joint unit, and use two fully threaded attachment screws as removal tools to press the joint unit out of position.
Page 819 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Securing the base (-10/1.52 and -12/1.27) Action Note Lift the base to standing and secure it to the Attachment screws: M10x35 8.8 (4 foundation with the attachment screws and pcs).
Page 820 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the swing attachment screws. Valid for CRB 15000-10/1.52 CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 821 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Lift away the swing. CAUTION The torque sensor (on the exposed PCBA) is sensitive to mechanical damage. Handle the as- sembly with care. Loosening the base and removing the base cover...
Page 822 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Snap loose and disconnect the connectors: • J1.DC+ • J1.DC- • J1.CS • J1.CP xx2000002010 Disconnect the connectors from the drive board. • D1.X1 from X1 •...
Page 823 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC087787-001 sensor side. Screws: M5x30 (4 pcs for plate and 2 pcs for beam)
Page 824 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the lifting aid. xx2300000778 xx2300000776 Removing the joint cable Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the...
Page 825 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Remove the cable support from the drive board by removing the attachment screws.
Page 826 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the cable plate by removing the attach- ment screws. xx2000002049 Remove the joint cable from the hollow shaft from the torque sensor side.
Page 827 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure the cable plate to the joint unit with the Hex socket head cap screw: attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm.
Page 828 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit.
Page 829 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For cable tie, using a cable tie gun. securing joint unit cable.
Page 830 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Refitting the axis-1 joint unit (-10/1.52 and -12/1.27) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Check the o-rings.
Page 831 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001 with the pin hole. Lifting aid: 3HAC087787-001 Screws: M5x30 (4 pcs for plate and...
Page 832 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Check the joint unit position by placing the lower boss of one semicircular block between the lifting aid and base. The joint unit is properly placed when no gaps...
Page 833 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure the joint unit with the remaining attach- Hex socket head cap screw: ment screws. 3HAB3409-20 xx2300000785 Torque tighten all screws crosswise. M5x55 12.9 Lafre 2C2B/FC6.9, 12 Tightening torque: 8.2 Nm.
Page 834 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Connect the connectors to each other and snap them to the cable holders. • J1.DC+ to J1.DC+ • J1.DC- to J1.DC- • J1.CS to J1.CS •...
Page 835 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Refitting the base cover (-10/1.52 and -12/1.27) Action Note Wipe, lubricate and fit the o-ring to its groove. 3HAC061327-072 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002016 Refit the bottom cover with the attachment screws.
Page 836 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Valid for CRB 15000-10/1.52 Hex socket head cap screw: M5x25 12.9 Lafre 2C2B/FC6.9 (16 pcs) Refit the swing flange with the attachment screws. Tightening torque: 8.2 Nm...
Page 837 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure the swing with the attachment screws. Hex socket head cap screw: M5x30 12.9 Lafre 2C2B/FC6.9 (16 pcs) Pre-tighten the screws crosswise firstly. Valid for CRB 15000-12/1.27...
Page 838 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Refitting the axis-2 joint unit (-10/1.52 and -12/1.27) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Check the o-rings.
Page 839 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001 with the pin hole. Lifting aid: 3HAC087787-001 Screws: M5x30 (4 pcs for plate and...
Page 840 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Fit the joint unit to the swing, aligning the pin with the pin hole. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care.
Page 841 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure with four attachment screws and pre- tighten the screws crosswise. xx2300000796 Remove the lifting aid by removing the screws. xx2300000797 Secure the joint unit with the remaining attach- Hex socket head cap screw: ment screws.
Page 842 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27) Action Note Fit three guide pins to the axis-2 joint unit. Guide pin, M5x150: 3HAC087786- xx2300001021...
Page 843 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the guide pins and fasten the remaining Hex socket head cap screw: M5x30 two screws and washers. 12.9 Lafre 2C2B/FC6.9, 16 pcs CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB...
Page 844 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Connect the connectors to each other and snap them to the cable holders. • J2.DC+ to J2.DC+ • J2.DC- to J2.DC- • J2.CS to J2.CS •...
Page 845 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Connecting the cabling between the lower arm and swing Action Note Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties.
Page 846 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the lower cover of lower arm by removing the screws. xx2300000812 Remove the lower inner cover by removing the screws. xx2300000813 Refitting the swing cover and insert(-10/1.52 and -12/1.27)
Page 847 5 Repair 5.6.2 Replacing the axis-1 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Refit the cover with the four screws. Hex socket head cap screw: M3x12 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm xx2300000814 Concluding procedure...
Page 848: Replacing The Axis-2 Joint Unit (Crb 15000-5/0.95)
5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Location of the axis-2 joint unit The joint unit is located as shown in the figure. xx2000001948 Summary of the replacement procedure This is a brief summary of the replacement procedure, containing the major actions to be performed.
Page 849 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 850 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Removing the joint unit Use these procedures to remove the joint unit. Preparations before removing the joint unit Action Note Jog the robot to the specified position: • Axis 1: 0°...
Page 851 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the four lower arm cover screws. xx2000001929 Remove the cover by inserting a small flat screwdriver to snap open the locks at each end of the cover.
Page 852 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Disconnecting the cabling between the lower arm and the swing Action Note Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors.
Page 853 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Removing the lower and upper arm assembled Action Note Remove the cable bracket by removing the four screws. xx2000001939 Secure the weight of the upper and lower arm. Suggestion with lifting sling and an overhead crane.
Page 854 Always use guide pins in pairs. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 855 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the complete arm system from the swing. xx2000001941 Remove the guide pins. xx2000002432 Removing the swing cover (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off.
Page 856 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note CAUTION Valid for CRB 15000-5/0.95 There is cabling connected between the cover and the joint unit drive board. Open the cover with care to avoid damage to the cabling or the connector(s).
Page 857 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Cut the cable ties. xx2000001946 Remove the functional and protective earth cables by removing the screw. xx2000001945 Snap loose and disconnect the connectors: • J2.DC+ • J2.DC- •...
Page 858 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Removing the axis-2 joint unit (-5/0.95) Action Note Fit the lifting aid to the joint unit, on the torque Lifting aid: 3HAC077788-001 sensor side. Screws: M4x35 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage.
Page 859 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Put the cabling at the slot in order not to squeeze it during removal of joint unit. xx2100000045 Press the joint unit out of position using two of the previous attachment screws as removal tools.
Page 860 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) Using the protection plate is important for protect- ing the drive board unit.
Page 861 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the cable support from the drive board by removing the attachment screws. xx2000002055 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B...
Page 862 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Place the joint cable through the hollow shaft from the torque sensor side. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002048 sembly with care.
Page 863 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Insert the cabling through the cable support and fit the support to the drive board with the attach- ment screws. xx2000002056 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs)
Page 864 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) xx2000002057 Secure the cables to the cable support with a Cable tie: 3HAC075545-001.
Page 865 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the protection plate. xx2100000301 Preparations before fitting the joint unit (-5/0.95) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section...
Page 866 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Refitting the axis-2 joint unit (-5/0.95) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Fit the lifting aid to the joint unit.
Page 867 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Fit the joint unit to the swing, aligning the pin with the pin hole. CAUTION xx2000001959 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care.
Page 868 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Remove the lifting aid by removing the screws. xx2000001956 Clean pushed-out flange sealant, if any. Connecting the axis-2 joint unit cabling Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling...
Page 869 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note Secure the cables for functional earth and Hex socket head cap screw: M3x6 (1 protective earth with a screw. pcs). Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties.
Page 870 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Action Note For robots with RobotWare earlier than 7.10 Place the cover at mounting position and recon- nect the brake release connector DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable.
Page 871 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Refitting the lower and upper arm assembled (-5/0.95) Action Note Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786- xx2000001949 Remove any old residuals of flange sealant from...
Page 872 M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. CAUTION Do not mix the flange screws used for CRB 15000- 5/0.95 and the threaded screws used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Always use washers together with the threaded screws for CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 873 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Connecting the cabling between the lower arm and swing Action Note Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties.
Page 874 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Refitting the lower arm covers (-5/0.95) Action Note Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000001954 Refit the inner cover with four screws.
Page 875 5 Repair 5.6.3 Replacing the axis-2 joint unit (CRB 15000-5/0.95) Continued Concluding procedure Action Note Calibrate the joint unit torque sensor. Calibration on page 1051 1 On the FlexPendant, go to the Code app and call the calibration procedure using PP to Routine, not by using Call Routine.
Page 876: Replacing The Axis-2 Joint Unit (Crb 15000-10/1.52 And Crb 15000-12/1.27)
5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Location of the axis-2 joint unit The joint unit is located as shown in the figure.
Page 877 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Spare part Article number Note Joint unit 3HAC087472-001 Used for CRB 15000-10/1.52 and CRB 15000-12/1.27. New O-rings 3HAC061327-044 and cable tie 3HAC075545-001 are included in the delivery.
Page 878 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Removing the joint unit Use these procedures to remove the joint unit. Preparations before removing the joint unit Action Note Jog the robot to the specified position: xxx •...
Page 879 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the lower inner cover by removing the screws. xx2300000813 Disconnecting the cabling between the lower arm and the swing Action Note Remove the functional earth cable by removing the screw.
Page 880 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Removing the lower and upper arm assembled Action Note Remove the cable bracket by removing the four screws. xx2000001939 Secure the weight of the upper and lower arm.
Page 881 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove two attachment screws and fit two guide Guide pin, M5x150: 3HAC087786- pins to the axis-2 joint unit. Always use guide pins in pairs.
Page 882 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the complete arm system from the swing. xx2000001941 Remove the guide pins. xx2000002432 Removing the swing cover and insert (-10/1.52 and -12/1.27) Action...
Page 883 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note CAUTION Valid for CRB 15000-5/0.95 There is cabling connected between the cover and the joint unit drive board. Open the cover with care to avoid damage to the cabling or the connector(s).
Page 884 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the functional and protective earth cables by removing the screw. xx2000001945 Snap loose and disconnect the connectors: • J2.DC+ • J2.DC- • J2.CS •...
Page 885 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Loosen the robot base from the foundation by removing the foundation attachment screws. Lay the robot down with the torque sensor side upwards on a working bench. Do not damage the base socket.
Page 886 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Place the two semicircular blocks surrounding the joint unit, and use two fully threaded attachment screws as removal tools to press the joint unit out of position.
Page 887 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Removing the joint cable Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Fit the protection plate to the drive board unit.
Page 888 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the protection plate. xx2100000301 Remove the cable support from the drive board by removing the attachment screws. xx2000002055 Disconnect the two connectors from the torque sensor board.
Page 889 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Remove the joint cable from the hollow shaft from the torque sensor side. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002060 sembly with care.
Page 890 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure the cable plate to the joint unit with the Hex socket head cap screw: attachment screws. M2.5x6 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm.
Page 891 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit.
Page 892 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure the cables to the cable support with a Cable tie: 3HAC075545-001. For cable tie, using a cable tie gun. securing joint unit cable.
Page 893 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Refitting the axis-2 joint unit (-10/1.52 and -12/1.27) Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Check the o-rings.
Page 894 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Fit the lifting aid to the joint unit, aligning the pin Joint unit: 3HAC087472-001 with the pin hole. Lifting aid: 3HAC087787-001 Screws: M5x30 (4 pcs for plate and...
Page 895 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Fit the joint unit to the swing, aligning the pin with the pin hole. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care.
Page 896 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure with four attachment screws and pre- tighten the screws crosswise. xx2300000796 Remove the lifting aid by removing the screws. xx2300000797 Secure the joint unit with the remaining attach- Hex socket head cap screw: ment screws.
Page 897 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Connecting the axis-2 joint unit cabling Action Note ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page Reconnect the connectors to the drive board.
Page 898 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001946 Refitting the swing cover and insert(-10/1.52 and -12/1.27) Action Note Refit the insert.
Page 899 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Refit the cover with the four screws. Hex socket head cap screw: M3x12 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm xx2300000814 Refitting the lower and upper arm assembled (-10/1.52 and -12/1.27)
Page 900 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Lift the upper and lower arm assembly to mount- Example of CRB 15000-5/0.95, ing position and slide it onto the guide pins. similar to CRB 15000-10/1.52 and CRB 15000-12/1.27.
Page 901 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Refit the cable bracket with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001939 Connecting the cabling between the lower arm and swing...
Page 902 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001936 Refitting the lower arm covers (-10/1.52 and -12/1.27)
Page 903 5 Repair 5.6.4 Replacing the axis-2 joint unit (CRB 15000-10/1.52 and CRB 15000-12/1.27) Continued Action Note Refit the lower cover of lower arm with three Lower arm cover, lower: Lower screws. arm, used for CRB 15000-10/1.52 and CRB 15000-12/1.27. Tightening torque: 1.4 Nm.
Page 904: Replacing The Axis-3 Joint Unit
3 Remove the housing cover. 4 Replace the joint unit. Move the cabling from old to new joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 905 5.6.5 Replacing the axis-3 joint unit Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 906 CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 907 Remove the cover by inserting a small flat screwdriver to snap open the locks at each end of the cover. xx2100000267 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 908 Make sure that all supplies for electrical power are turned off. Remove the lower arm covers by removing the screws. xx2300000812 xx2300000829 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 909 Disconnecting the upper arm cabling Action Note Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 910 Secure the weight of the upper arm. CAUTION The weight of the complete upper arm is 14 kg. Remove two attachment screws. xx2000001967 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 911 Removing the housing cover (-5/0.95) Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 912 For robots with RobotWare earlier than 7.10 Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 913 Do not leave the cover in location without being secured with the attachment screws. Remove the insert. xx2300000834 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 914 Snap loose and disconnect the connectors: • J4.DC+ • J4.DC- • J4.CS • J4.CP xx2000002067 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 915 For joint units on axes 1, 2 and 3 of CRB 15000-5/0.95 and axis 3 of CRB 15000-10/1.52 and CRB 15000-12/1.27. xx2000002576 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 916 Handle the as- sembly with care. xx2000002071 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 917 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000802 Remove the lifting aid. xx2300000804 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 919 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 920 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 921 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 922 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 923 Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 924 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 925 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002072 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 926 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 - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 927 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2300000804 xx2300000777 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 928 Remove the guide pins. xx2300000809 Secure with four attachment screws and pre- tighten the screws crosswise. xx2300000810 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 929 D3/4.DC+ to DC+ • D3/4.DC- to Ground • D3.X4 to X4 • D3/4.X2 to X2 • D3.X5 to X5 xx2000002068 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 930 Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 931 For robots with RobotWare earlier than 7.10 Cable ties Secure the brake release cable with a cable tie. xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 932 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm xx2300000834 Fit the o-ring to its groove. O-ring: 3HAC061327-047 Replace if damaged. xx2300000835 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 933 Apply flange sealant to the corner of the lower arm mounting surface, as pointed out in the figure. xx2000001973 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 934 Refit the cable bracket with the four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 935 Connecting the upper arm cabling Action Note Connect the connectors to each other and snap them to the cable holders. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 936 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000001955 xx2000001954 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 937 Hex socket head cap screw: M3x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Secure the cover with four screws. Tightening torque: 0.45 Nm. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 938 Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) x 2 Tightening torque: 1.4 Nm. xx2300000813 xx2300000830 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 939 8 Test the brake release (movement without drive power) functionality, see Testing the brake release functionality on page 196. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 940 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 941: Replacing The Axis-4 Joint Unit
3 Remove the axis-4 cover. 4 Replace the joint unit. Move the cabling from old to new joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 942 5.6.6 Replacing the axis-4 joint unit Continued 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 943 15000-5/0.95. Replace if damaged. O-ring 3HAC061327-047 Housing cover, used for CRB 15000-10/1.52 and CRB 15000- 12/1.27. Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 944 Valid for CRB 15000-10/1.52 xx2300000838 Valid for CRB 15000-12/1.27 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 945 Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000002021 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 946 Make sure that all supplies for electrical power are turned off. Remove the cover by removing the screws. xx2300000833 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 947 Action Note Cut the cable ties. xx2000002066 Remove the functional and protective earth cables by removing the screw. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 948 • D3/4.DC- xx2000002120 Opening the housing top cover Action Note Remove the cover by removing the four screws. xx2000002075 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 949 Action Note Cut the cable tie. Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 950 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-4 joint unit. Always use guide pins in pairs. xx2000002079 xx2000002080 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 951 Assist the cabling to be removed from the housing while lifting away the complete tubular. Place the tubular on a workbench. xx2000002082 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 952 For robots with RobotWare earlier than 7.10 Tweezers Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 953 Separating the cabling between the tubular and the tilt Action Note Cut the cable ties on joint unit. xx2000002086 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 954 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 955 Disconnect the connectors from the drive board. Tweezers CAUTION Use tweezers to unlock connectors and pull them off. • D4/5.X1 • D4/5.X4 • D4/5.X5 xx2000002088 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 956 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2100000327 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 957 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 958 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 959 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 960 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 961 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 (for CRB 15000-5/0.95) / 3HAC087789-001 (for CRB 15000- 10/1.52 and CRB 15000-12/1.27) xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 962 Cable tie gun EVO 7i the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 963 Note CAUTION Axis-4 joint unit used for CRB 15000-5/0.95 has the same appearance as that used for CRB 15000- 10/1.52 and CRB 15000-12/1.27. Do not mix the joint units for different manipulator variants. Al- ways check the mark or label on the joint units before refitting.
Page 964 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000326 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 965 Reconnect the connectors to the drive board. • D4/5.X1 to X1 • D4/5.X4 to X4 • D4/5.X5 to X5 xx2000002088 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 966 • J4/5.DC+ to J5/6.DC+ • J4/5.DC- to J5/6.DC- • J4/5.CS to J5/6.CS • J4/5.CP to J5/6.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 967 Secure the cabling to tubular with cable ties. Cable ties (2 pcs) Valid for CRB 15000-5/0.95 xx2000002124 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000842 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 968 If ordering a new axis-4 or axis-5 joint unit spare part, new screws for the tubular cover are included. Tightening torque: 1.6 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 969 Refit the covers with new attachment screws. Hex socket head cap screw: 3HAB3409-224 M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 970 For robots with RobotWare earlier than 7.10 Cable ties Secure the brake release cable with a cable tie. xx2000002084 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 971 Apply flange sealant to the corner of the housing Flange sealant: Loctite 574 mounting surface, as pointed out in the figure. xx2000002094 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 972 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 xx2000002079 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 973 Secure the cabling with a cable tie. Cable ties (1 pcs) Valid for CRB 15000-5/0.95 xx2000002077 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 974 Refit the cover with the four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.45 Nm xx2000002075 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 975 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 976 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 977 Refit the insert. Insert: 3HAC084002-001 Hex socket head cap screw: M3x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 1.4 Nm xx2300000834 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 978 8 Test the brake release (movement without drive power) functionality, see Testing the brake release functionality on page 196. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 979 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 980: Replacing The Axis-5 Joint Unit And The Axis-5 To Axis-6 Transition Cabling
5.6.7 Replacing the axis-5 joint unit and the axis-5 to axis-6 transition cabling Location of the axis-5 joint unit The joint unit is located as shown in the figure. xx2000002121 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 981 7 Replace the axis-5 to axis-6 transition cabling. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 982 If ordering a new axis-4 or axis-5 joint unit spare part, new screws for the tubular cover are included. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 983 Dispose the screws. New screws must be used when refitting the cover. New screws are included in the spare part delivery of the joint unit. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 984 For robots with RobotWare earlier than 7.10 Open the cover and cut the cable tie that holds the brake release cable. xx2000002084 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 985 Cut the cable ties on tubular, if needed. Valid for CRB 15000-5/0.95 xx2000002124 Valid for CRB 15000-10/1.52 and CRB 15000-12/1.27 xx2300000842 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 986 Tweezers axis-5 cabling, from the axis-4 drive board: • D3/4.X2 • D3/4.DC- • D3/4.DC+ Use tweezers, if needed. xx2000002125 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 987 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-5 joint unit. Always use guide pins in pairs. xx2000002128 xx2000002129 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 988 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 989 Remove the functional earth cable by removing the screw. xx2000002159 Removing the tool flange adapter Action Note Remove the tool flange adapter screws. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 990 Do not leave the arm-side interface in location without being secured with the attachment screws. Remove the attachment screws. xx2000002550 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 991 Remove the functional and protective earth cables by removing the screw. xx2000002162 Snap loose and disconnect the connectors: • J7.CS • J7.CP xx2000002163 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 992 5 jogged to +20°, which is a more convenient position when re- placing only the axis-6 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 993 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2100000330 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 994 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 995 Action Note Cut the cable ties. xx2000002135 Remove the functional and protective earth cables by removing the screw. xx2000002136 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 996 Remove two attachment screws. Dispose the screws. New screws are included in the spare part delivery of the joint unit. xx2000002140 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 997 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002141 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 999 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.
Page 1000 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page 1000 Product manual - CRB 15000 3HAC077389-001 Revision: L © Copyright 2021 - 2023 ABB. All rights reserved.

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