Page 1 Product manual IRB 1200...
Page 2 Trace back information: Workspace Main version a74 (not checked in) Published 2014-09-05 at 09:21:00 Skribenta version 4.1.210...
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Fitting of equipment on the robot ............... 2.3.7.1 Introduction to fitting of equipment ..........2.3.7.2 Holes for fitting extra equipment ............ Installation of options ..................2.4.1 Installing the signal lamp ................. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 6 4.6.7 Replacing the axis-5 motor with pulley ............4.6.8 Replacing the axis-5 timing belt ..............4.6.9 Replacing the axis-5 and axis-6 drive unit ........... Calibration Introduction ...................... Calibration method .................... 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 7 Weight specifications ..................Standard toolkit ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagrams About circuit diagrams ..................Index 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
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Page 9: Overview Of This Manual
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. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 Reference to the circuit diagram for the robot. References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - IRB 1200 3HAC046984-001 Product specification - IRB 1200 3HAC046982-001 Circuit diagram - IRB 1200...
Page 11: Product Documentation, Irc5
This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for IRC5 robot systems.
Page 12 Operating manual - Introduction to RAPID • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Trouble shooting IRC5, for the controller and manipulator. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 13: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
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Page 15: Safety
Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section Safety related instructions on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 16: General Safety Information
• stopping functions Safety stops describes different types of • description of emergency stop stops. • description of safety stop • description of safeguarding 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 17: Safety In The Robot System
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...
Page 18: Safety Risks
ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the manipulator system.
Page 19 Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm ac- cording to repair instruction if removing mo- tor, axis 2. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 20 Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balan- cing device is potentially lethal! 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 21: Caution - Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 22: Safety Risks Related To Tools/Work Pieces
Unauthorized modifications of the originally delivered manipulator are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.
Page 23: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems to drop. • Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, etc., from falling due to gravity. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 24: Safety Risks During Operational Disturbances
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 25: Risks Associated With Live Electric Parts
The power supply unit for additional tools, or special power supply units for the machining process. • The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 26 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 27: Safety Actions
(see the section Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 28: Fire Extinguishing
1 Safety 1.2.4.2 Fire extinguishing 1.2.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 29: Emergency Release Of The Manipulator's Arm
Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury! 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 30: Brake Testing
3 Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 31: Risk Of Disabling Function "Reduced Speed 250 Mm/S
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" Note Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 32: Safe Use Of The Jogging Device
The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 33: Work Inside The Manipulator's Working Range
NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is always a risk that the manipulator will move unexpectedly when manipulator axes are moved using the enabling device or during other work inside the manipulator’s working range. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 34: Safety Stops
The safety standards that regulate automation and robot equipment define categories in which each type of stop applies: If the stop is..then it is classified as... category 0 (zero) uncontrolled Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 35 FlexPendant and on the controller cabinet. There can also be other types of emergency stops on your manipulator. Consult your plant or cell documentation to see how your manipulator system is configured. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 36: Safety Related Instructions
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 37 1.3.1 Safety signals in the manual Continued Symbol Designation Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 38: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 39 Pressing this button will release the brakes. This means that the manipulator arm can fall down. xx0900000808 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened. xx0900000810 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 40 Risk of crush injuries. xx0900000817 Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 41 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 42 Symbol Description Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 43: Danger - Moving Manipulators Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the manipulator be- fore pressing the start button. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 44: Danger - First Test Run May Cause Injury Or Damage
Pay special attention to the function of the part previously serviced Collision risks CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 45: Danger - Make Sure That The Main Power Has Been Switched Off
Switch off the main switch on the Drive Module. xx0600002783 K: Main switch, Drive Module Switch off the main switch on the Control A: Main switch, Control Module Module. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 46 Note that the position of the main switch can vary depend- switch on the controller ing on the year model. cabinet. xx0900000313 A: Main power switch Disconnect the input power cable from the wall socket. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 47: Warning - The Unit Is Sensitive To Esd
The location of the wrist strap button is shown in the following illustration. IRC5 The wrist strap button is located in the top right corner. xx1300000856 Wrist strap button Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 49: Warning - Safety Risks During Handling Of Batteries
Risk of fire or explosion. page Use safety glasses when handling the batteries. In the event of leakage, wear gloves and chemical apron. In the event of fire, use self-contained breathing apparatus. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 50: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Do not present in the gearbox, causing overfill the gearbox when filling. lubricant to spray from the xx0100000002 opening. Possible pressure build-up in gearbox Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
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Page 53: Installation And Commissioning
If the robot is connected to power, always make sure that the robot is connected to protective earth before starting any installation work! For more information see: • Product manual - IRC5 • Product manual - IRC5 Compact 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 54: Unpacking
It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation Installation craftsmen working with an ABB robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 55 ±580 Nm Wall mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ±1210 N ±1940 N Force z 0 ±900 N 0 ±1340 N Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 56 Maximum tilt 5º The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Minimum resonance 22 Hz frequency...
Page 57 Protection classes, robot The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP40 IP67 (option 287-10) 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 58: Dimensions
Minimum turning radius axis 4 R=79 mm Minimum turning radius axis 3 R=111 mm Minimum turning radius axis 1 R=138 mm Valid for option Robot cabling routing, 966-1 From below Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 59 Minimum turning radius axis 4 R=79 mm Minimum turning radius axis 3 R=139 mm Minimum turning radius axis 1 R=138 mm Valid for option Robot cabling routing, 966-1 From below 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 60: Working Range
2.2.3 Working range 2.2.3 Working range Illustration, working range IRB 1200-5/0.9 IRB 1200-5/0.9 Working range, positions at wrist center and angle of axes 2 and 3 The illustration shows the unrestricted working range of the robot. Pos 1 Pos 0...
Page 61 2 Installation and commissioning 2.2.3 Working range Continued Illustration, working range IRB 1200-7/0.7 IRB 1200-7/0.7 Working range, positions at wrist center and angle of axes 2 and 3 The illustration shows the unrestricted working range of the robot. Pos 1 Pos 0...
Page 62 Axis 4 Wrist motion +270° to -270° +270° to -270° Axis 5 Bend motion +130° to -130° +130° to -130° Axis 6 Turn motion +360° to -360° +360° to -360° 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 63: Risk Of Tipping/Stability
This figure shows the robot in its shipping position, which also is a recommended transport position. xx1400000500 WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 64: On-Site Installation
2 pcs. Length: 0.6 m. Lifting capacity: 60 kg. Roundsling, 1.5 m 2 pcs. Length: 1.5 m. Lifting capacity: 60 kg. Lifting accessory, robot 3HAC049711-001 Includes lifting accessories, lifting beam and screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 65 Fit the lifting tools to the robot. Lifting accessory, robot: 3HAC049711- Use the enclosed screws. xx1400000498 Tightening torque: 40 Nm Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 66 Fit the roundslings to the lifting beam and to Roundsling, 0.6 m the overhead crane. xx1400000501 CAUTION The IRB 1200 robot weighs 54 kg. All lifting accessories used must be sized ac- cordingly! WARNING Personnel must not, under any circumstances, be present under the suspended load! Raise the overhead crane to lift the robot.
Page 67: Lifting And Turning A Suspended Mounted Robot
Special tools on page 626. Contact ABB for more information. How to lift and turn the robot into position for wall or tilted position: Contact ABB for more information! 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 68: Manually Releasing The Brakes
This section describes how to release the holding brakes for the motors of each axis. Location of brake release unit The internal brake release unit is located as shown in the figure. xx1400000030 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 69 R1.MP on the robot in order to enable the brake release buttons. Action Note DANGER Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 70 Supply +24V on pin 13 and 0V on pin 12. Note Do not interchange the 24V and 0V pins. If they are mixed up, damage can be caused to the brake release unit and to the system board. xx1400000031 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 71: Orienting And Securing The Robot
Loads on foundation, robot on page 55 • Requirements, foundation on page Hole configuration, base The illustration shows the hole configuration used when securing the robot. + 0,018 6 H8 0.03 xx1300000368 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 72 Fit the securing screws and washers in the attach- Screws: M12x35 (robot installation ment holes of the base. directly on foundation), quality: 8.8 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 73 When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. Screw joints must be able to withstand the stress loads defined in section Loads on foundation, robot on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 74: Setting The System Parameters For A Suspended Robot
B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor (A) 0° 0.000000 (Default) Tilted (B) 45° 0.785398 Wall (C) 90° 1.570796 Suspended (D) 180° 3.141593 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 75 The parameter can be edited either with the FlexPendant or in RobotStudio. See Operating manual - IRC5 with FlexPendant or Operating manual - RobotStudio. Article numbers for the manuals are specified in References on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 76: Loads Fitted To The Robot, Stopping Time And Braking Distances
Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 77: Fitting Of Equipment On The Robot
The robot is supplied with holes for fitting of extra equipment. (See Holes for fitting extra equipment on page 78). IRB 1200-7/0.7 IRB 1200-5/0.9 xx1300000384 Load area (A) Max load IRB 1200-5/0.9 0.3 kg IRB 1200-7/0.7 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 78: Holes For Fitting Extra Equipment
2 x M4 2xM5 xx1300000381 Description IRB 1200-5/0.9 = 451 mm, IRB 1200-7/0.7 = 351 mm IRB 1200-5/0.9 = 216 mm, IRB 1200-7/0.7 = 116 mm Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 79 2 Installation and commissioning 2.3.7.2 Holes for fitting extra equipment Continued Lower arm 2 x M5 30 ±0,15 122,5 122,5 122,5 122,5 IRB 1200-7/0.7 IRB 1200-5/0.9 xx1300000382 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 80 2 Installation and commissioning 2.3.7.2 Holes for fitting extra equipment Continued Frame 30 ±0.15 2xM10 xx1400000590 Description Holes on both sides Robot tool flange 0.012 5 H7 0.04 4xM5 0.25 31.5 xx1300000383 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 81: Installation Of Options
Location of signal lamp The signal lamp is located as shown in the figure. xx1300000455 Required spare parts Spare part Article number Note Signal lamp 3HAC16738-1 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 82 Fit the lamp and tighten the nut. Connect the two lamp cables connectors (R3.H1 and R3.H2) to the cable harness lamp connectors (H1 and H2). Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 83 Tightening torque: 1.5 Nm. xx1300000456 Note Only use specified screws, never replace them with other screws. The signal lamp is now ready for use and is lit in MOTORS ON mode. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 84: Electrical Connections
Article number 3HAC040503-007 3HAC040503-001 15 m 3HAC040503-002 22 m 3HAC040503-003 30 m 3HAC040503-004 Robot cable, signals Signal cable length Article number 3HAC035320-001 3HAC2493-1 15 m 3HAC2530-1 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 85 22 m (IRC5C) 3HAC049186-006 30 m (IRC5C) 3HAC049186-007 Customer cables - Ethernet floor cable (option) Ethernet floor cable length Article number 3HAC049360-001 3HAC049360-004 15 m 3HAC049360-005 22 m 3HAC049360-006 30 m 3HAC049360-007 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
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Page 87: Maintenance
Safety on page 15 before performing any service work! Note If the IRB 1200 is connected to power, always make sure that the IRB 1200 is connected to protective earth before starting any maintenance work! For more information see: •...
Page 88: Maintenance Schedule
3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 1200: • Calendar time: specified in months regardless of whether the system is running or not.
Page 89: Maintenance Schedule
The table below specifies the required maintenance activities and intervals: Maintenance activities Reference Cleaning activities Cleaning the robot Cleaning the IRB 1200 on page 109 Inspection acitivities Inspecting the robot Check for abnormal wear or contam- ination. Inspecting the robot cabling...
Page 90 Activities and intervals, optional equipment The table below specifies the required maintenance activities and intervals: Maintenance activities Reference Inspection acitivities Inspecting the signal lamp Inspecting, signal lamp (op- tion) on page 101 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 91: Inspection Activities
Before entering the robot working area. Visually inspect: • the control cabling between the robot and control cabinet Look for abrasions, cuts or crush damages. Replace the cabling if wear or damage is detected. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 92: Inspection, Information Labels
Safety symbols on manipulator labels on page Illustration 1 of 2 Axis Resolver values ABB Robotics Products AB Tilt warning lable IRB 1200-7/0.7 IRB 1200-5/0.9 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 93 Illustration 2 of 2 UL lable Lifting Warning instruction lable IRB 1200-0.5/9 SECTION A-A VIEW B IRB 1200 Option Description Illustration Calibration label Warning label Flash xx1300001091 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 94 Instruction label Lifting of robot xx1400000518 Warning label Heat xx1300001087 Instruction label Brake release Moving robot Brake release buttons 3HAC 2577-1/ 04 xx1400000519 UL label Rating label Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 95 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 96: Inspecting Mechanical Stops
Location of mechanical stops The mechanical stops on axes 1, 2 and 3 are located as shown in the figures. Axis 1 xx1400000391 Axis 2 xx1400000389 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 97 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 98 Replace if the mechanical stop is: • bent • loose • damaged. Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 99: Inspecting Timing Belts
3.3.4 Inspecting timing belts 3.3.4 Inspecting timing belts Location of timing belts The timing belts are located as shown in the figures. Axis 4 xx1400000036 Axis 5 xx1400000032 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 100 If any damage or wear is detected, the part must be replaced! Check each belt for tension. Axis 4: F = 15 N. If the belt tension is not correct, adjust it! Axis 5: F = 13 N. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 101: Inspecting, Signal Lamp (Option)
625. Other tools and procedures may be required if the spare part needs to be replaced. These are specified in the replacement procedure. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 103: Replacement/Changing Activities
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Continues on next page 3HAC046983-001 Revision: -...
Page 104 Removing the battery pack Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 105 Be aware of the cabling that is attached to the cover! xx1300002427 Disconnect the connectors R1.ME1-3, R1.ME4-6 and R2.EIB on the EIB unit. xx1400000812 Disconnect the battery cable. xx1300002571 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 106 Cut the cable strap that secures the battery and remove the battery from the EIB unit. Note Battery includes protection circuits. Only replace with a specified spare part or with an ABB- ap- proved equivalent. xx1300002579 Refitting the battery pack Use these procedures to refit the battery pack.
Page 107 Refit the EIB cover to the lower arm with the at- Screws: 3HAB3409-207 (M3x8). tachment screws. Tightening torque: 1.5 Nm xx1300002427 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 108 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 109: Cleaning Activities
General To secure high uptime it is important that the IRB 1200 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the IRB 1200.
Page 110 Cleaning with water and steam Instructions for rinsing with water IRB 1200 with protection class IP67 (option) can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: • Maximum water pressure at the nozzle: 700 kN/m (7 bar) •...
Page 111: Repair
Make sure to read through the chapter Safety on page 15 before commencing any service work. Note If the IRB 1200 is connected to power, always make sure that the IRB 1200 is connected to earth before starting any repair work. For more information see: •...
Page 113: Mounting Instructions For Seals
Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 114 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 115: Sealing Differences Depending On Protection Class
4.2.3 Sealing differences depending on protection class Standard IP40 vs optional IP67 The IRB 1200 has IP40 as standard protection class. If the robot is delivered with option IP67, many of the covers are equipped with gaskets, several components has been applied with locking liquid etc.
Page 116: Cable Harness
As standard feature, the connector interface is located at the rear of the base. The interface can also be bottom mounted, as an option. This section describes both configurations. Connector interface at the rear of the base (standard) xx1300002414 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 117 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 118 PTFE film on cable housing 3HAC044660-001 Replace if damaged. cover Gasket on cable housing cover 3HAC044849-001 Used with protection class IP67. Replace if damaged. EIB cover 3HAC049643-001 Replace if damaged. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 119 625. Required consumables Equipment Article number Note Cable straps Grease 3HAB3537-1 Used for lubrication of cable con- tact areas. Locking liquid 3HAB7116-1 Loctite 243 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 120 For robots with protection class IP67 (option 287-10) The two front screws on the left hand side cover (encircled in the figure) have been fitted with locking liquid. xx1300002349 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 121 Snap loose and disconnect the axis-5 FPC connectors. xx1300002390 Disconnecting the air hoses Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 122 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 123 4.3.1 Replacing the main cable package Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 124 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Cut the strap that holds the connectors. xx1300002494 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 125 Removing the cable package in the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 126 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 127 Disconnect the connectors R1.ME1-3, R1.ME4-6 and R2.EIB on the EIB unit. Remove the EIB cover completely from the lower arm. Disconnect the lugs on the EIB cover. xx1300002428 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 129 Action Note Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 130 Disconnect the motor connectors. • R2.ME2 • R2.MP2 xx1300002434 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 131 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The robot weighs 54 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 132 All lifting accessories used must be sized accordingly! Loosen the robot from the foundation by removing the foundation attachment screws and put the robot on its side. xx1400000680 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 133 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the bottom cover. Rear connector interface: xx1300000469 Bottom connector interface: xx1400000403 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 134 Remove the axis-1 motor bracket. Rear connector interface: xx1300000470 Bottom connector interface: xx1400000404 Loosen the connectors from the bracket by cutting the cable straps, and disconnect the connectors. xx1300002496 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 135 Pull out the base slightly and turn it aside. Remember the cable layout in the base. The cabling must be positioned and angled in the same way during refitting. xx1300000472 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 136 Remove the cable bracket from the axis-1 sealing ring. xx1300002439 Remove the cable bracket from the cabling, if the cable package is to be replaced with a new spare part. xx1300002446 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 137 Use this procedure if the cable connector interface is located at the bottom of the base. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 138 Remove the cable bracket by removing the screws. xx1400000406 Remove the bracket inside the base by removing the screws. xx1400000407 Pull the cable package out from the base, through the bottom. xx1400000411 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 139 4.3.1 Replacing the main cable package Continued Refitting the main cable package Use these procedures to refit the cable package. Adjusting the air hose length for IRB 1200-7/0.7 Action Note Valid for IRB 1200-7/0.7 If the cable harness is a new spare part, cut off 100 mm length of each air hose at the upper end.
Page 140 Insert the cable package in and up through the base, through the bottom. Refit the bracket inside the base with the screws. Tightening torque: 1.5 Nm. xx1400000407 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 141 Refit the brake release button to the base cover. Refit the base cover. Screws: 3HAB3409-212 (M4x16). Tightening torque: 4 Nm. xx1400000405 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 142 Torx countersunk head screw Replace if damaged. M3x5: 3HAC14286-4 If replacing the cable protection, use locking liquid Tightening torque: 0.8 Nm Loctite 243 on the screws. xx1400000456 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 143 IP67) in the base. Replace if damaged. xx1400000472 Replacement is detailed in Replacing the base spare parts (base, axis-1 radial seal- ing, protection sleeve) on page 349. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 144 Secure with attachment screws and wash- Screws: 3HAB3409-52 (M10x35). ers, but do not tighten yet. xx1300002567 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 145 Tighten all screws. Tightening torque: 40 Nm. For robots with protection class IP67 Gasket on top swing cover: 3HAC044845- (option 287-10) Check the gasket. Replace if damaged. xx1400000425 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 146 Only use specified screws, never replace them with other screws. Connecting the axis-1 motor connectors Action Note Reconnect the connectors and secure the connectors to the bracket with cable straps. xx1300002496 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 147 Tightening torque: 1.5 Nm. Rear connector interface: xx1300000470 Bottom connector interface: xx1400000404 For robots with protection class IP67 O-ring: 3HAB3772-86 (option 287-10) Check the o-ring. Replace if damaged. xx1400000412 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 148 Washers: 13 x 20 x 2, steel hardness class 300HV. Pin: 2 pcs, D6x20, ISO 2338 - 6m6x20 - A1. Tightening Torque: 55 Nm ± 5 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 149 Check the gasket of the cable housing plastic plate. Replace if damaged. xx1400000457 Fetch the cable housing, the plastic plate and the axis-2 sealing ring and run the cable package through them. xx1400000025 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 150 Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641- 287-10) Check the sealing. Replace if damaged. xx1400000454 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 151 Its position can easily be felt by hand. Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 152 Note Only use specified screws, never replace them with other screws. Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 154 2 Insert a third cable strap through the top strap and the bottom strap, and close the strap to secure the cable package and keep it in place. See the figure. xx1400001131 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 155 Tightening torque: 1.5 Nm. Note Remember to refit the two lower screws shown in the figure. xx1300002431 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 156 WARNING - The unit is sensitive to ESD! on page 47 For robots with protection class IP67 (option Gasket on EIB cover: 287-10) 3HAC044847-001 Check the EIB cover gasket. Replace if damaged. xx1400000475 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 157 Note Only use specified screws, never replace them with other screws. Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm. arm. xx1300002426 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 158 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 159 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 160 Valid for IRB 1200-5/0.9 Secure the cable package at the bottom of the housing with cable straps. Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 161 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 162 4.3.1 Replacing the main cable package Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 163 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 164 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 165 Connecting the air hoses Action Note Reconnect the air hoses. Air connector set with Ethernet hole in flange: 3HAC049664-001 Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 166 Refitting the wrist covers Action Note For robots with protection class IP67 Gasket for tubular cover: 3HAC044870-001 (option 287-10) Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 167 Apply locking liquid Loctite 243 to the two front screws on the left hand side cover, encircled in the figure. xx1300002349 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 168 4 Repair 4.3.1 Replacing the main cable package Continued Concluding procedure Action Note For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ): (option 287-10) 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200-5/0.9 ): 3HAC045697-001 Replace if damaged.
Page 169: Replacing The Axis-4 Fpc Unit, Housing Extender Unit And Housing Extender Sealings
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 170 Jog axis 4 to zero position. DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 171 Removing the axis-5 motor with pulley Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 172 Remove the timing belt. xx1300002351 Snap loose and disconnect the axis-5 FPC connectors. xx1300002390 Remove the connector plate by first remov- ing the screws. xx1300002391 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 173 Disconnect the connectors shown in the figure. xx1300002353 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 174 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 175 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 176 4.3.2 Replacing the axis-4 FPC unit, housing extender unit and housing extender sealings Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 177 Remove the axis-4 FPC unit screws. xx1300002373 Remove the extender unit screws. xx1300002372 Remove the housing extender unit. Be careful not to damage the cabling. xx1300002374 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 178 The lower screw, highlighted with a ring in the figure, is very closely located to the cabling. Be careful not to damage the cabling with the screwdriver when remov- ing/refitting the screw. xx1300002417 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 179 Radial sealing with dust lip: 3HAB3701-48 (option 287-10) Check the radial sealing. Replace if damaged, as described below. xx1400000438 Fit the radial sealing into the housing ex- tender unit. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 180 Screw the screws, little by little, to press the sealing into place. xx1400000437 Remove the assembly tool. Check that the sealing is undamaged and properly fitted. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 181 Refitting the axis-4 mechanical stop Action Note Fit the mechanical stop screw to the axis- Screws: 3HAB3409-231 (M4x8). 4 shaft. Tightening torque: 4 Nm. xx1400000393 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 182 Make sure that the axis-4 FPC unit is in its zero position when refitting the housing extender unit. xx1300002374 Note Mate the unit to the two locating pins attached to the housing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 183 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 184 4.3.2 Replacing the axis-4 FPC unit, housing extender unit and housing extender sealings Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 185 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 186 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 187 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 188 Refit the rest of the screws (M5x35 (7 pcs)). Screw: 3HAB3409-237 (M5x35 (7 pcs)). xx1400000003 Note Only use specified screws, never replace them with other screws. Tighten all screws. Tightening torque: 8 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 189 Preparations before securing the axis-5 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 190 (F = 13 N). Note Do not strech the timing belt too much! Secure the motor with its attachment screws. xx1300002350 Tightening torque: 3.5 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 191 Connect the axis-5 FPC connectors and snap them to their holders. xx1300002390 Connecting the axis-5 motor connectors Action Note Reconnect the motor cables. • R3.MP5 • R3.ME5 xx1300002360 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 192 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 193 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 194: Replacing The Axis-5 Fpc Unit
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 195 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove the tubular cable housing cover. xx1300002389 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 196 For robots with protection class IP67 (option 287- 10), the frame is glued and needs to be pried off. xx1300002392 Removing the axis-5 FPC unit Action Note Remove the sleeve screws. xx1300002393 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 197 It is important that axis 5 is in zero position when fitting the FPC unit. Make sure that the FPC is in zero position and does not get twisted during refitting. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 198 (option 287-10) Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the sleeve. xx1300002609 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 199 Replace if damaged, as described below. If undamaged and properly seated, skip to the next procedure table. xx1300002608 Fit the radial sealing into the tubular cable housing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 200 Screw the screws, little by little, to press the sealing into place. xx1400000486 Remove the assembly tool. Check that the sealing is undamaged and properly fitted. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 201 Refit the tubular cable housing with the Tightening torque: 1.5 Nm. screws. Tubular cable housing: 3HAC049655-001 xx1300002392 Refit the connector plate and secure with Tightening torque: 1.5 Nm. the M3 screws. xx1400001401 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 202 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 203 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 204: Replacing The Eib Unit
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 205 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove the lower arm cable housing cov- xx1300002400 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 206 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 47 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 207 4 Repair 4.3.4 Replacing the EIB unit Continued Action Note Disconnect the battery cable. xx1300002571 Remove the battery pack plate by removing the screws. xx1300002572 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 208 WARNING - The unit is sensitive to ESD! on page 47 Refit the EIB unit with the distance screws. xx1300002573 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 209 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 47 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 210 Make sure not to mix the R2.EIB and R2.ME2. Axis 2 may be severely damaged. See the labels on the connectors for correct connection. Connect the lugs to the EIB cover. xx1300002428 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 211 Note Only use specified screws, never replace them with other screws. Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm. arm. xx1300002426 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 212 For robots with protection class IP67 Gasket on cable housing cover: (option 287-10) 3HAC044849-001 Check the gasket of the cable housing cover. Replace if damaged. xx1400000048 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 213 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 214: 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 revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note Lower arm (IRB 1200-7/0.7 )
Page 215 3HAC044850-001 Used with protection class IP67. 1200-7/0.7 ) Replace if damaged. Housing cover gasket (IRB 3HAC045697-001 Used with protection class IP67. 1200-5/0.9 ) Replace if damaged. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 216 Removing the lower arm Use this procedure to remove the lower arm. Preparations before removing the lower arm Action Note Jog all axes to zero position. xx1300002581 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 217 • R3.MP5 • R3.ME5 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1300002360 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 218 Disconnect the air hoses. xx1400000738 Disconnecting the axis-4 FPC connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 219 4 Repair 4.4.1 Replacing the lower arm Continued Action Note Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 220 4.4.1 Replacing the lower arm Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 221 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Cut the strap that holds the connectors. xx1300002494 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 222 Removing the cable package in the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 223 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 224 Disconnect the connectors R1.ME1-3, R1.ME4-6 and R2.EIB on the EIB unit. Remove the EIB cover completely from the lower arm. Disconnect the lugs on the EIB cover. xx1300002428 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 226 Action Note Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 227 Disconnect the motor connectors. • R2.ME2 • R2.MP2 xx1300002434 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 228 Removing the lower arm cable housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 229 Remove the lower arm cover. xx1300002528 CAUTION The upper arm weighs 17 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 230 Guide pin for upper arm: 3HAC049705-001 Always use three guide pins together! xx1400000771 Separate the upper and lower arm with guidance from the guide pins. xx1300002533 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 231 The lower arm weighs 13 kg. If the upper arm is also attached to the lower arm, it adds an additional 17 kg to the total weight. xx1300002552 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 232 CAUTION The lower and upper arms together weigh 30 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 233 Insert two M4 screws to the press out holes and press out the drive unit. xx1400000008 Carefully pull out the complete drive unit. xx1300002555 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 235 Person 1: Hold the lower arm still. • Person 2: Tighten the screws. Refitting the lower arm Action Note Check the o-ring. O-ring: 3HAC048939-001 Replace if damaged. xx1300002556 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 236 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit: 3HAC049704-001 xx1300002562 Always use three guide pins together! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 237 M2 variseal sealing: 3HAC044641-003 (option 287-10) Check the sealing. Replace if damaged. xx1400000453 Fit the lower arm to the swing, with guid- ance from the guide pins. xx1300002563 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 238 Remove the guide pins and refit the remain- ing screws and washers using locking li- quid Loctite 243. xx1300002565 Tighten all screws. Tightening torque: 45 Nm Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 239 Check the swing cover gasket. Replace if damaged. xx1400000007 Refit the swing cover. Screws: 3HAB3409-207 (M3x8). Replace if damaged. Tightening torque: 1.5 Nm. Swing cover: 3HAC049635-001 xx1300002551 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 240 Always use three guide pins together! xx1400000027 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-005 (option 287-10) Check the sealing. Replace if damaged. xx1400000474 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 241 Only use specified screws, never replace them with other screws. Remove the guide pins and refit the remain- ing screws and washers. xx1400000029 Tighten all screws. Tightening torque: 4.5 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 242 Replace if damaged. xx1400000047 Refit the lower arm cover. Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. xx1300002528 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 243 (used with protection class IP67) in the cable housing. Replace if damaged. xx1400000473 Replacement is detailed in Replacing the axis-3 radial sealing and sealing ring on page 292. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 244 Refitting the cable package in the lower arm Action Note Check the axis-2 sealing ring and its gasket. Sealing ring: 3HAC044677-001 Replace if damaged. Gasket of axis-2 sealing ring: 3HAC045688-001 xx1400000476 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 245 Fasten the plastic plate to the cable housing, if The plastic plate is included in: removed. Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 246 4.4.1 Replacing the lower arm Continued Action Note For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641- 287-10) Check the sealing. Replace if damaged. xx1400000454 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 247 Its position can easily be felt by hand. Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 248 Note Only use specified screws, never replace them with other screws. Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 250 2 Insert a third cable strap through the top strap and the bottom strap, and close the strap to secure the cable package and keep it in place. See the figure. xx1400001131 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 251 Tightening torque: 1.5 Nm. Note Remember to refit the two lower screws shown in the figure. xx1300002431 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 252 WARNING - The unit is sensitive to ESD! on page 47 For robots with protection class IP67 (option Gasket on EIB cover: 287-10) 3HAC044847-001 Check the EIB cover gasket. Replace if damaged. xx1400000475 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 253 Note Only use specified screws, never replace them with other screws. Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm. arm. xx1300002426 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 254 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 255 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 256 Valid for IRB 1200-5/0.9 Secure the cable package at the bottom of the housing with cable straps. Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 257 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 258 4.4.1 Replacing the lower arm Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 259 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 260 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 261 Connecting the air hoses Action Note Reconnect the air hoses. Air connector set with Ethernet hole in flange: 3HAC049664-001 Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 262 Refitting the wrist covers Action Note For robots with protection class IP67 Gasket for tubular cover: 3HAC044870-001 (option 287-10) Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 263 Apply locking liquid Loctite 243 to the two front screws on the left hand side cover, encircled in the figure. xx1300002349 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 264 4 Repair 4.4.1 Replacing the lower arm Continued Concluding procedure Action Note For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ): (option 287-10) 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200-5/0.9 ): 3HAC045697-001 Replace if damaged.
Page 265: Replacing The Signal Lamp
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 266 For robots with protection class IP67 (option 287- Housing cover gasket (IRB 1200- 7/0.7 ): 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200- 5/0.9 ): 3HAC045697-001 Replace if damaged. xx1400000477 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 267 Tightening torque: 1.5 Nm. Note Only use specified screws, never replace them with other screws. The signal lamp is now ready for use and is lit in MOTORS ON mode. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 268: Replacing The Tubular Spare Parts
3HAC049657-001 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 269 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 270 Removing the tubular cable housing Action Note Snap loose and disconnect the axis-5 FPC con- nectors. xx1300002390 Remove the connector plate by first removing the screws. xx1300002391 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 271 Replace if damaged, as described below. If undamaged and properly seated, skip to the next procedure table. xx1300002608 Fit the radial sealing into the tubular cable housing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 272 Screw the screws, little by little, to press the sealing into place. xx1400000486 Remove the assembly tool. Check that the sealing is undamaged and properly fitted. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 273 Refit the tubular cable housing with the Tightening torque: 1.5 Nm. screws. Tubular cable housing: 3HAC049655-001 xx1300002392 Refit the connector plate and secure with Tightening torque: 1.5 Nm. the M3 screws. xx1400001401 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 274 Refitting the wrist covers Action Note For robots with protection class IP67 Gasket for tubular cover: 3HAC044870-001 (option 287-10) Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 275 Getting access to inside of the wrist unit Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 276 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Loosen the screws so that the motor can be moved sideways. xx1300002350 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 277 Snap loose and disconnect the axis-5 FPC connectors. xx1300002390 Remove the connector plate by first remov- ing the screws. xx1300002391 Remove the screws and pull out the motor. xx1300002352 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 278 Disconnect the connectors shown in the figure. xx1300002353 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 279 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 280 Fit guide pins to the gearbox. Guide pin for tilt unit (axis 5): 3HAC049706-001 Always use three guide pins togeth- xx1400000775 Remove the tilt unit. xx1300002470 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 281 Apply flange sealing Loctite 574 on the mounting surfaces of the drive unit. xx1400001404 Fit guide pins to the axis-5 gearbox. Guide pin for tilt unit (axis 5): 3HAC049706-001 xx1300002568 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 282 Tighten the screws. Tightening torque: 4.5 Nm. Checking the tubular cable housing sealings Action Note Check the sealing. M2 variseal sealing: 3HAC044641-009 Replace if damaged. xx1300002396 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 283 3HAC049701-001 Fit the tool plate to the other side of the tubular cable housing with the six screws M6X40. xx1400000485 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 284 Apply flange sealing Loctite 574 on the mounting surfaces of the tubular cable housing. xx1300002610 Refit the tubular cable housing with the screws. Tightening torque: 1.5 Nm. xx1300002392 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 285 FPC unit. xx1300002611 Refit the washer while at the same time putting Washer: 3HAC044869-001 the cables through its center. Replace washer, if damaged. xx1400000001 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 286 Tighten all screws. Tightening torque: 8 Nm. Put the cables through the plate hole and refit the Tightening torque: 0.3 Nm. plate. xx1300002356 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 288 Secure the motor with its attachment screws. xx1300002350 Tightening torque: 3.5 Nm. Refit the connector plate and secure with Tightening torque: 1.5 Nm. the M3 screws. xx1400001401 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 289 Connect the axis-5 FPC connectors and snap them to their holders. xx1300002390 Connecting the axis-5 motor connectors Action Note Reconnect the motor cables. • R3.MP5 • R3.ME5 xx1300002360 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 290 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 291 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 292: Replacing The Axis-3 Radial Sealing And Sealing Ring
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 293 Use these procedures to remove the axis-3 radial sealing and/or axis-3 sealing ring. Preparations before removing the sealings Action Note Jog all axes to zero position. xx1300002581 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 294 Disconnecting the axis-5 FPC connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 295 Disconnect the air hoses. xx1400000738 Disconnecting the axis-4 FPC connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 296 4 Repair 4.4.4 Replacing the axis-3 radial sealing and sealing ring Continued Action Note Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 297 4.4.4 Replacing the axis-3 radial sealing and sealing ring Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 298 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Cut the strap that holds the connectors. xx1300002494 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 299 Removing the cable package in the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 300 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 301 Use this procedure if the axis-3 radial sealing is to be removed. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 302 Use this procedure if the axis-3 sealing ring is to be removed. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 303 (option 287-10) Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the sealing ring. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 304 Use this procedure if the axis-3 radial sealing needs to be refitted. Action Note Fit the axis-3 radial sealing to the cable housing. Radial sealing: 3HAC024865-001 xx1400000334 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 305 Remove the assembly tool. Fit a new M2 variseal sealing. M2 variseal sealing: 3HAC044641- xx1400000473 Check that the sealings are undamaged and properly fitted. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 306 Check the radial sealing and the M2 variseal sealing (used with protection class IP67). Replace if damaged. xx1400000473 Replacement of the radial sealing is de- tailed in previous section. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 307 The air hose holder keeps the air hoses arranged in an optimized way. It is necessary to keep the air hose holder vertically and firmly against the left side of the axis-3 motor. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 308 M3 screws. Fit the holder to the bracket and then refit the complete assembly to the fix sheet again. Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 309 Valid for IRB 1200-5/0.9 Secure the cable package at the bottom of the housing with cable straps. Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 310 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 311 4.4.4 Replacing the axis-3 radial sealing and sealing ring Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 312 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 313 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 314 Connecting the air hoses Action Note Reconnect the air hoses. Air connector set with Ethernet hole in flange: 3HAC049664-001 Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 315 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 316 Only use specified screws, never replace them with other screws. Concluding procedure Action Note For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ): (option 287-10) 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200-5/0.9 ): 3HAC045697-001 Replace if damaged.
Page 317 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 318: Replacing The Axis-2 Mechanical Stop
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 319 Refit and secure the new stop with the en- closed screws. xx1400000390 Screws: 9ADA624-45 (M5x16). Tightening torque: 4 Nm. Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 320 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 321: Replacing The Axis-3 Mechanical Stop
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 322 Refit and secure the new stop with the en- closed screws. xx1400000387 Screws: 9ADA624-45 (M5x16). Tightening torque: 4 Nm Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 323 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 324: Replacing The Axis-4 Mechanical Stop
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 325 Consumable Art. no. Note Cleaning agent Loctite 7063 Flange sealing 12340011-116 Loctite 574 For robots with protection class IP67 (option 287-10) Locking liquid 3HAB7116-1 Loctite 243 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 326 For robots with protection class IP67 (option 287-10) The two front screws on the left hand side cover (encircled in the figure) have been fitted with locking liquid. xx1300002349 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 327 Loosen the screws so that the motor can be moved sideways. xx1300002350 Remove the timing belt. xx1300002351 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 328 Remove the screws and pull out the motor. xx1300002352 Removing the wrist Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 329 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Guide the hoses through the plate hole and re- move the plate. xx1300002357 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 330 FPC unit. xx1300002611 Disconnecting the axis-4 FPC connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 331 4 Repair 4.4.7 Replacing the axis-4 mechanical stop Continued Action Note Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 332 4.4.7 Replacing the axis-4 mechanical stop Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 333 Remove the axis-4 FPC unit screws. xx1300002373 Remove the extender unit screws. xx1300002372 Remove the housing extender unit. Be careful not to damage the cabling. xx1300002374 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 334 Use these procedures to refit the mechanical stop. Refitting the axis-4 mechanical stop Action Note Fit the mechanical stop screw to the axis- Screws: 3HAB3409-231 (M4x8). 4 shaft. Tightening torque: 4 Nm. xx1400000393 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 335 Checking the housing extender sealings Action Note For robots with protection class IP67 M2 variseal sealing: 3HAC044641-007 (option 287-10) Check the sealing. Replace if damaged. xx1300002418 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 336 3HAC049699-001 Fit the tool plate to the other side of the housing extender unit with the six screws M6X50. xx1400000436 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 337 Make sure that the axis-4 FPC unit is in its zero position when refitting the housing extender unit. xx1300002374 Note Mate the unit to the two locating pins attached to the housing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 338 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 339 4.4.7 Replacing the axis-4 mechanical stop Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 340 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 341 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 342 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 343 Refit the rest of the screws (M5x35 (7 pcs)). Screw: 3HAB3409-237 (M5x35 (7 pcs)). xx1400000003 Note Only use specified screws, never replace them with other screws. Tighten all screws. Tightening torque: 8 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 344 Preparations before securing the axis-5 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 345 (F = 13 N). Note Do not strech the timing belt too much! Secure the motor with its attachment screws. xx1300002350 Tightening torque: 3.5 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 346 Connect the axis-5 FPC connectors and snap them to their holders. xx1300002390 Connecting the axis-5 motor connectors Action Note Reconnect the motor cables. • R3.MP5 • R3.ME5 xx1300002360 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 347 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 348 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 349: Swing And Base
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 350 Content is defined in section Standard toolkit on page 625. Required consumables Equipment Art. no. Note Cable straps Grease 3HAB3537-1 Used for lubrication of cable con- tact areas. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 351 Remove the wrist cover. xx1300002389 Disconnecting the axis-5 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 352 Disconnecting the air hoses Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Disconnect the air hoses. xx1400000738 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 353 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 354 4.5.1 Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 355 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Cut the strap that holds the connectors. xx1300002494 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 356 Removing the cable package in the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 357 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 358 Disconnect the connectors R1.ME1-3, R1.ME4-6 and R2.EIB on the EIB unit. Remove the EIB cover completely from the lower arm. Disconnect the lugs on the EIB cover. xx1300002428 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 360 Action Note Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 361 Disconnect the motor connectors. • R2.ME2 • R2.MP2 xx1300002434 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 362 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The robot weighs 54 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 363 All lifting accessories used must be sized accordingly! Loosen the robot from the foundation by removing the foundation attachment screws and put the robot on its side. xx1400000680 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 364 Pull out the base slightly and turn it aside. Remember the cable layout in the base. The cabling must be positioned and angled in the same way during refitting. xx1300000472 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 365 Replacing the radial sealing (IP67) First remove the cabling according to Removing the cabling on page 351, then use this procedure to replace the axis-1 radial sealing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 366 (in the space of the protection sleeve). Remove the M2 variseal sealing. xx1400000780 Remove the radial sealing. xx1400000270 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 367 3HAC049692-001 base by screwing the five screws (M10X35) into the axis-1 gear screws little by little. xx1400000271 Remove the assembly tool. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 368 Replacing the axis-1 M2 variseal sealing (IP67) Action Note Remove the sealing. Fit the new sealing in its groove in the base. xx1400000472 M2 variseal sealing: 3HAC044641-002 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 369 Fit the new protection sleeve and secure with Tightening torque: 1 Nm. screws. Apply grease on the inner surface of the protec- tion sleeve, also on the bottom surface. xx1400000778 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 370 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the bottom cover. Rear connector interface: xx1300000469 Bottom connector interface: xx1400000403 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 371 Remove the axis-1 motor bracket. Rear connector interface: xx1300000470 Bottom connector interface: xx1400000404 Loosen the connectors from the bracket by cutting the cable straps, and disconnect the connectors. xx1300002496 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 372 Use this procedure if the cable connector interface is located at the bottom of the base. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 373 Remove the cable bracket by removing the screws. xx1400000406 Remove the bracket inside the base by removing the screws. xx1400000407 Pull the cable package out from the base, through the bottom. xx1400000411 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 374 (in the space of the protection sleeve). Remove the M2 variseal sealing. xx1400000780 Remove the radial sealing. xx1400000270 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 375 Refitting the axis-1 radial sealing and M2 variseal sealing Action Note Fit the new sealing in its groove in the Radial sealing with dust lip: 3HAB3701-47 base. xx1400000270 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 376 Fit a new M2 variseal sealing in its groove in the base. xx1400000780 M2 variseal sealing: 3HAC044641-002 Check that the sealings are undamaged and properly fitted. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 377 Route the cable package inside the base as shown in the figure. Apply grease to the cable package, cover all moving area of the package. xx1400000480 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 378 287-10) 3HAC044909-001 Check the gasket of the base cover. Replace if damaged. xx1400000413 Reconnect the earth cable. Refit the brake release button to the base cover. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 379 Refit the cable bracket to the cabling, if removed. Tightening torque: 1.5 Nm. xx1300002446 Check the axis-1 sealing ring. Axis-1 sealing ring: 3HAC044676- Replace if damaged. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 380 Tightening torque: 1.5 Nm. xx1300002439 Refit the axis-1 sealing ring to the swing and Tightening torque: 1.5 Nm. carefully run the cabling into the swing. xx1300002438 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 381 Position and angle the cabling inside the base as it was positioned during removal. CAUTION Be careful not to squeeze any cabling dur- ing the refitting procedure. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 382 Only use specified screws, never replace them with other screws. Remove the guide pins and refit the remain- ing attachment screws and washers. xx1300000523 Tighten all screws. Tightening torque: 40 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 383 Cover on top of swing: 3HAC049636-001 Replace if damaged. Screws: 3HAB3409-209 (M3x20). Tightening torque: 1.5 Nm. xx1300000467 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 384 Reconnect the connectors and secure the connectors to the bracket with cable straps. xx1300002496 Refit the axis-1 motor bracket. Tightening torque: 1.5 Nm. Rear connector interface: xx1300000470 Bottom connector interface: xx1400000404 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 385 Screws: 3HAB3409-207 (M3x8). Tightening torque: 1.5 Nm. Rear connector interface: xx1300000469 Bottom connector interface: xx1400000403 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 386 Refitting the cable package in the lower arm Action Note Check the axis-2 sealing ring and its gasket. Sealing ring: 3HAC044677-001 Replace if damaged. Gasket of axis-2 sealing ring: 3HAC045688-001 xx1400000476 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 387 Fasten the plastic plate to the cable housing, if The plastic plate is included in: removed. Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 388 4.5.1 Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) Continued Action Note For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641- 287-10) Check the sealing. Replace if damaged. xx1400000454 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 389 Its position can easily be felt by hand. Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 390 Note Only use specified screws, never replace them with other screws. Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 392 2 Insert a third cable strap through the top strap and the bottom strap, and close the strap to secure the cable package and keep it in place. See the figure. xx1400001131 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 393 Tightening torque: 1.5 Nm. Note Remember to refit the two lower screws shown in the figure. xx1300002431 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 394 WARNING - The unit is sensitive to ESD! on page 47 For robots with protection class IP67 (option Gasket on EIB cover: 287-10) 3HAC044847-001 Check the EIB cover gasket. Replace if damaged. xx1400000475 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 395 Note Only use specified screws, never replace them with other screws. Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm. arm. xx1300002426 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 396 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 397 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 398 Valid for IRB 1200-5/0.9 Secure the cable package at the bottom of the housing with cable straps. Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 399 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 400 4.5.1 Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 401 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 402 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 403 Connecting the air hoses Action Note Reconnect the air hoses. Air connector set with Ethernet hole in flange: 3HAC049664-001 Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 404 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 405 Only use specified screws, never replace them with other screws. Concluding procedure Action Note For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ): (option 287-10) 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200-5/0.9 ): 3HAC045697-001 Replace if damaged.
Page 406 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 407: Replacing The Swing Spare Parts (Swing, Axis-2 Radial Sealing)
Cable housing of the swing Cable housing cover of the Radial sealing with dust lip swing xx1400000446 xx1400000445 xx1400000444 3HAC049633-001 3HAC049634-001 3HAB3701-41 Used with protection class IP67. Replace if damaged. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 408 Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 409 Removing the swing parts Use these procedures to remove the swing spare parts. Preparations before removing the swing spare parts Action Note Jog all axes to zero position. xx1300002581 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 410 Disconnecting the axis-5 FPC connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 411 Disconnect the air hoses. xx1400000738 Disconnecting the axis-4 FPC connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 412 4 Repair 4.5.2 Replacing the swing spare parts (swing, axis-2 radial sealing) Continued Action Note Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 413 4.5.2 Replacing the swing spare parts (swing, axis-2 radial sealing) Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 414 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Cut the strap that holds the connectors. xx1300002494 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 415 Removing the cable package in the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 416 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 417 Disconnect the connectors R1.ME1-3, R1.ME4-6 and R2.EIB on the EIB unit. Remove the EIB cover completely from the lower arm. Disconnect the lugs on the EIB cover. xx1300002428 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 419 Action Note Remove the swing cable housing cover by remov- ing the screws. xx1300002431 Cut the cable straps. xx1400001528 Remove the axis-2 motor bracket screws. xx1300002432 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 420 Disconnect the motor connectors. • R2.ME2 • R2.MP2 xx1300002434 Loosen the cable housing from the swing by re- moving the screws. Leave it hanging on the cable package. xx1300002435 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 421 Roundsling, 2 m Removing the lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 422 The lower arm weighs 13 kg. If the upper arm is also attached to the lower arm, it adds an additional 17 kg to the total weight. xx1300002552 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 423 Fit M4 screws in the cover holes to pull out the cover more easily. Only tighten the screws lightly in order not to damage the threads. xx1400000447 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 424 Remove the axis-1 sealing ring from the swing and carefully run the cabling out from the swing. xx1400000455 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 425 Use this procedure if replacing the swing. Action Note Check the gasket on the axis-1 sealing ring. Axis-1 sealing ring gasket: 3HAC045685-001 Replace if damaged. xx1400000458 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 426 Fit the axis-1 sealing ring to the swing with the Axis-1 sealing ring: 3HAC044676- screws and carefully run the cabling out up through the swing. Tightening torque: 1.5 Nm. xx1400000455 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 427 Refit the swing attachment screws and washers. Screws: 3HAB3409-52 (M10x35). Tightening torque: 40 Nm. xx1400000448 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 428 Note Only use specified screws, never replace them with other screws. Refitting the axis-2 radial sealing (IP67) Use this procedure if replacing the axis-2 radial sealing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 429 Axis-2 sealing assembly tool set: against the radial sealing. 3HAC049694-001 Fit the tool plate to the other side of the cable housing with the six screws M6X50. xx1400000451 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 430 Fit lifting slings to the upper and lower arm. Roundsling, 2 m Refitting the lower arm Action Note Check the o-ring. O-ring: 3HAC048939-001 Replace if damaged. xx1300002556 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 431 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit: 3HAC049704-001 xx1300002562 Always use three guide pins together! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 432 M2 variseal sealing: 3HAC044641-003 (option 287-10) Check the sealing. Replace if damaged. xx1400000453 Fit the lower arm to the swing, with guid- ance from the guide pins. xx1300002563 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 433 Remove the guide pins and refit the remain- ing screws and washers using locking li- quid Loctite 243. xx1300002565 Tighten all screws. Tightening torque: 45 Nm Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 434 Check the swing cover gasket. Replace if damaged. xx1400000007 Refit the swing cover. Screws: 3HAB3409-207 (M3x8). Replace if damaged. Tightening torque: 1.5 Nm. Swing cover: 3HAC049635-001 xx1300002551 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 435 Check the gasket of the cable housing plastic plate. Replace if damaged. xx1400000457 Fetch the cable housing, the plastic plate and the axis-2 sealing ring and run the cable package through them. xx1400000025 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 436 Cable harness material set: 3HAC049663-001. Replace if damaged. xx1400000023 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641- 287-10) Check the sealing. Replace if damaged. xx1400000454 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 437 Its position can easily be felt by hand. Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm. xx1400000020 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 438 Note Only use specified screws, never replace them with other screws. Apply grease to the cable package, cover all moving area of the package. xx1400000481 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 440 2 Insert a third cable strap through the top strap and the bottom strap, and close the strap to secure the cable package and keep it in place. See the figure. xx1400001131 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 441 Tightening torque: 1.5 Nm. Note Remember to refit the two lower screws shown in the figure. xx1300002431 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 442 WARNING - The unit is sensitive to ESD! on page 47 For robots with protection class IP67 (option Gasket on EIB cover: 287-10) 3HAC044847-001 Check the EIB cover gasket. Replace if damaged. xx1400000475 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 443 Note Only use specified screws, never replace them with other screws. Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm. arm. xx1300002426 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 444 Do not loosen the cable clamp screw! There is a risk of rearrangement of the cable layout which would result in shortened lifetime of the cable harness. xx1300002424 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 445 Tightening torque for the two M3 screws: 1.5 Nm. xx1300002422 xx1400001133 Reconnect the axis-3 motor connectors. xx1300002420 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 446 Valid for IRB 1200-5/0.9 Secure the cable package at the bottom of the housing with cable straps. Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 447 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 448 4.5.2 Replacing the swing spare parts (swing, axis-2 radial sealing) Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 449 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 450 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 451 Connecting the air hoses Action Note Reconnect the air hoses. Air connector set with Ethernet hole in flange: 3HAC049664-001 Air connector set without Ethernet hole in flange: 3HAC049665-001 xx1400000738 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 452 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 453 Only use specified screws, never replace them with other screws. Concluding procedure Action Note For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ): (option 287-10) 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200-5/0.9 ): 3HAC045697-001 Replace if damaged.
Page 454 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 455: Replacing The Axis-1 Mechanical Stop
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 456 Refit and secure the new stop with the en- closed screw and washer. xx1400000392 Screw: 9ADA183-37 (M8x25). Tightening torque: 12 Nm. Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 457 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 458: Motors And Gearboxes
The axis-1 gear unit and axis-1 motor is part of the complete base spare part assembly, see Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) on page 349. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 459: Replacing The Axis-2 Drive Unit
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Continues on next page 3HAC046983-001 Revision: -...
Page 460 Total amount: 80 g. Used to lubricate the gearbox. The gear is pre-filled at delivery but grease may need to be added depending on the actual condi- tion. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 461 (no force) Loosening the cabling in the swing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 462 4.6.2 Replacing the axis-2 drive unit Continued Action Note Remove the cable housing cover of the swing by removing the screws. xx1300002431 Cut the cable straps. xx1400001528 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 463 Pull out the cable harness sligthly from the lower arm housing. Note The cabling is still connected inside the robot, so be careful not to strain the cables! xx1300002548 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 464 Removing the lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the swing cover. xx1300002551 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 465 Leave some space between the screw head and the swing casting. Then use a plastic hammer to knock on the screws lightly and evenly. xx1300002553 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 466 Removing them can damage the gearbox severely. Insert two M4 screws to the press out holes and press out the drive unit. xx1400000008 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 467 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the lower arm. xx1400000006 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 468 If the drive unit is refitted in a hanging lower Tightening torque: 5 Nm arm, this step requires two persons. • Person 1: Hold the lower arm still. • Person 2: Tighten the screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 469 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 to the cyl- indrical surface in the swing. xx1400001403 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 470 M2 variseal sealing: 3HAC044641-003 (option 287-10) Check the sealing. Replace if damaged. xx1400000453 Fit the lower arm to the swing, with guid- ance from the guide pins. xx1300002563 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 471 Remove the guide pins and refit the remain- ing screws and washers using locking li- quid Loctite 243. xx1300002565 Tighten all screws. Tightening torque: 45 Nm Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 472 Check the swing cover gasket. Replace if damaged. xx1400000007 Refit the swing cover. Screws: 3HAB3409-207 (M3x8). Replace if damaged. Tightening torque: 1.5 Nm. Swing cover: 3HAC049635-001 xx1300002551 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 473 Action Note Refit the cable housing to the swing with Tightening torque: 4 Nm. the screws. xx1300002549 Insert the cable harness into the lower arm. xx1300002548 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 474 Secure the connector R2.MP2 and its cable with cable straps onto the motor bracket. Make sure the connector is fixed by its tab to the bracket. xx1400001529 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 475 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 476: Replacing The Axis-3 Drive Unit
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 477 Total amount: 42 g. Used to lubricate the gearbox. The gear is pre-filled at delivery but grease may need to be added depending on the actual condi- tion. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 478 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove the cable housing cover. xx1300002400 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 479 Creating space for separation of upper and lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 480 Remove the cable housing of the lower arm by removing the screws, and tilt it out- wards. xx1400000785 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 481 WARNING This releases the upper arm from the lower arm. Make sure the weight of the upper arm is properly secured by the lifting slings. xx1300002531 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 482 Separate the upper and lower arm with guidance from the guide pins. xx1300002533 Removing the axis-3 drive unit Action Note Remove the drive unit screws. xx1300002532 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 483 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the motor adapter. xx1400000784 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 484 Refitting the upper arm Action Note Fit guide pins to the axis-3 gear unit. Guide pin for upper arm: 3HAC049705-001 Always use three guide pins together! xx1400000027 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 485 Screws: 3HAB3409-213 (M4x25). secure with the upper arm screws and washers. Do not tighten yet. xx1400000028 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 486 Tightening torque: 4.5 Nm. For robots with protection class IP67 Gasket on lower arm cover: 3HAC044848- (option 287-10) Check the lower arm cover gasket. Replace if damaged. xx1400000047 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 487 For robots with protection class IP67 Gasket on lower arm cable housing: (option 287-10) 3HAC044895-001 Check the cable housing gasket. Replace if damaged. xx1400000414 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 488 Replacement is detailed in Replacing the axis-3 radial sealing and sealing ring on page 292. Refit the cable housing of the lower arm. Tightening torque: 4 Nm xx1400000785 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 489 Fasten the fix sheet to the axis-3 motor by Tightening torque: 1.5 Nm. fastening the screws. xx1300002423 Reconnect the axis-3 motor connectors. xx1300002420 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 490 For robots with protection class IP67 Gasket on cable housing cover: (option 287-10) 3HAC044849-001 Check the gasket of the cable housing cover. Replace if damaged. xx1400000048 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 491 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 492: Replacing The Axis-4 Gearbox, Drive Shaft And Pulley
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 493 Art. no. Note Cable straps Cleaning agent Loctite 7063 Flange sealing 12340011-116 Loctite 574 For robots with protection class IP67 (option 287-10) Locking liquid 3HAB7116-1 Loctite 243 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 494 For robots with protection class IP67 (option 287-10) The two front screws on the left hand side cover (encircled in the figure) have been fitted with locking liquid. xx1300002349 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 495 Loosen the screws so that the motor can be moved sideways. xx1300002350 Remove the timing belt. xx1300002351 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 496 Remove the screws and pull out the motor. xx1300002352 Removing the wrist Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 497 Disconnect the air hoses. xx1300002355 Remove the connector plate attachment screws. xx1300002356 Guide the hoses through the plate hole and re- move the plate. xx1300002357 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 498 FPC unit. xx1300002611 Disconnecting the axis-4 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 499 Disconnecting the axis-4 FPC connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 500 4 Repair 4.6.4 Replacing the axis-4 gearbox, drive shaft and pulley Continued Action Note Remove the cable housing cover. xx1300002400 Remove the plate. xx1300002413 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 501 4.6.4 Replacing the axis-4 gearbox, drive shaft and pulley Continued Action Note Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 : disconnect them. xx1300002412 Cable layout in IRB 1200-5/0.9 : xx1400001471 Remove the small cover of the housing.
Page 502 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Loosen the two attachment screws and move the motor downwards to slacken the timing belt. xx1300002524 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 503 Remove the timing belt from its groove on the motor. Removing the air hoses Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 504 Pull in the air hoses into the housing, out from the housing extender unit. Removing the housing extender unit Action Note Remove the axis-4 FPC unit screws. xx1300002373 Remove the extender unit screws. xx1300002372 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 505 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the screws and washers. xx1300002376 Remove the shaft. xx1300002377 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 506 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the gear attachment screws. xx1300002378 Pull out the gear. xx1300002379 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 507 Tightening torque: 1.1 Nm. xx1300002380 Note Only use specified screws, never replace them with other screws. Refit the gear to the housing. xx1300002379 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 508 Also move the screw on top of the old drive shaft to the new shaft. xx1300002387 Position the shaft so that the encircled screw is on top, then refit the shaft. xx1300002377 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 509 Checking the housing extender sealings Action Note For robots with protection class IP67 M2 variseal sealing: 3HAC044641-007 (option 287-10) Check the sealing. Replace if damaged. xx1300002418 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 510 Make sure that the axis-4 FPC unit is in its zero position when refitting the housing extender unit. xx1300002374 Note Mate the unit to the two locating pins attached to the housing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 511 Place the timing belt at the gear pulley and run the air hoses through the belt. Install the air hoses in and through the housing extender unit. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 512 Note Check that: • all assembly surfaces are clean and undamaged. • the motor is clean and undamaged. Fit the timing belt to the motor pulley. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 513 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx1300002525 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 514 Connecting the axis-4 FPC connectors Action Note Reconnect the FPC connectors. See the number markings on the connectors for help to find the corresponding connector. xx1300002399 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 515 4.6.4 Replacing the axis-4 gearbox, drive shaft and pulley Continued Action Note Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 : into place inside the housing. See the number markings on the connectors for help to find the corresponding connector. xx1300002412 Cable layout in IRB 1200-5/0.9 :...
Page 516 Refit the plate. Tightening torque: 1.5 Nm. xx1300002413 Check the PTFE film on the cable housing. PTFE film on lower arm cable housing: 3HAC044710-001 Replace if damaged. xx1400000740 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 517 Check the PTFE film on the cable housing cover. Replace if damaged. Apply grease to the inner surface of the cable housing cover and the PTFE film surface. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 518 Tightening torque: 1.5 Nm xx1300002400 Note Only use specified screws, never replace them with other screws. Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 519 Pay special attention to the plastic block on the FPC unit. It is easily pulled off, make sure it stays fitted to the FPC unit. xx1300002611 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 520 Refit the rest of the screws (M5x35 (7 pcs)). Screw: 3HAB3409-237 (M5x35 (7 pcs)). xx1400000003 Note Only use specified screws, never replace them with other screws. Tighten all screws. Tightening torque: 8 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 521 Preparations before securing the axis-5 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 522 (F = 13 N). Note Do not strech the timing belt too much! Secure the motor with its attachment screws. xx1300002350 Tightening torque: 3.5 Nm. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 523 Connect the axis-5 FPC connectors and snap them to their holders. xx1300002390 Connecting the axis-5 motor connectors Action Note Reconnect the motor cables. • R3.MP5 • R3.ME5 xx1300002360 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 524 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 525 Refit the upper arm housing cover with the Screws: 3HAB3409-207 (M3x8). screws. Tightening torque: 1.5 Nm. xx1300000456 Note Only use specified screws, never replace them with other screws. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 526 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 527: Replacing The Axis-4 Motor With Pulley
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 528 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 529 Cut the strap that holds the connectors. xx1300002494 Disconnect the motor connectors. Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1300002495 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 530 Remove the two screws that secure the motor bracket to the axis-4 motor flange. Lay down the bracket inside the housing. xx1300002521 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 531 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the motor flange from the motor by re- moving the screws. xx1300002523 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 532 Note Check that: • all assembly surfaces are clean and undamaged. • the motor is clean and undamaged. Fit the timing belt to the motor pulley. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 533 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx1300002525 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 534 Motor bracket: 3HAC044689-001 flange with the screws. Tightening torque: 1.5 Nm. Replace if damaged. xx1300002521 Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 535 Secure the connectors to the motor with a cable strap. xx1300002494 Concluding procedure Action Note For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ): (option 287-10) 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200-5/0.9 ): 3HAC045697-001 Replace if damaged.
Page 536 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 537: Replacing The Axis-4 Timing Belt
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 538 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 539 Disconnect the lamp cable connectors R3.H1 and R3.H2 and then lift away the cover completely. xx1300000456 Cut the strap that holds the connectors. xx1300002494 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 540 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Loosen the two attachment screws and move the motor downwards to slacken the timing belt. xx1300002524 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 541 Remove the timing belt from its groove on the motor. Removing the air hoses Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 542 Place the timing belt at the gear pulley and run the air hoses through the belt. Install the air hoses in and through the housing extender unit. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 543 Note Check that: • all assembly surfaces are clean and undamaged. • the motor is clean and undamaged. Fit the timing belt to the motor pulley. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 544 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx1300002525 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 545 Motor bracket: 3HAC044689-001 flange with the screws. Tightening torque: 1.5 Nm. Replace if damaged. xx1300002521 Connecting the axis-4 motor connectors Action Note Reconnect the motor connectors. xx1300002371 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 546 Secure the connectors to the motor with a cable strap. xx1300002494 Concluding procedure Action Note For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ): (option 287-10) 3HAC044850-001 Check the gasket. Housing cover gasket (IRB 1200-5/0.9 ): 3HAC045697-001 Replace if damaged.
Page 547 For robots with protection class IP67 Gasket on cable housing cover: (option 287-10) 3HAC044849-001 Check the gasket of the cable housing cover. Replace if damaged. xx1400000048 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 548 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 549: Replacing The Axis-5 Motor With Pulley
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Equipment, etc. Article number Note...
Page 550 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 551 Removing the axis-5 motor with pulley Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 552 Remove the timing belt. xx1300002351 Snap loose and disconnect the axis-5 FPC connectors. xx1300002390 Remove the connector plate by first remov- ing the screws. xx1300002391 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 553 Only use specified screws, never replace them with other screws. Securing the axis-5 motor and timing belt Action Note Refit the timing belt on the pulley. xx1300002351 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 554 Tightening torque: 3.5 Nm. Refit the connector plate and secure with Tightening torque: 1.5 Nm. the M3 screws. xx1400001401 Secure the three M2.5 screws. Tightening torque: 0.3 Nm. xx1400001402 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 555 Refitting the wrist covers Action Note For robots with protection class IP67 Gasket for tubular cover: 3HAC044870-001 (option 287-10) Check the tubular cover gasket. Replace if damaged. xx1400000034 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 556 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 557: Replacing The Axis-5 Timing Belt
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Article number Note...
Page 558 Remove the left hand side wrist cover. xx1400000033 Removing the axis-5 timing belt Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 559 Refit the timing belt on the pulley. xx1300002351 Move the motor to achieve correct belt Belt tension: F = 13 N. tension (F = 13 N). Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 560 Note Only use specified screws, never replace them with other screws. Recalibrate the robot. Calibration information is included in sec- tion Calibration on page 579. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 561 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 562: Replacing The Axis-5 And Axis-6 Drive Unit
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest revision of Product manual, spare parts - IRB 1200 on ABB Library. Spare part Art. no. Note...
Page 563 Content is defined in section Standard toolkit on page 625. Required consumables Consumable Art. no. Note Cleaning agent Loctite 7063 Locking liquid 3HAB7116-1 Loctite 243 Flange sealing 12340011-116 Loctite 574 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 564 Getting access to inside of the wrist unit Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 565 Remove the cable housing of the tubular by first removing the screws. Note For robots with protection class IP67 (option 287- 10), the frame is glued and needs to be pried off. xx1300002392 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 566 FPC unit as far as required for the axis-6 motor connectors to be accessed. xx1300002394 Disconnect the axis-6 motor connectors and re- move the FPC unit completely. xx1300002395 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 567 Support the weight of the drive unit and remove the screws. xx1300002469 Fit guide pins to the gearbox. Guide pin for tilt unit (axis 5): 3HAC049706-001 Always use three guide pins togeth- xx1400000775 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 568 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the tilt covers. xx1300002607 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 569 Remove residual locking liquid and other pollut- ants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the drive unit. xx1400001404 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 570 It is important that axis 5 is in zero position when fitting the FPC unit. Make sure that the FPC is in zero position and does not get twisted during refitting. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 571 (option 287-10) Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. Apply flange sealing Loctite 574 on the mounting surfaces of the sleeve. xx1300002609 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 572 Replace if damaged, as described below. If undamaged and properly seated, skip to the next procedure table. xx1300002608 Fit the radial sealing into the tubular cable housing. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 573 Screw the screws, little by little, to press the sealing into place. xx1400000486 Remove the assembly tool. Check that the sealing is undamaged and properly fitted. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 574 Refit the tubular cable housing with the Tightening torque: 1.5 Nm. screws. Tubular cable housing: 3HAC049655-001 xx1300002392 Refit the connector plate and secure with Tightening torque: 1.5 Nm. the M3 screws. xx1400001401 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 575 Move the motor to a position where a good timing belt tension is reached (F = 13 N). Note Do not strech the timing belt too much! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 576 M3 screws. xx1400001401 Secure the three M2.5 screws. Tightening torque: 0.3 Nm. xx1400001402 Connect the axis-5 FPC connectors and snap them to their holders. xx1300002390 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 577 For robots with protection class IP67 Gasket for tubular cable housing cover: (option 287-10) 3HAC044871-001 Check the tubular cable housing cover gasket. Replace if damaged. xx1400000345 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 578 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 579: Calibration
The encoder values are changed If encoder values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The method is described in the section Calibrating the robot on page 581.
Page 580: Calibration Method
The axes must be calibrated one at a time. The fine calibration method is used for all IRB 1200 robots and is the recommended method in order to achieve proper performance. 3HAC046983-001 Revision: -...
Page 581: Calibrating The Robot
The position of the axis to be calibrated is illustrated in each calibration section respectively. The table below specifies the exact axis positions in degrees. Axis IRB 1200-5/0.9 IRB 1200-7/0.7 +84.474066º +84.474066º +131.862755º +136.862755º +72.250000º +72.250000º 0º 0º -90º -90º 0º 0º 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 582: Content Of Calibration Toolkit 3Hac051256-001
Hex socket head screw 9ADA183-19 M5x40 Hex socket head screw 9ADA183-41 M8x45 Hex socket head screw 9ADA183-15 M5x20 Hex socket head screw 9ADA183-5 M4x16 Hex socket head screw 9ADA183-14 M5x16 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 583: Calibrating Axis 1
Note Calibration toolkit 3HAC051256-001 Includes calibration tools, pins and attachment screws. Protection plug 3HAC051199-001 Replace if damaged. Required consumables Equipment Art. no. Note Cleaning agent Isopropanol Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 584 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove the protection plug from the swing. xx1400001134 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 585 When doing this, pay attention to robot pose in order to avoid arm collision. When the axis is in position, release the brake release button to activate the brakes again. xx1400001209 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 586 • Tap Yes to proceed. • Tap No to cancel. Select the check-box for the current axis/axes to be calibrated. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 587 Remove the axis-1 calibration stop pin from the Tightening torque: 12 Nm base and refit the axis-1 mechanical stop. xx1400000392 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 588 5.3.3 Calibrating axis 1 Continued After calibration Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 589: Calibrating Axis 2
2. swing is used for calibration of axis 2. No additional equipment is required. No additional equipment is required. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 590 Choose fine calibration from Calib menu On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 591 Manually rotate the axis to apart the calibration pins from each other. This is done to avoid dam- age on the pins if incorrect operation should occur during next step of jogging. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 592 If no, redo the fine calibration procedure. xx1400001093 After calibration Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 593: Calibrating Axis 3
Calibration of axis 3 is done by moving the upper arm so that the calibration pin and calibration stop touches each other gently. These parts are already fitted to the robot, no extra installation of calibration equipment is required. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 594 When releasing the holding brakes, the robot axes may move very quickly and sometimes in unex- pected ways! Make sure no personnel is near or beneath the robot arm! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 595 Choose fine calibration from Calib menu On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 596 Manually rotate the axis to apart the calibration pins from each other. This is done to avoid dam- age on the pins if incorrect operation should occur during next step of jogging. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 597 If no, redo the fine calibration procedure. xx1400001094 After calibration Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 598: Calibrating Axis 4
DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 599 When releasing the holding brakes, the robot axes may move very quickly and sometimes in unex- pected ways! Make sure no personnel is near or beneath the robot arm! Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 600 All mechanical units connected to the system are shown along with their calibration status. Tap to select the mechanical unit and then tap Calib. Parameters. en0400001127 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 601 Are they aligned within the tolerances? • If yes, the calibration is verified OK. • If no, redo the fine calibration procedure. xx1400001095 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 602 Refit the protection cover to the housing. xx1400001205 After calibration Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 603: Calibrating Axis 5 And Axis 6
Jog all axes to zero position. DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 604 When doing this, pay attention to robot pose in order to avoid arm collision. When the axis is in position, release the brake release button to activate the brakes again. xx1400001206 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 605 • Tap Yes to proceed. • Tap No to cancel. Select the check-box for the current axis/axes to be calibrated. Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 606 Remove the calibration tool of axes 5 and 6 from the disk. After calibration Action Note Write down the new system parameters on a new label and stick on top of the calibration label on the robot. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 607: Updating Revolution Counters
All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 608 If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi- tioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See Checking the zero position on page 611. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 609: Calibration Scale And Correct Axis Position
This section specifies the calibration scale positions and/or correct axis positions. Calibration scales/marks, IRB 1200 This illustration shows the positions of the calibration scales and marks on the robot. xx1400000402 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 610: Calibration Movement Directions For All Axes
This is normally handled by the robot calibration software. Calibration movement directions xx1300000365 Posi- Description Posi- Description tion tion Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 611: Checking The Zero Position
Check that the calibration marks for the Calibration scale and correct axis pos- axes align correctly. If they do not, update ition on page 609, and Updating revolution the revolution counters! counters on page 607. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 612 This page is intentionally left blank...
Page 613: Decommissioning
These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 614: Environmental Information
Also note that: • Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 615: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 616 This page is intentionally left blank...
Page 617: Reference Information
7 Reference information 7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 618: Applicable Safety Standards
Safety of machinery - General requirements for the design and construction of fixed and movable guards Other standards Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 619 7.2 Applicable safety standards Continued Standard Description ANSI/UL 1740 (option 429- Safety standard for robots and robotic equipment CAN/CSA Z 434-03 (option Industrial robots and robot Systems - General safety require- 429-1) ments 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 620: Unit Conversion
3.28 ft. 39.37 in Weight 1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 621: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 622 Any special torque specified in the repair, maintenance or installation procedure overrides the standard torque! Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 623 7 Reference information 7.4 Screw joints Continued Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Lubricated with Molycote 1000, Gleitmo 603 or equivalent 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 624: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 625: Standard Toolkit
For securing robot to foundation. Ratchet head for torque wrench 1/2 Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm Small screwdriver T-handle with ball head Small cutting plier Plastic mallet 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 626: Special Tools
The required tools are a sum of standard tools, defined in the section Standard toolkit on page 625, and of special tools, listed directly in the instructions and also gathered in this section. Special tools Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 627 7 Reference information 7.7 Special tools Tools and equipment with spare part number: (These tools can be ordered from ABB) Guide pins 3HAC049703-001 Guide pin for axis-1 gear unit 3HAC049704-001 Guide pin for axis-2 gear unit 3HAC049705-001 Guide pin for upper arm...
Page 628 7 Reference information 7.7 Special tools Tools and equipment with spare part number: (These tools can be ordered from ABB) Axis-3 sealing assembly tool set 3HAC049697-001 Used to refit the axis-3 radial sealing. xx1400000538 Axis-4 sealing assembly tool set 3HAC049699-001 Used to refit the radial sealing, if replacement is needed.
Page 629: Lifting Accessories And Lifting Instructions
The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. This implies that the instructions delivered with the lifting accessories should be stored for later reference. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 630 This page is intentionally left blank...
Page 631: Spare Parts
8 Spare parts 8.1 Spare part lists and illustrations Location Spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation DVD. 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 632 This page is intentionally left blank...
Page 633: Circuit Diagrams
Circuit diagram - IRB 2400 3HAC6670-3 Circuit diagram - IRB 2600 3HAC029570-007 Circuit diagram - IRB 4400/4450S 3HAC9821-1 Circuit diagram - IRB 4600 3HAC029038-003 Circuit diagram - IRB 6400RF 3HAC8935-1 Continues on next page 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 634 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 635: Index
MoveAbsJ instruction, 611 cabinet lock, 18 updating revolution counters, 607 cable package main foundation replacing, 116 requirements, 56 cabling, robot, 84 FPC unit cabling between robot and controller, 84 axis-5, 194 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 636 45 axis-4 timing belt, 537 maintenance intervals, 89 axis-3 maintenance schedule, 89 radial sealing, 292 manipulator sealing ring, 292 symbols, 38 axis-3 drive unit, 476 mechanical stop axis-3 gearbox, 476 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 637 25 validity and responsibility, 17 hot parts, 21 hydraulic system, 23 installation, 18 wall mounting, 74 oil change, 50 weight, 54 operational disturbance, 24 robot, 66, 624 pneumatic system, 23 3HAC046983-001 Revision: - © Copyright 2014 ABB. All rights reserved.
Page 640 ABB AS, Robotics Discrete Automation and Motion Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 51489000 ABB Engineering (Shanghai) Ltd. 5 Lane 369, ChuangYe Road KangQiao Town, PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666...

This manual is also suitable for:

Irb 1200-5/0.9 Irb 1200-7/0.7

ABB IRB 1200 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Parts

9 Circuit Diagrams

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